An Introduction to Aircraft Wiring Harnesses

Aircraft technology and avionics are constantly expanding and becoming more advanced. We have come a long way since the early days of flight when electrical systems did not exist, and aircraft today cannot not work without reliable wiring systems. Used for hydraulic systems, communication devices, and so much more, electrical wiring infrastructures are required in such high quantities that mechanics today must rely on aircraft wiring harnesses for productively grouping and routing large quantities of cables. For your better understanding, this blog will further explore the purpose of using aircraft wiring harnesses for various aviation systems, alongside the various parts that comprise a typical harness.

Early flights relied on ropes and manual labor for controlling their various moving parts, and the first electrical system to be introduced to aircraft was a simple wire to accommodate a lightbulb and switch. Over time, architects developed more uses for wires in aircraft, and eventually, installing these wires one by one became too inconvenient a task. Groups of wires were needed for each additional device, making the setup process lengthy. As such, mechanics began grouping and routing cables together in bundles to increase productivity, and the first wire harness was born from this development.

An aircraft’s wiring harness essentially works on the same principle as those used in cars, directing electrical impulses across the entire vehicle. Containing miles of wires and cables, as well as thousands of individual parts, aircraft harnesses have many functions going on within them. Furthermore, all of these functioning parts must work seamlessly together to allow for safe, smooth flight.

At the same time, consolidating all electrical systems within the wiring harness makes electrical repairs more efficient by allowing for the convenient identification of faulty technology. Depending on your aircraft, the exact elements and components of your wiring harness will vary. As such, there are three categories of parts that comprise such systems: standard, non-standard, and commercial parts.

Typically, the military has final say over the components used in wiring systems, with standards known as MIL-SPEC (military standard). The letters M or MS appended to the beginning of the serial number designate them as a military issue; however, an NAS prefix may be used to indicate an item meets National Aerospace Standards. Meanwhile, non-standard parts are typically variants of commercial parts that meet a slightly different military standard, such as original equipment manufacturer criteria for non-standard components (OEM). Lastly, commercial, off the shelf (COTS) components may be used without permission from the government or the defense.

Installing aircraft wire harnesses requires careful planning with precision and careful structures in mind. This helps prevent problems, and labels should also be used for different wires to prevent further confusion. An organized wiring harness is a convenient tool for any aircraft and its subsequent systems. To procure any reliable part types for your aircraft wire harness, be sure to source any connectors, wires, and more, from a trusted distributor like NSN Parts Hub.

Owned and operated by ASAP Semiconductor, NSN Parts Hub is a leading online purchasing platform for over 2 billion new, used, obsolete, and hard-to-find parts from around the globe. Offering around the clock service with rapid lead times and competitive pricing, submit a Request for Quote (RFQ) form today for any item(s) that catch your interest to receive a custom quote within 15 minutes or less. Using provided details like target prices, shipping deadlines, and desired quantities, our experts are better able to tailor quotes that fit your needs. To learn more, you may contact us via phone or email at any time!


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