Ultrasonics Join Harley-Davidson Wire Harnesses by John Wnek
While many U.S. automotive manufacturers are struggling to compete head-on against imports, Harley-Davidson Motor Co. boasts a backlog of orders reflecting the worldwide waiting list for its motorcycles. But during the 80's, like most companies, Harley-Davidson found itself mired in a weak market. The desire to improve the company's fiscal strength began with a renewed emphasis on quality.
One area Harley-Davidson targeted for improved over- all quality and process control was the manufacture of wire harnesses for its FLT family of bikes (see photo).
Featuring accessories such as AM-FM cassette stereo, CB radio and cruise control, it requires a complicated wire harness.
The FLT family, which is the company's biggest full dress line of bikes, boasts accessories such as AM-FM cassette stereo, CB radio, and cruise control. According to Dave Freimuth, manufacturing engineer, all these options mean that the FLT family also has approximately 30 splices on it.
The wire that makes up Harley's harnesses ranges from 18 to 10 gauge and is welded into a variety of splice sizes and configurations. Previously, Harley-Davidson terminated the wires for its harnesses using a double lugging or daisy-chaining method. Using this technique, an operator manually places two wires in a terminal and crimps them, using a benchtop termination process. Although this is generally effective, the company refused to take any chances. Explains Dwain E. Cook, an electrical setup technician, "Due to the size and power of the larger bikes, there is always a vibration factor present. We redesigned our harness to try and eliminate any possibilities of an incomplete electrical or a bad connection occurring."
Wire harnesses. Ultrasonic welding was the splicing method of choice for the FLT motorcycle harness because the welds are resistant to vibration and corrosion.
Featuring accessories such as AM-FM cassette stereo, CB radio and cruise control, it requires a complicated wire harness. 
Wire harnesses. Ultrasonic welding was the splicing method of choice for the FLT motorcycle harness because the welds are resistant to vibration and corrosion.
