Cable Assembly FAQ

A wire is a single conductive element, typically made of metal. A cable is a multi-conductor element, typically composed of multiple wires bundled together. A harness is an electrical system consisting of both wire and cable assemblies designed to transmit electrical signals or power. The key difference between a wire, a cable and a harness is the purpose for which each is designed.

Design:
The cable assembly process begins with the design of the cable. This involves creating a schematic that shows how the conductors will be arranged and how the connectors will be attached.

Prototyping:
Once the design is complete, a prototype is created. This is a working model of the cable that can be tested to make sure it meets all of the requirements. Once the prototype is approved, production can begin.

Assembly Production:
The cable assembly process may include precise wire cutting, stripping the wire insulation, tinning of the conductor, crimping on connectors

Quality Assurance testing?:
each cable assembly is tested for continuity, resistance and meets predetermined specs. There are many different ways to approach quality assurance, but all involve careful planning and execution throughout the product development cycle. That means starting with a clear understanding of customer requirements, then designing processes and tests to ensure those requirements are met at every stage, leading to a first article and full production.

UL styles are a way of classifying and organizing wires and cables based on their application. The most common hookup/lead-wire UL styles are:

UL Style 1007: This style is used for general wiring applications, such as in homes, offices, and factories.

UL Style 1015: This style is used for wiring circuits that carry low voltage, such as those found in alarm systems and telecommunications systems.

UL Style 1061: This style is used for wiring circuits that carry medium voltage, such as those found in industrial control systems and switchboards.

UL Style 1242: This style is used for wiring circuits that carry high voltage, such as those found in electrical substations.

standard and push-mount

The most common types are insulation and cloth

Expandable Woven Braid

Heat-shrink Tubing

Spiral Wrap

Insulating Tubing/Sleeving

Slit-wall Corrugated Loom Tubing

The term “mil-spec” is short for military specification, which is a set of standards that specifies the requirements for products used by the U.S. military. The mil-spec standards are often more stringent than commercial standards, and they’re usually reserved for products that will be used in mission-critical applications. Some examples of mil-spec products include aircraft parts, medical devices, and communication equipment.

Military specifications are usually developed by the military themselves, but sometimes they’re developed by private companies or organizations that have been contracted by the military. There are a wide variety of mil-spec standards, covering everything from the materials used in a product to the way it’s manufactured.

The correct conductor size in a cable assembly is determined by the current carrying capacity of the wire and the voltage drop allowable in the circuit.

The wire gauge can be calculated using the following equation:

Wire Gauge = (Current Rating) / (Voltage Drop)

For example, if you are using a 12-gauge wire with a 5-amp current rating and you want to allow for a voltage drop of no more than 0.5 volts, then the equation would look like this:

Wire Gauge = (5 amps) / (0.5 volts) = 10

Your custom cable should be protected by a strong sleeve. You can get custom cables that have a powerful sleeve that will protect the cables when underwater or will stand up to high heat or extremely cold temperatures.

 You can also design cables that have a very thick sleeve that cannot be cut. You need a thicker sleeve when you cannot monitor the cable, or you might need a thinner protective sleeve because you are trying to squeeze the cables into a small space.

There are a variety of materials that can be used as conductors in cable assemblies, but the most common choices are copper and aluminum. Both of these materials have excellent electrical conductivity, which makes them ideal for use in cable assemblies. Copper is the more expensive option, but it offers superior conductivity and durability compared to aluminum. Aluminum is less expensive and easier to work with, but it doesn’t have the same level of conductivity or durability as copper. ultimately, the decision of which material to use will come down to a balance of cost and performance.

There are a few different strand constructions that can be used in cable assemblies. The most common type is made up of individual wires that are twisted together to form a cable. This type of construction is often used for power cables, as it provides good protection against electrical interference.

Another type of strand construction uses a metal ribbon instead of individual wires. This type of construction is often used for data cables, as it allows for faster data transmission rates. A third type of construction uses fiber optic strands, which are perfect for transmitting data signals over long distances.