Optronics International has completed acquisition of Winnsboro, Texas-based USA Harness. A leader in trailer harnesses and electronic control systems, USA Harness serves the RV and transportation industries with its USA-Plus Sealed Modular Wiring Harness System and its patented USA-Plus Modular Connection System.
“In the past, we would see what is commonly referred to as ‘wire and loom’ systems for electrical distribution in many RVs,” said Brett Miller, engineering manager for Optronics USA Harness. “These convoluted systems would often be rather primitive affairs wrapped in plastic with wires exiting out of the core loom. They offered high flexibility, but were low on durability.”
According to Miller, the weakness of wire and loom systems is their inherent instability and vulnerability to contamination. Most wire and loom systems are informally constructed with spliced connectors at the wire ends that may not be properly sealed against the elements. The systems also generally have too little protection around the main loom, and what protection does exist, is compromised by the many openings needed to enable individual wires to exit.
Some wire and loom systems may incorporate wire that is undersized and unable to handle the amperage demands placed on it. In these cases, wires can heat up to such an extent that their outer sheath may melt, become brittle, crack, and in severe cases, even cause a vehicle fire.
“Any opening in the system will admit dirt and debris over time, but the big problem is moisture,” Miller said. “Moisture enters an electrical system through even the smallest breach in the protective outer jacket and penetrates through insulation, ultimately reaching the conducting wire.”
Connectors are also a primary source for moisture intrusion and electrical system contamination. Connectors become more vulnerable over time, because the dielectric grease that once repelled dirt and water dries out, reducing its effectiveness as a protective barrier.
Optronics USA Harness designs and manufactures purpose-built wiring and harness systems that are made to take what the real world can dish out. The company works with up-fitters, bodybuilders and specialty vehicle manufactures to custom engineer a wiring and harness system that not only serves its purpose, but that lasts for the service life of the vehicle. Systems designs occurt only after a complete and thorough understanding of a vehicle, its structure and its field application are understood.
“We design fully-jacketed cable assemblies with over-molded splices and plug-in connectors,” Miller said. “Our durable PVC plastic material envelops all the wiring in a protective outer layer that resists multiple forms of contamination, including moisture.”
Miller notes that a well-designed system really pays off in the long run, because it reduces the vehicle owner’s exposure to electrical problems down the road. Optronics USA Harness systems handle severe-duty on- and off-highway applications, and this added level of protection benefits all users, including those operating in less demanding environments.
“We look at what the manufacturer is trying to accomplish,” Miller said. “Application sophistication dictates how the system is designed and how well it needs to be protected.”
Coupled with its diverse international background and experience, the newly acquired engineering and manufacturing capabilities of USA Harness will position Optronics International to be even more competitive in North America, while fully leveraging its synergies as a global lighting and harness supplier.
“We have watched Optronics’ exponential growth over the years and have engineered more and more harness systems for use exclusively with their lighting,” USA Harness Interim President Debby Thompson said. “Though we’ll continue to produce harness systems that interface with all major lighting manufacturers, we’re excited to now be able to offer a fully integrated modular power delivery and lighting solution.”
For more information about USA Harness, click here. For more information about Optronics International, click here.
