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What to Look out for When Using Cable Assemblies?

Jun. 06, 2024

Some of the upfront questions that need to be answered are those related to the environment in which the cable assembly/cable harness will be used. For example, if a cable assembly is to be used in a dynamic installation, which means it will be exposed to bending to some extent, the assembly's components need to be able to withstand the expected bending. The same options need to be considered if the assembly is to be used in a harsh environment, if the cable assembly is to be used in a clean room environment, or if the cable assembly is to be used in an area exposed to sunlight or moisture.

Stranding/wiring of conductors

Invented by Alexander Graham Bell in 1881, EMI (electromagnetic interference) from external sources is eliminated by stranding the wires. The most common noise problem is with cables used for telecommunications, where pairs of wires in the same cable are placed next to each other over long distances. Due to the close proximity, a pair may cause crosstalk on adjacent pairs, and this noise increases along the length of the cable. As cable pairs are only close to each other at half-twist, twisting the pairs together can counteract this effect. If the assembly will be used for communications or data signal transmission, twisted pairs should be considered to eliminate any risk of noise or EMI affecting the performance of the cable assembly.

Cable Assembly with *P D-sub& USB Connector

Cable Assembly with *P D-sub& USB Connector

Conductors or twisted pairs are also connected together with cables. Cabling is a manufacturing operation in which conductors or pairs of spirals are twisted, or 'wired' together. Cabling has a variety of uses, it provides more flexible cable components and also produces circular configurations which will allow for aesthetically pleasing end assemblies.

Connectors/Strain Relief 

There are many options for the cable assemblies design when it comes to the connectors to be used on their assemblies. The type and speed of the signal to be transmitted will determine the choice of connector. For example, if power is to be transmitted through the cable assembly, a crimp type connector may be chosen, or if high-speed signals are to be transmitted, a solder or weld type connection will be used. Connector options may be limited depending on the equipment the component will be used with. It may be that a connector has been selected and fitted to the equipment that the component must match. If this is the case, then the choice of connectors will be very limited.

Another choice the cable assembly designer will need to make is whether strain relief is required. Strain relief provides a transition point from the cable to the termination area and prevents the load applied to the cable from being transferred to the termination that caused the termination failure. There are options for strain relief, such as solid or segmented designs. Segmented designs provide the greatest amount of strain relief but are more difficult to keep clean if used in a sterile environment.  If you want to get more information about the best cable assemblies wholesale, welcome to contact us today or request a quote.  

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