Application of ECOCABLES Industrial Cable Assembly
Cable assemblies are used in all industries that involve electricity and signals, not just the equipment in the following industries.
- Industrial machines and automation equipment
Industrial cable assembly is widely used in devices such as sensors, control cabinets, and robotic arms.
- Material transportation equipment
Industrial cable assembly is commonly used in transportation equipment such as conveying equipment and conveyor belts.
- Power and energy equipment
In the actual use of the wiring cable components of the power control cabinet and the drive line bundles of the frequency converter, industrial cable assembly can simplify the equipment space by customizing the length of the industrial cable for the control cabinet.
- Large-scale mechanical equipment
For instance, agricultural machinery and construction machinery, among these devices, the Industrial cable assembly used generally consists of multiple strands of copper conductors. It features high conductivity and high flexibility, with an average service life of up to 10 years.
Customization of Industrial Cable Assembly
When you search for "wire harness assembly near me" on a search engine, do you feel confused about how to find a suitable cable harness manufacturer?
If you start your search from your own industry, such as "Industrial cable assembly", it will be much clearer. Below are the customized sections summarized from the over 10,000+ custom industrial cable assembly projects that ECOCABLES has solved in the past.
When customizing Industrial cable assembly, our primary concern is to determine exactly what kind of performance effect needs to be achieved. In this section, we will specifically examine the required conductor material for the assembly cable, the insulation jacket material, whether a shielding layer is needed, etc.
- Conductor: Different purity levels of conductor materials can affect the electrical conductivity. Using 100% pure copper conductors, combined with gold plating to enhance durability, is an excellent combination for most custom Industrial cable assembly projects. There are also conductor treatment processes such as tin-plated copper and copper-gold plated.
- Insulation layer: The selection of insulation jacket material is also an important factor affecting the overall durability of the cable assembly. Materials like PVC, silicone rubber, and Teflon for the jacket, PVC is more flexible, while Teflon is more corrosion-resistant and has better insulation properties.
- Shielding layer: If you frequently use Industrial cable assembly in environments with significant external signal interference, it is recommended that you design the shielding layer of the assembly cable. Common types include aluminum foil shielding, composite shielding, and braided copper mesh shielding. Among these, the aluminum foil shielding layer has the strongest ability to resist high-frequency interference.
In the aspect of structure customization for industrial cable assembly, it includes the selection of connectors, the choice of jackets for the industrial cables, and the connection process of terminals, etc.
- Connector selection: You can choose connectors from other brands, such as TE, Amphenol, Molex, etc., which are well-known brands. We have been cooperating with these brands for over ten years. You can also choose our domestic Chinese brand connectors.
- Cable jacket: In terms of industrial cable protection, you can set the jacket thickness to be thicker, which can better protect the industrial cable assembly.
- Terminal connection process: In addition, the terminals have different connection processes. You can choose according to your actual needs. There are welding, encapsulation, and crimping processes. Contact us to consult the suitable customized solution for you.
For industrial cable assembly, it can be customized according to the actual requirements of your project in terms of packaging, certification, and specified usage environment.
- Packaging: Regarding packaging, if you need to print your company's logo, production date, etc. on the jacket of the cable assembly, it is possible.
- Certification: Or if you need to undergo specific product certifications, such as UL certification, ROHS certification, or SGS certification, we can conduct dedicated certification testing for a particular type of certification.
- Special operating environment: Additionally, in the usage environment of Industrial cable assembly, if there are special circumstances, such as frequent use in high-temperature environments, outdoor use, or environments with chemical corrosives, separate cable assembly performance settings are required. You can choose cable assemblies that are resistant to high temperatures and corrosion.
Industrial Cable Assembly Case
In an increasingly competitive market environment, are you troubled by the issue of wiring harness costs? ECOCABLES, as a professional Custom Cable Assembly Supplier, has carried out over 10,000 custom cable assembly projects on this matter.
By optimizing the components of the wiring harness, such as replacing TE parts with Amphenol or Molex cables, and replacing the original sleeve method with the local heat shrink sleeve method, after actual power-on testing, the original functions were not affected. By simplifying the complex structure of industrial cable assembly and reducing materials. Replacing assembly cables with the same functions but with more competitive prices. Directly helping custom cable assembly customers save $100 per piece of cost.
If you want to know more, you can refer to "Wiring Harness Cost Design Solution" for more detailed information.
Frequently Asked Questions
What is a cable assembly?
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A cable assembly is a complete connection component that includes connectors, wires, shielding layers and other parts, combined to form a directly installable connection component, which improves the connection efficiency of equipment. Its practical applications are distributed in various industries. Industrial cable assembly is widely used in the industrial field, and cable assembly is also frequently used in industries such as transportation and communication.
What is the cable assembly process?
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The cable assembly process is generally divided into the following 6 steps:
1. Preparation of materials and tools: Confirm all the necessary details of the materials such as wire materials, core count, connector models and components, and check if all the related tools (such as crimping machines, welding machines and wire strippers) are functioning properly.
2. Preprocessing of cables: The cables are preprocessed by cutting, stripping, stripping the core wires, removing the shielding layer, and preparing the cable ends.
3. Installation of connectors: Different connectors require different installation methods. For example, there are welding installation, crimping installation, and insulated piercing installation.
4. Assemble the connector: Insert the pre-connected sockets into the insulators of the connector in sequence.
5. Inspection and Testing: Conduct power-on tests, resistance tests, insulation tests, signal detection, mechanical force tests, etc.
6. Packaging and Labeling: Attach labels containing the model number, size, etc. to the cable assembly specifications. Provide protective packaging to prevent damage from squeezing during transportation.
What determines cable assembly power electrical?
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The electrical performance of a cable assembly is not determined by a single component, but by the overall performance of the cable and the connector. It can be analyzed based on the following three decisive factors:
1. Insulation layer: The type of insulation material used can affect the electrical performance of the cable assembly. Materials such as PE, PVC, and silicone rubber insulation have different functions.
2. Conductor material: The quality of the conductor material also determines the electrical performance of the cable assembly. Generally, copper or copper alloy materials have better electrical conductivity.
3. Jacket: The presence of a jacket also affects the long-term performance of the cable assembly's electrical properties. The jacket can provide protection in environments with oil stains, high-intensity mechanical forces, and chemical substances.
What types of cable assemblies are there?
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According to the signal type and the transmission medium, the types of cable assembly are as follows:
1. Communication/Data cable assembly: Applied in network devices and telecommunications equipment.
2. Coaxial cable assembly: Widely used in antennas, communication base stations, and radio frequency testing.
3. Power cable assembly: Used for power transmission in industrial equipment, machinery, electric vehicle charging, medical devices, etc.
4. Fiber optic cable assembly: Frequently used in long-distance communication, video transmission, and data networks.
5. Instrument and control cable assembly: Widely used in sensors, instruments and meters, PLC, etc. equipment.
Do you offer custom Molex Cable Assemblies, or only standard ones?
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We can offer customized Molex cable assembly services. Additionally, we also have standard products that can be directly used. The choice depends on your specific application requirements. If the standard products cannot meet the requirements of your equipment, we recommend that you customize Molex cable assemblies exclusively. This not only ensures a precise match between your equipment and the usage environment, but also reduces losses, enables more efficient application, and will save maintenance costs in the long run.