1.

How to calculate bundle diameter

-Calculate the total cross-sectional area including wire diameter, sleeves, spacing between cables
-Divide the total cross-sectional area by π (pi) (3.141)
2. What type of support you use to route harness
Tapes, cable tie, customized brackets, snaps, coming to cad we use dummy supports or points for routing.

3. Difference between electrical schematics and synoptic

Schematic contains complete electrical wire diagram

A synoptic diagram is typically used to provide a high-level view of a system, highlighting key components and
their connections, and allowing engineers and technicians to quickly understand the overall structure and
operation of the system.

4. What are situations of EMF, EMI, EMC & its remedies?

Electromagnetic field, electromagnetic interference, electromagnetic compatibility, to avoid such errors we
maintain segregation distance, we use sleeves and separates in ducts.

5. What are general requirement of harness.

Load, purpose, area,

6. Drip Loop
In external environment electrical component where exposed to moisture, to avoid well be using U bend, that u
bend is called Drip Loop

7. Difference between Earthing, Bonding and Grounding

Earthing – component external surface to ground surface
Bounding- components to body frame
Ground – natural wire to ground

8. What is slack
Slack is the extra length for the wire been installed, this slack helps for free movement of the component without
putting stress on the wire.

9. What is the difference between Global Slack and Local Slack

A. Global slack will be applicable for entire harness,
B. Local slack is applicable for one fixation to another where ever we need extra length we can use it.

10. Bend Radius Ratio.

A. We have to maintain 4 times of the dia of the cable for power cables

And 10 times of the dia of the fiber cables.

11. Types of sleeves

Heat shrink sleeves:

Expandable braided sleeves:
Non-split braided sleeves:
PVC Sleeves
12. What are the class of cables
Class 1: This class of cables are intended for use in low voltage electrical systems, typically rated for less than 50
volts. They are used for lighting, control, and power circuits.
Class 2: This class of cables are also intended for use in low voltage electrical systems, typically rated for less than
50 volts, but are designed to meet more stringent safety requirements than Class 1 cables. They are used in
electronic equipment and communication systems.
Class 3: This class of cables are designed for use in high voltage electrical systems, typically rated for more than
50 volts. They are used in power generation, transmission, and distribution systems.

13. How can you arrest the harness

Cable trays, harness clamps, cable ties, Taping or wrapping, Clamping, Housings or enclosures.

14. How to start Routing Parameters and considerations during Routing the harness
Path planning,
Length of the harness with slack,
Bend radius,
Environmental condition, temperature, humidity, vibration,
Termination points:
15. What are the parameters you need to consider while selecting the connectors and types of connectors?

Consider the voltage and current ratings, resistance,

Environmental condition, temperature, humidity, vibration,(IP value)
Mounting method, the size and shape, and the required strength,
Consider the cost of the connector
Ease of installation & Ease of maintenance

Types of connector:
Circular, rectangular, modular connectors

16. How do you classify the size of cables?

American Wire Gauge (AWG): The American Wire Gauge is a standardized system that is commonly used in the
United States and other countries. It uses a numbering system to indicate the size of a cable, with lower numbers
indicating smaller cables and higher numbers indicating larger cables.

17. How do you select the conduit process?

High levels of moisture, heat, or vibration,
It will not be damaged during installation or operation.
Cost of materials, installation, and maintenance.