The cable assemblies manufacturer designs the cable assemblies to organize the wires, especially in situations where multiple cables take up too much space, and for the protection of various electrical wires, ensuring that workers can monitor the flow of the electricity and simultaneously prevent the wires from crossing each other.
Cable assemblies are essential because the cables can be grouped according to the required length and orientation to make installation easier and quicker. Cable assemblies include different cable constructions, varying sizes, colors, and lengths depending on the application.
When designing a product that requires a cable assembly, it is essential to share all the details regarding the complete application with the cable assemblies manufacturer to determine the cable assembly that best suits the requirements.
Selecting the proper components for cable assemblies
There are many components involved in the cable assembly design, and each component impacts the performance of the finished cable assembly. The components of the cable assembly must be able to withstand the expected flex. The components to consider for designing a cable assembly include conductor or circuits, primary insulations/sheaths, twisting/cabling of conductors, shielding, outer sheath, connectors/strain reliefs, safety certification, etc.
A particular application of the cable assembly will determine the components of the cables. The cable assemblies manufacturer also designs cable assemblies for instrumentation systems, local area networks, personal computers, and industrial control applications. An important point to note is where the cable assembly will be used.
The cable assemblies manufacturer must have safety certifications for that specific region, and the cable assemblies must meet environmental standards.
Testing Procedures for Cable Assemblies
While manufacturing a product, it is essential to test its effectiveness and proper functioning. A cable assemblies manufacturer tests a cable assembly to ensure they meet their standards. Cable assemblies serve different purposes; therefore, the cable should be strong to bear all kinds of mechanical stress and must be durable in its operational environment.
Different tests are performed to measure the efficiency of a cable assembly, including Visual tests, Electrical tests, Hipot tests/Dielectric strength tests, Mechanical tests, Pull, Flex/Bend tests, etc. Cable assemblies are examined visually to check for dimensional compliance according to the specifications they were built for. Cable assemblies undergo electrical tests to check for incorrect wiring, opens, or shorts.
Cable assemblies are continually put in different environments to ensure that the assemblies can resist the environment, including low/high temperatures, humidity, vibration, shock, and corrosion. Other tests can be performed on cable assemblies apart from the visual, electrical, and environmental tests mentioned. Different cable assemblies manufacturers perform different tests to produce cable assemblies of standard quality for specific applications.
Tips for designing cost-effective cable assemblies
Manufacturers must design reliable and cost-effective cable assemblies to protect the devices from surges or environmental issues. The type of insulation, external protection, contacts, tie-wrap, and tolerances are essential in designing cost-effective cable assemblies. A cable assemblies manufacturer can use PVC insulation as it is less expensive and easier to work than other materials like Teflon.
For cable assemblies protection, manufacturers can use a jacket or shield. Shielding is more expensive as it requires additional labour to install terminals and connectors. The type and number of tie wraps determine the costs involved. Different manufacturers provide different prices of tie wraps; therefore, choose the manufacturer and your tie wrap wisely.
The tighter the tolerances are, the more difficult it becomes for the cable assemblies manufacturer, thus making the end product more expensive. How the connectors are installed in the assembly, whether crimped or hand soldered, will impact the cost. Crimped contacts help to save costs as compared with soldering contacts that require a very high degree of trained operations.
Also read: The Kinds of Things Businesses will Test For
