Cable assembly, as the name simplifies that arranging of groups of cables into single unit which is used for both for Transmitting power or informational signals. Cable assembly has been used in different industries like Telecom, power, automobile, aeronautics, medical etc. If we consider the usability of the cable assembly they are mostly used in Automotive Industry (Approx. 32%), Telecom and Datacom (Approx. 15%) a Computer and Peripherals (Approx. 11%),  Military/ Aerospace (Approx. 8%), Industrial(Approx. 8%) others.

In short, they are used nearly everywhere electrical power and signals must be transmitted.

Depending on the requirement:

A harness or cable assemble may have jacketed legs to protect from abrasion.

Harnesses may have several hundred wires and be very large.

Industrial/commercial purpose – usually have large to very large volumes and low complexity. Uses COTS wire and connectors.

 

First of all we should exact know the requirement to process the process cable assembling. Depending on the below points we use to consider while manufacturing:

 

Working Environment: It’s one of the key point to be look upon.

  • Shipboard
  • Aircraft
  • Secure Communications
  • Ground Support
  • Rail/Mass Transit
  • Space
  • Missile Defense
  • Telecommunications
  • Armored Vehicle

Electrical/Optical Requirements: Application defined requirements for cable performance may include

 

    • Current rating
    • Test voltage
    • Insulation resistance
    • DWV
    • Signal leakage
    • Attenuation
    • Voltage drop
    • Capacitance
  • EMI Shielding Requirements: Customer defined shielding specifications for the cable may include:
    • Shielding effectiveness (dB)
    • Frequency Range (Hertz)
    • EMP
    • TEMPEST
  • Key Environmental Requirements: Customer environmental requirements for the cable may include:
    • Moisture/chemical Protection
    • Low Smoke/Zero Halogen
    • UL94-V0 Flammability
    • NBC/CBRNE Resistance
    • UV Resistance
    • Temperature Resistance
    • Controlling Specification

Key Mechanical Requirements: Customer mechanical specifications for the cable may include:

    • Field Reparability
    • Crush/Abrasion Resistance
    • Pull (Tensile) Strength
    • Flexibility/Flex Cycles
    • Minimum bend radius
    • Workmanship standards
    • Strain-relief

Packaging:

 

  • Customer packaging/construction requirements for the cable may include:
    • Critical dimensions/tolerances
    • Required tooling, such as crimp dies, molds and test fixtures
    • Specific cable management and identification choices
    • Approved jacket, boot and dielectric materials
    • Jacket finish
    • Specifications on length of lay in twisted pairs or other cable construction details

 

After completion of the assembly it undergoes different kind of test to check the quality:

Electrical:

Electrical connections

Component Testing

4-wire Testing

Pin-to-pin isolation

Continuity and Function

Fiber Optic

Single-mode insertion & return loss

Multi-mode insertion loss

Break detection

Others tests like:

  • Bubble Leak
  • Fluorocarbon
  • Alcohol vacuum
  • Pneumatic Testing (1-60 PSI)

The Ideal Interconnect Cable Assembly must have below qualities:

  • Fault Free: Form, Fit and Function
  • 100%  Electrical Continuity
  • Corrosion-Resistant Materials
  • Maximum Flexibility and Durability
  • Minimum Size and Weight
  • Abrasion-Proof Coverings
  • Crush-Proof Conduit
  • Precision, Gold Plated Contacts

 

As a reputed manufacturer from decade we always maintain ISO 9001:2000 Certified for our production. And always try to accommodate customer’s requirement thoroughly.

 

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