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Have you ever seen overhead cables outside your house or in the markets? Have you ever noticed underground cables? All these cables are power cables that help in the transmission and distribution of electric power. You will find a wide variety of power cables in the market; however, you have to choose a specific type for a particular purpose to ensure smooth electrical performance. Yes, a custom power cable assembly.

What are power cables?

Power cables comprise one or more conductors bound together with an outer sheath. This assembly of multi-conductor cables helps in the transmission and distribution of electrical power. Different applications for power cables include their use within buildings or construction sites as permanent wiring, burial inside the ground, overhead cables, or even exposed cables.

Caption: electricity plant

Construction of power cables

They comprise three parts; conductors, insulation, and the outer cable cover or protective jacket. These components may differ in different power cables due to three main factors. 

• Working voltage as it decides the insulation thickness.
• The current rating of the cable determines the cross-section area of the conductor. Also, power cables generally have copper or aluminum conductors in stranded form; however, some may even have solid conductors. Some cables may also have uninsulated conductors used for neutral or ground connection, known as tinned bare or bare conductors. The power cables may be round or flat; some cables have non-conducting filler strands to maintain their shapes.
• Environmental conditions like water, temperature, sunlight, chemical exposure, and physical impact determine the outer jacket’s form and composition. For the nuclear industry, the jacket must have ionizing radiation resistance. For buried cables, the jacket must protect dig-ins or backfills; thus, polypropylene jackets are standard for these cables. 

Apart from the main three, power cables may differ according to the situation, such as:

• When directly buried or used in exposed installations, power cable requirements include metal armor of steel or aluminum. This armor is either in the form of a corrugated tube wrapped around the cable. The armor connects to the earth’s ground to avoid electric current conduction. 
• Power cables sometimes have armor wires on the jacket’s surface to support the cable’s weight in different applications. Electricians use a supporting plate at the tower or building floor in vertical cable installations.
• If used in raceways, the cables may have electrical conduits or cable trays having one or more conductors.
• For buildings, there are NM-B cable or non-metallic sheathed building cables having two and more conductors inside a thermoplastic insulated sheath.
• Power cables for overhead applications comprise high-strength alloy, alum weld messenger, or ACSR. These are aerial cables or pre-assembled aerial cables. 
• When power cables face mechanical stress, the cables come with flexible steel tape or a jacket of wire further covered with a water-resistant jacket. Some utilities use lead sheaths as an overall covering of the cable.
• Lastly, some power cables are hybrid, with conductors for transmitting signals and optical fibers for transmitting data.

The flexibility of power cables

The power cables have some flexibility so that shipping and installation become easier. However, the flexibility of power cables differs, putting them in different stranding classes. 

There are three stranding classes for power cables: A, B, and C. These cables differ based on their minimum bending radius. Based on these classes, a cable is trained to be installed in the final position so it does not get disturbed. All these classes are highly durable and cost-effective also. Power utilities mainly use class B stranded power cables for primary and secondary voltage installations. However, when water blocking is a priority, one can use solid conductor cables with medium voltage.

For applications that require constant movement of power cables, like in portable devices, you may need flexible power cables or cords. These cords or flex have stranded fine conductors, and these conductors have jackets with filler materials to maintain their overall flexibility and durability. There are flexible power cables for machine tools, robotics, or other automated machinery. 

Caption: power cables

Types of power cables

The construction of power cables differs based on their application, size, construction, type of material, current carrying capacity, and so on. However, based on voltage, power cables are of two types.

High voltage cables

As evident from the name, the high-power cable assemblies help in high-voltage transmissions, specifically in transmissions and power plants. The voltage of these cables varies between 33Kv to 220kV. You will find these cables mostly in power grids. These cables have very high-current carrying efficiency. However, with such a high current and high voltage, the insulation requirements of these power cables are also high. Thus, you will find a very high layer of insulation in these cables, ensuring reliable transmission.

Further, technicians use many automated technologies like SCADA or DCA to ensure that transmission occurs safely without risk to humans and surroundings.

Low-voltage cable

The voltage capacity of these cables falls between 70v to 600v; thus, you can safely use them for domestic, small-scale industries and various applications. A large number of factories and various automated technologies use these cables.

Be it high- or low-voltage cables; it is never safe to touch either of them; otherwise, it may result in death. High voltage cables carry high voltage current, which is stepped down at substations and reliably reaches homes and offices through low voltage cables.

Caption: high voltage substation

Power cord standard

You must have the power cord in your mind when it comes to custom power cable assemblies. Power cords have different quality standards worldwide, and different countries use different power cords, plug types, and connectors.

IEC 60320

is an international standard for power cord appliances up to 250 volts. Though different countries use different power cord standards and types, this is a common standard that most countries use. Here, the C refers to the connector code standards defined by IEC 60320. You must pick different connectors for current, voltage, and temperature combinations.

In data centers, the standard connectors used are C13, C15 and C19.

The IEC 60320 power cords define an even number for the plug connector and an odd number for the female receptacle. Here, the male plug number is one higher than the corresponding receptacle connector number; for example, the standard power cord type combinations are C14 to C 13, C20 to C19, etc.

The IEC 60320 standard mainly focuses on the connector types. For the plugs, the different countries use different standards.

North American: NEMA 5-15P (Type B)

Most North American countries use NEMA standards. Among several NEMA plug standards, NEMA 5-15P plug is the most common. There is a three-wire circuit where one wire is for hot, the second for neutral, and the third for ground. These plugs have a rating of 250V and 15 amperes. The most common power cord is NEMA 5 15P (plug) to NEMA 5 15R (receptacle). Other common combinations include NEMA 5-15P to C15 and NEMA 5-15P to C13.

Europe: CEE 7/7 (Type F and Type E)

CEE 7/7 is the widely used industry standard for plugs in most European countries and countries that follow CENELEC standards. European countries like Cyprus, Malta, Denmark, and Switzerland do not use CEE standards. The typical power cords adopting CEE standards are CEE7/7 to C19, C15, and C13.

Other standards: 

The table below lists some countries with different plug standards.

Country	Plug standard	Plug type
Argentina	IRM2073	Type C, I
Australia and New Zealand	AS/NZS 3112	Type I
Brazil	NBR 6147/NBR14136	Type C, N
China	GB1002/Gb 2099	Type A, C, I
Denmark	AFSINT 107-2-D1	Type C, E, F, K
Japan	JIS C 8303	Type A, B
South Africa	SANS 164/BS 546	Type C, F, M, N
South Korea	KSC 8305	Type C, F

Conclusion:

When choosing power cables, commitment to quality is required to avert any potential risks and sudden electrical faults. Before any installations, it is always good to seek professionals’ advice. Further, if you need custom cable assemblies, Wiringo can help you get one suitable for your application requirements. 

You will often need cables that can bend repeatedly and plug or unplug for industrial and automotive applications. To achieve your goal of reducing mechanical stress and providing strain relief, you will require custom-molded cable assembly.

What are Molded Cable Assemblies?

A molded cable assembly is an assembly with molded ends creating a sealed plug or connector. 

Overmolded assemblies increase the value of your design by providing 360⁰ strain relief, flexible support at cable exits, and increased pull strength. Additionally, molded cable assemblies offer abrasion resistance, increased electromagnetic interference, and protection against harsh environments.

You can use several methods to accomplish overmolding or molding using different components depending on the end product’s electrical, physical, and mechanical requirements.

A crucial factor in the molding or overmolding process is your choice of a compound. It must properly adhere to the surface you intend to apply it on. Whether injection molded or overmolded cable is silicone, PVC, thermoplastic material, or Teflon, ensure you choose the right compound to guarantee a structurally sound end product.

Custom cables are of different types designed for specific requirements. They cost more than standard cable types. And the price might increase significantly, depending on the complexity of your custom-molded cable assembly.

Different types of molded cable assemblies

Benefits of Overmolded Cable Assemblies

Overmolded cable assemblies increase durability and performance. The point at which cables exit connectors exposes them to additional stress. Overmolded components increase strain relief and flexibility, creating a more durable cable that is less prone to premature failure. Also, they have the following characteristics.

• Customization

Thanks to the wide array of materials available, you can design a custom-molded cable assembly tailored to the precise environmental concerns of the equipment.

• Fewer Installation Errors

Custom-molded cable assemblies don’t require additional assembly. Therefore, installation is quick and easy, leaving little room for human error.

Cable Assembly Overmolding Process

To achieve the cable assembly overmolding process, you must push the material into the mold cavity, exposing it to excess pressure. The most common material used in overmolds is thermoplastic. There’s some storage space for resin in the injection molding machine. The material is often delivered in a screw-type plunger enclosed in a metal tube (barrel) or an injection ram after the heating elements are equipped into the barrel to heat the resin to molten form.

First, push the resin into the healing barrel of the molding machine at the hopper end. It mixes using any colorants and transits the barrel’s length to the actual mold, where the colorant mixture and resin get pushed into the mold cavities. Finally, the material cools, imitating any designed features in the mold, including part numbers, trade names, and logos. 

Injection molding machine

Overmolding Design Considerations

During the cable assembly design process, engineers use overmolding to provide bend and strain relief. For instance, they may use grommets as part of the assembly for any points that require installing through an opening and as a shield for the connector backshells protecting the contacts and termination points. Due to the increase in complexity tooling and the variety of materials you can use, any components that are to be injection molded should be carefully designed.

Cable Overmold Tooling Materials

Thanks to 3D printing, you can now use photopolymers for simple injection molds. Photopolymers enable the molding of resins at lower temperatures for a limited number of molding cycles.  

Manufacturers categorize Injection molding machines according to tonnage. Tonnage defines the amount of force the machine uses to keep the mold closed during the injection process. Therefore, the larger the injection machine, the more cargo it exerts, producing more molded parts. 

A die or mold is a tool manufacturers use to make the molded part. Molds are costly. Also, the more detailed and complex the mold, the higher the costs. Depending on the number of cycles to which you expose a mold, you can use different materials. And if you expect a mold to undergo thousands of mold cycles, then hardened steel is the ideal metal choice. 

Because they’re made of the most robust material, hardened steel molds are costly. However, it’s a fair price, considering the mold’s prolonged lifespan and ability to withstand many cycles without wearing out quickly. Manufacturers often use steel molds in mass-production environments. 

For molds likely to undergo several cycles, aluminum is a common choice. Aluminum serves a shorter period, but its malleability results in lower tool fabrication costs. Often, manufacturers produce molds using Computer Numeric Control machines or electrical discharge machining processes.

The material you intend to use on the molding itself will steer you in the right direction as to the material to use for the molds. If you plan on using thermoplastic resin, you can use aluminum or stainless/hardened steel. However, if the material is a liquid injection type, such as silicone, use molding tools made of hardened steel. When looking to accomplish a liquid injection, the tooling must produce exact measurements to avoid any gaps or secs that could allow the liquid to escape.

Before implementing various applications, designers often create 3D-printed models of the overmold to test the design’s fit and form. That helps avoid using costly hard tooling that could lead to the wrong results, which, should it happen, it’s impossible to alter the tooling. 

Single or Multiple Cavity Designs

When designing molding, you can choose between single or multiple cavities. Each cavity is identical to produce multiple molds in a single mold cycle with a multi-cavity mold. Some designs create multiple nonidentical cavities. A common issue is ensuring the resin flows into different designs without creating air gaps or voids.

Manufacturers deliver resin material into the heated barrel through the hopper during molding. After the heat and forces of the screw, the material softens, and the mixed resin gets pushed toward the mold tooling. Manufacturers refer to the resin that accumulates at the end of the barrel as a shot at the point. A shot is the amount of resin required to fill a cavity, which also includes an extra amount to compensate for the anticipated shrinking of the resin. Cavities typically take seconds to fill up.

Then the ram or injection screw applies pressure on the shot until the resin at the gate to the cavity cools and solidifies. The gates to the cavity are the smallest part of the mold tooling. Therefore, it’s the first area to solidify completely. Once the resin at the gate hardens, the injection molding machine cycles and prepares another shot while waiting for the next molding cycle. The resin in the cavity keeps cooling, and you can remove it once it solidifies. 

Oil or water gets circulated through the mold tooling in a series of channels to help the cooling process. Once the resin solidifies, the mold opens, removing the complete mold. Manufacturers use metal fingers or pans to make removing the mold in the mold tooling easier. And once they remove the mold from the cavity, the cycle begins again.

Pre-Mold and Overmold Designs

Some designs require that the mold comprise two parts; an overmold and pre mold. The pre-mold can consist of machine parts (pins or screws) or previously molded smaller parts. Normally, you will place these various parts in the cavity while the mold is empty. Then when the overmold cycles, the resin flows and then gets solidified.

Manufacturers often use this process when the overmold needs screws to fasten the connector to other installation components.

The Appearance of the Finished Product

After the molding process, the end product will always have blemishes and marks. Some of the reasons the molding process leaves marks to include:

• The ejector pins touch the resin when pushing it out of the mold cavity.
• Dimensional differences among the pieces of mold tooling.
• Marks where the resin entered through the gate.
• Mold tooling exhibiting signs of wear.

Blemishes and marks are inevitable. However, you can minimize the effects by specifying tight dimensional tolerance as you design the mold tooling and place gets in positions of the cavity that are not so noticeable. It’s important to consider the above factors when designing molding tools.

Injection Screw 

Conclusion: 

Custom-molded cable assemblies are robust and reliable, making them a common choice in various industries today. Most applications use molded cable assemblies to protect and interconnect cable assemblies. Feel free to contact Cloom Tech for the best custom-molded cable assembly solutions.

All arms of the Department of Defense, be it the Navy, Coast Guard, Marine, or Army, need precise control and reliable power. Thus, cable assembly military design forms the core of every piece of equipment used, armored vehicles, tanks, infantry vehicles, mine protection vehicles, ships, humvees, armored personnel carriers, SUVs, cargo vehicles, rugged ATVs, and four-wheel drive vehicles. 

What Are Military Cable Assemblies?

Manufacturers design and engineer military wire harnesses and cable assemblies to meet certain MIL-SPEC specifications. Also, they must fabricate the cable assemblies using connectors, wires, terminations, cables, and other components approved and specified for military application. 

Standard wire and cable configurations will do the trick for most everyday applications. But due to the harsh conditions in aerospace and military applications, you’ll need configurations of higher quality and reliability.

Today, the primary use of military wire guidelines is differentiating wire and cable assemblies. Some references were successfully transitioned to standards by private entities such as ANSI, NEMA, and SAE. Therefore, manufacturers should refer to the standards before deciding on the construction cables and wires or materials for specific military-grade applications.

MIL-SPEC Wire & Cables 

MIL-SPEC wires and cables are unique since they have their designation, unlike other products like high-temperature or hook-up wire. Like CSA and UL standards, people consider the product genuine or an actual MIL-SPEC wire by following a specific set of standards.

The wires get used in every military vehicle’s internal wiring of electric panels, electrical equipment, meter, and electrical components. The specific applications vary from antennas, airframe wiring, point-to-point wiring, bonding moving parts, and any instances that require durable shielding.  

Today, manufacturers use several standards to differentiate a wire’s specific attributes. For example,

MIL-SPEC Connectors

MIL-SPEC connectors are shell-type connectors built to meet certain military specifications. When designing MIL-SPEC connectors, manufacturers considered the need to protect connections from harsh environmental conditions, making them usable in aerospace and military applications. 

A connector consists of a plug, receptacle, and mating pair, each with a socket and pin contact. Usually, electrical connections consist of phosphor bronze or beryllium copper that’s later plated with gold or other non-corrosive high-conductive metal. However, manufacturers plug the connectors with a protruding ferrule holding the fibers for fiber-optic connections while also aligning two fibers for mating. With fiber optic connections, an essential specification is the insertion loss; that’s the amount of light lost during the connection.

Some of the military standards and specifications that MIL-SPEC connectors must meet include

Benefits of Military Cable Assemblies

Because of how much aerospace, military, and security technologies get exposed to extreme conditions, reliable custom cable assemblies and electrical wiring is needed to ensure safe and dependable equipment operation. Therefore, the connectors and cables share the following characteristics.

Ruggedisation

Connectors and cables meet various military-grade specifications. So they can handle medium and high-temperature installations for optimum performance even when exposed to extreme mechanical stress. Also, they’re suitable for high-frequency electronic applications where high temperatures pose a threat. In addition, MIL-SPEC cables offer outstanding, steady electrical characteristics with minimum power loss.

Miniaturization

The demand for miniaturization is increasing rapidly in the aerospace, military, and security industries. Miniaturized connectors and cables are equally efficient and reliable as conventional methods, only much lighter and smaller, offering better flexibility, easier integration, and shorter time delays for faster signals. Additionally, miniaturization makes integrating extra space for crucial aerospace and military applications easier.

Microwave & RF

A wide array of coaxial connectors enable the design of custom and high-performance military and aerospace cable assemblies. Standard core ranges cover a maximum frequency range of 4GHz to 40GHz. But if needed, specialized RF and microwave products can handle frequencies as high as 110GHz.

Applications of Military Cable Assemblies

Military and aerospace wire and cable assemblies enable dependable and safe operation for various critical applications, such as 

• Space force systems
• Military ground components
• Avionics systems
• EMI-sensitive equipment
• Field and inter-shelter communication components
• Satellites and space shuttles
• Ships, submersibles, and other marine systems
• Airborne communication and navigation systems
• Remote weapons control

5 Primary Factors That Help You Determine If you Need a MIL-SPEC Cable Assembly

Although you won’t always have to adhere to military specifications in every project, applying MIL-SPEC in some circumstances is useful. In addition, military-specified cable assemblies are more costly. Therefore, deciding whether it’s crucial to your application is important.

1. Are you planning on using it in a critical process? If this component’s failure threatens the entire process, it’s advisable to invest in a military-specified cable assembly that guarantees optimum durability and continuity of the process.
2. Next, consider the environment surrounding the cable assembly. Manufacturers design MIL-SPEC cable assemblies to withstand harsh conditions without malfunctioning. The cable assemblies can undergo extreme temperatures while offering corrosion and abrasion resistance. If your intended application demands high levels of robustness, then MIL-SPEC cable assemblies will effectively handle the job.
3. Consider the impact of vibrations and motions. If the intended application exposes components to constant vibrations and motion, you should consider getting military-specified cable assemblies. Especially in military applications where there are frequent motions and constant vibrations due to the travel of tricky terrain, MIL-SPEC cable assemblies are a must-have. Therefore, if your intended application poses similar conditions, it’s best to opt for MIL-SPEC cable assemblies.
4. Is EMI/RFI radiation an issue? Unless radiation is necessary, such as in radio jamming, you should avoid exposing your application to such radiation. Consider getting MIL-SPEC cable assemblies. These offer complete RFI/EMI shielding, which is especially vital in various applications.
5. Are you complying with the industry regulations and requirements? Some applications require MIL-SPEC cable assemblies to get the best out of equipment. Also, this could ensure product reliability and safety compliance.

Conclusion: 

Manufacturers designed the MIL-SPEC cable assembly according to military standards and specifications. Often, they employ specially designed and durable materials in these cables. 

Such materials make the cable assembly more resilient in several situations, such as when exposed to high vibrations.  For aerospace and military applications, you need reliable and high-quality wire harnesses and cable assemblies for the best result. At Cloom Tech, our team of experts design and fabricate MIL-SPEC cable assemblies to better serve your needs.

Agriculture and other heavy-duty equipment must run 24 hours a day for all seven days of the week. So, you need reliable wire harnesses that are made of durable material. Braided wiring harnesses are common types used in such industries.  This post will learn about these wire assemblies’ protections.

What Is a Braided Wiring Harness?

Braided wiring harnesses are wire harnesses wrapped with braided sleeves. A looming machine executes this process. 

Braided cable sleeves work as cable organizers or protectors; thus, you can also call them wire protection sleeves. The loom helps protect from vibration and heat in several heat resistance ratings. Often, these sleeves have interwoven plastic fibers (either polyester or any other plastic), but braided metal sleeves are also very common.

These sleeves protect cables and wires against abrasion, corrosion, moisture, heat, chemicals, and electromechanical waves.

Types of braided cable sleeves

Split braided wire sleeve

Split braided wire sleeves have a cut along their length and close automatically after installation. Thus, you can call them self-closing braided sleeves. These lightweight sleeves offer abrasion resistance. You can use them in pre-existing cable harnesses, which you cannot disassemble. These sleeves comprise polyester and provide easy access to wire bundles inside.

Expandable Braided Sleeving

These sleeves comprise polyester and are very easy to install. Due to their open weave construction, they allow heat and moisture to pass through. As they are expandable, you can put multiple wires into them and still get desired flexibility. You can also find polyphenylene expandable sleeves. However, these are more suitable cable assemblies used in high temperatures. They have high chemical resistance and less moisture stability.

Caption: Expandable sleeves vs Split braided wire sleeves

Use Cases of Braided Wiring harness 

Some industries using braided sleeves include:

• Marine: Primarily in control panels, vessel engines, and switchboards. 
• Automotive: Multiple uses, predominantly around the vehicle’s electronic system.
• Military: Commonly used in transport vehicles.
• Robotics: The complexity and precision of robotics wiring make braided sleeves a popular option. 
• Manufacturing: Used in manufacturing machinery and production lines because of its durability and expandability.
• Power Generation: Ideal for outdoor uses because of resilience in UV light, moisture, heat, wind, and dust.
• Rail Transportation: Protects cables hanging from undercarriages.
• Mining and Heavy Construction: Well-suited to dust, vibration, chemicals, etc. 

Benefits of Braided Cable Sleeves

They have proven advantages for commercial and industrial applications:

Constriction Around Irregular Shapes 

Braided sleeves can constrict around irregular cable shapes to provide cushioning without creating space that could allow the collection of moisture. 

Better Organization

You can group numerous wires in a compact and neat sheath, making the design more appealing. In addition, braided sleeves enable quicker identification of specific wires. 

• Direct braiding is on the wiring harness in the braided wire loom, offering aesthetic cable concealment. Thus, it looks very clean and one piece. There is no extra tape and cable ties on it. 
• PVC-coated nylon is available in a wide variety of colors, which can enhance the looks of the harness. You can also use different colors to differentiate your brand from others. If you are picking black-colored nylon, you can use tracers. Tracers are strands of different colors which are woven into the braid. Tracers in a braided wire loom help your OEM know which supplier partners the wire comes from and what system it controls or operates. 

Extra Cushioning 

Braided sleeves have some extra cushioning in their design to protect the wires from shock damage, especially in cases where heavy impact and vibrations are unavoidable.

Moisture Draining

In the braided wire loom, water can pass through the loom, which is essential when the harness faces freezing conditions.

Effective Heat Transfer 

Their open weave design also enables heat transfer. Any built-up heat around the cables can easily dissipate, preventing potential issues or electrical fires.

Expansion Capabilities 

Interestingly, braided wire harnesses have remarkable expansion capabilities, which come in handy, especially for large-sized cables that would not ideally fit in a more rigid form.

Materials Used in Braided Cable Sleeves

You have several material options for braided sleeves.

Nylon

Nylon is popular because of its flexibility and lightness. It allows for easier installation and adjustment, which makes it suitable for automotive applications.

Nylon is very effective at preventing the accumulation of moisture. However, it’s less stable when exposed to high temperatures and has limited UV radiation, corrosion, and chemical resistance compared to other options.

Polyester

Polyester can expand almost three times its original size. Thus, it allows for a close fit around irregular-shaped and oversized cables.

Polyester braided sleeves offer exquisite abrasion, heat, and corrosion resistance, but they can be unstable in extreme hot or cold conditions.

Polyethylene Terephthalate (PET)

Polyethylene terephthalate is a category of polyester that’s pliable and lightweight, like nylon. PET sleeves are easy to install as they easily adapt to various shapes to serve various purposes.

Also, PET has extreme fluid and water resistance. It’s an ideal option for applications that subject cables to automotive fluids (engine fluids and gas) and cleaning chemicals. PET sleeves alleviate strain on stretched cables, preventing any breaking or cracking.

Polyphenylene Sulfide (PPS) Monofilaments

Polyphenylene sulfide monofilaments are among the lightest braided sleeves. This durable material can withstand chemicals and solvents very well. It’s inert to acids, fuels, steam, and strong bases, making it ideal for applications involving exposure to such substances. 

Also, PPS is flame-resistant.

Additionally, PPS is ideal for specific applications, such as aerospace and telecommunications industries, because it’s moisture and chemical resistant and can withstand high temperatures. 

On the downside, PPS has lower flexibility capabilities and provides limited corrosion and UV resistance.

Fiberglass/ Nomex

The fiberglass braided sleeving is more durable as they are made of fiberglass braiding material such as Nomex. Nomex is very expandable and has heat and flame tolerance. It has a notably higher melting point.

This material also protects against moisture, acids, chemicals, abrasion, radiation (gamma, beta, and X-rays), and solvents. However, Nomex can be inflexible and isn’t impervious to UV light.

Metal

With braided metal sleeving, you get abrasion and cut resistance. Such properties make this sleeving ideal for high-intensity weather, grounding solutions, and where temperature resistance is necessary. 

Additionally, metal sleeving has exceptional durability and offers RFI, EFI, ESD, and UV resistance. And some have germicidal and antimicrobial properties. Further, braided metal sleeving is flexible, uniquely functional, aesthetically pleasing, and durable, making it ideal for outdoor, aerospace, and automotive applications. 

Remember, it’s best to use virtually indestructible sleeving options, such as stainless steel sleeves, for more demanding projects. Doing so ensures that all the exposed wires are safely tucked in and the project remains rust-free and aesthetically pleasing.

Different Application Levels of Braided Wiring harnesses

As braided sleeves have different constructions and materials, they serve different purposes.

General-Purpose

For projects where the main concerns are durability and easy application, general-purpose sleeving is an excellent solution. This product is easily adaptable because of its expandability and side entry, ensuring the integrity needed for resistance and durability. 

You might opt for tight weave options if you want increased abrasion resistance. For situations where you can’t cut or disconnect wires, choose side-entry sleeving. For reapplication or installation processes, wrap-around sleeving will do the trick.

Heavy Duty

Heavy-duty sleeving functions well under extreme conditions. This sleeve option is highly cut and capable of resisting abrasion and heat, ensuring that it does not melt, burn, or support combustion. 

Also, heavy-duty sleeves are nimble while maintaining the integrity needed to safeguard components exposed to a harsh environment adequately. For example, this braided sleeving type can resist bases, fuels, acids, solvents, and salt, preventing any compromises in the hose functions. Additionally, it’s capable of deflecting and containing hose ruptures.

Flame Retardant

Flame-retardant sleeving offers a similar solution to a general-purpose one, plus the added benefit of flame prevention. This added property is ideal for automotive, engineering, electrical, and several applications vulnerable to the threat of fire damage. Flame-retardant sleeving mitigates the threat of a flame sparking.

High-Temperature

As the name suggests, high-temperature sleeving is highly resistant to extreme temperatures. It not only can withstand extremely high temperatures but also low temperatures, resisting common solvents and chemicals. 

Installing it is a straightforward process, making it ideal for automotive, engineering, and aerospace applications. High-temperature sleeving contains a silica and fiberglass composition that ensures your cables remain cool in temperatures up to 20000F.

Specialty

With specialty sleeving, you can handle very specific braided sleeving tasks. It offers options that are easy to edit out of video production, plus noise reduction. 

Also, it’s remarkably reflective. Even bright white comes nowhere close, as specialty sleeving is almost 1,500 times more reflective. Additionally, its sleeving is adequately slim, an added advantage for micro-optics. 

Further, specialty sleeving makes wires and cables less vulnerable without affecting the project.

Braided Loom vs Convoluted Tubing: Which one to choose

Convoluted tubing is another popular option. The two technologies both give you pros and cons. 

	Harnesses with braided technology	Harnesses with convoluted tubing
Loading capacity	Wire harnesses with braided technology are designed for 100% loading capacity and reduce wire movement, preventing wire insulation deterioration.	Harnesses with convoluted tubing covering can handle a maximum load of 70-80% wire. It means the remaining 20-30% tubing should be free space so that wires can move around with the equipment vibration.
Wiring protection	Braid sleeving has high abrasion resistance as it prevents the entering of abrasive materials due to its tightly bound nature. So, wire loom sleeving offers optimum wiring protection.	Convoluted tubing causes wear and tear due to abrasion. As there is free space, it attracts dirt, dust, stones, and other particles leading to erosion and weakening of wire insulation.
Breathability	Braided sleeving in wire assemblies has open holes to allow water and air to pass through so that insulation remains protected. As a result of this breathable nature, higher heat resistance leads to a longer lifespan.	Convoluted tubing assemblies accumulate engine fluids and other debris within. Further, convoluted tubing cannot provide thermal protection in extremely high and low-temperature environments.
Life span	Braided sleeving has a longer life span of around 10-12 years	Convoluted tubing can last only about 2-4 years
Assembly challanges	You’ll need to tape the wires together neatly while separating the different branches.  You need a machine capable of handling the wire harness size, which could be labor-intensive. In addition, the laborers must take frequent breaks to avoid neck, shoulder, and back strain. The equipment poses a noise pollution threat that requires workers to wear headgear.	Liquid-tight and capable of accommodating a variety of connector backshells. Offers various fittings for branch configurations to maintain the liquid-tight seal. Wide array of diameters that enable flexibility of the harness, and a variety of colors for brand and aesthetic specifications.

Caption: Convoluted tubing

Order Today from Wiringo

When you need a braided wiring harness, you must consider several factors. Contact Wiringo and our technicians can help you get an accurate product. We have all kinds of cable management sleeves made of quality materials and offer high performance & reliability in agriculture equipment and the heavy-duty construction industry.  

Customize the Correct Size for your Products

Here’s how we make sure you get the right size:

1. First, measure the diameter of the cable. 
2. Determine the fit (snug or loose). A loose fit allows for flexibility, while a snug fit provides extra cushioning.
3. Determine your sleeve diameter.
4. Ensure the length of the sleeve (a few millimeters longer than the cable because it will contract when stretched in diameter).

Whether marine or automotive, it’s best to store wires, cables, and hoses neatly and out of the way. That’s where clips come in. They help organize your wire harness and electrical system. Read on to learn about automotive wire harness clips, including how to use them.

What Are Cable Clips?

Cable clips feature a loop or cradle and hook, which holds it neatly in place after you fold the wiring. Then, depending on the type, cable clips will have or not have holes, which will determine how you use them. 

For clips with holes, you need nails, pins, or screws to fasten them to the surface. Just ensure the nail or screw size is correct. 

But if the clips don’t have holes, they’ll have an adhesive strip instead. All you need to do is peel off the backing and stick the clip to the surface.

What’s the Difference Between a Cable Clamp and a Cable Clip

Cable clips are tools used to mount wires or cables. Many refer to them as cable mounts or wire mounts.

On the other hand, cable clamps assist with clearly defining how cable and wire installations get mounted. In addition to holding the wires or cables in place, they restrict movement and clearly define a cable path from where it starts to its destination.

Types of Cable Clips and Their Uses

Below is an outline of different cable clip types and their uses:

Self-Adhesive Cable Clips

These clips have an adhesive strip (sticky surface) covered with a backing layer. Simply peel off the backing and affix the clip. Note, though, that the strength of the adhesive strip varies depending on the gauge wire it’s meant to secure.

Normally, self-adhesive cable clips are best for securing cables or harnesses where drilling holes is not an option.  

Metal Cable Clips

Usually, manufacturers use steel, stainless steel, and brass to make cable clips. That’s primarily because the clips are highly wear-resistant and not susceptible to damage from chemicals, heat, humidity, or water. 

Some examples of metal cable clips include routing clips and wire loom clips. 

Nail Cable Clips

These are the most commonly used professional and DIY clips. Usually, they have a hole with a nail or pin for fixing onto a surface.

Image of a nail cable clip

Nail cable clips are round or rectangular and come in several sizes and materials. And this diversity contributes to their popularity.

In addition to their use in cars, people use these clips for running wires for lighting or power, keeping TV and ethernet cables neatly, and motors and machinery.

Image of running cable tucked neatly using a nail cable clip

Screw-in Cable Clips

Coaxial cable clips make mounting wiring and cable easy. And when it’s necessary to make any changes, these clips are easy to remove and replace. 

The two primary coaxial cable clips are nail and rounded push-puns, both plastic and available in black or white.

Mostly, people use coaxial clips for stereo wiring.

Image of white coaxial cable clips

P Clips

As the name suggests, P clips, when closed, appear like the letter P in shape. What’s interesting about these clips is that they wrap around the wiring or cable bundle, and then you can fix the bundle into position using a screw. 

Further, P clips come in varying materials to suit different environments. And they’re also available in various sizes depending on bundle diameter.

Usually, people use P clips where chafing and damage to car components are likely. 

Saddle Cable Clips

Saddle cable clips enable securing wiring and cable slightly away from the surface onto which you’re affixing them. That way, there’s less chafing or strain. Additionally, these clips have snap-in bases that make installing them easy and tops that lock so you can add or reduce wires as desired.

Further, saddle clips consist of molded plastics ànd metals. Usually, people use these clips for various automotive, industrial, and home applications.

Adjustable Cable Clips

Like the saddle cable clips, these clips allow adding or removing wire to suit your rerouting changes. What’s great about the adjustable cable clip is that it won’t open until you release the tab. 

Metal Cable Clips Vs. Plastic Cable Clips

Metal cable clips in electrical wiring are stainless steel, steel, aluminum, or copper. And in case you’re wondering, the metal clips are all corrosion-resistant. As you know, aluminum, stainless steel, and copper are corrosion-free,  and the steel clips are zinc-plated. 

Some examples of steel clips are P clips. These have a rubber ring that absorbs vibration and provides electrical insulation.

However, rapid corrosion occurs when metals like copper or brass come into contact with galvanized steel. Therefore, you’re better off choosing another material like plastic. Nylon cable clips, for example, are a great option that’s pocket friendly.

Additionally,  you must consider where you’re using the clips when choosing between metal and plastic. For example, metal is suitable when exposed to extreme heat as it won’t melt. But for most other applications, it’s safe to go with plastic.

Conclusion

There are several types of cable clips. Your choice depends on the wires or cables you want to mount and where you’ll install them. At Wiringo, we pride ourselves on superior cable assembly capability and expertise. If you need help, please don’t hesitate to contact us.

Today, features like Light sensors, Powerful stereo systems, Internet access, advanced driver assistance systems, and voice control systems are common in every vehicle, which means the ever-increasing diversity of the connection systems. According to SourceToday, there were 240 connectors in an average vehicle five years ago. We will understand automotive wire harness connectors in detail.

Automotive Wire Harness Connector Basics

The automotive wire harness is an assembly of the connectors, cables, and terminals spread throughout the vehicle. 

And connectors are responsible for transmitting electric power and information to different components within your car. There are different types and varieties of connectors used by automakers; for example, printed circuit boards, circular, rectangular, charging connectors, etc.

These connectors connect or disconnect the electrical lines and consist of male and female terminals. Male and Female terminals are collectively combined with linking you to the electrical connection, which results in fulfilling your desired action (e.g., automatic window or stereo system).

Wire harness in Motor Vehicle

What are the main functions of the Automotive Wire Harness Connector?

These connectors fulfill three purposes.

Internal connectivity

These connectors connect the components inside the car. For example, stereo systems, sensors, etc. 

External connectivity

You can use the connectors during the car repair process. Mechanics try to detect the real situation of the car by connecting the vehicle with external equipment via an external connector.

Replacement

You can also use the connectors to replace other connected devices. Although for a temporary period, these connectors play a crucial role. By then, you are free to use your vehicle.

Electric cabling in car

Characteristics of Automotive Wire Harness Connector

It is no secret that automotive connection systems have high standards due to the different environmental factors involved in the vehicle’s functionality. And the OEMs (Original Equipment Manufacturers) keep the technical reliability sharp in light of the environmental conditions such as vibrations, braking oil, engine oil, high temperature, etc.

Here, it is super important that the different connections within the vehicles are connectable or disconnectable in rough working conditions. Therefore, producers focus on inventing a powerful connection system to ensure your car’s best performance.

Automotive-colored connectors

Automotive Wire Harness Connector components and their functionality

Consider the following different components to make things easier for your understanding of the connector.

Connector Housing

You can use the connector housing to carry the terminals and pins while securing the connection with the mating part. You can also call it plastic insulation, whereas its design differentiates between male, female, sealed, and unsealed connectors.

However, it is crucial to know that the sealed connection system contains a radial seal that guards your electrical system against dust and water. Furthermore, this component has different coding in various notches. Also, manufacturers mark it with various colors to help new people understand its works.

Terminal Position Assurance

As the name implies, you will mobilize the terminal positions together in the housing through your hands. You insert the crimps into the housing and create a technical link. For assurance, the automaker/mechanic hears a sound of a certain click.

Electricians introduced this clicking property of the terminal to reduce mistakes in mass production. Once you make the perfect technical link, you will set the secondary lock to keep the connector in its location.

Connector Position Assurance

All the connectors are assembled connection systems via hands. Of course, if connectors lack proper assembly, you may be able to achieve the electrical connection. However, the connector will not protect the connection against water and wind.

Single Wire Seal

Most people use it to protect the cavity against environmental conditions. Automakers ensure to crimp the seals into the terminal and cable in one step and push it into each cavity. These Single wire seals comprise an important fluid known as silicon oil that supports the assembly process.

Block seals

Block seals also play a role similar to a single wire seal and protect the cavity from external factors while offering openings to retain cables. It means that a block seal guards several cavities altogether.

Cavity Plug

A cavity plug protects unused cavities from external environmental factors by blocking them. You can insert and remove them using your hands or a screwdriver.

Wire harness with plastic housing

Types of Automotive Wire Harness Connectors based on connection systems

You can connect three types of connection systems as per desire.

Wire-to-wire Connection 

This type of connection comprises male and female connectors. Mostly, it connects and disconnects small applications and creates a link with the main wire harness.

Board-to-wire connection

The connection is fixed to a conductor board using this type of connection system. Here, the conductor board is linked to the male connector known as the “PCB Header.” On the other hand, the female terminal links to the wiring harness. This connection connects the engine control unit with the main power source.

Device Connections

This type of connection system is used mainly in sensor systems. And similar to the board-to-wire connection, it is composed of female mating parts already assembled for the given application.

Cable assemblies

Types of Automotive Wire Harness Connectors based on the electrical system

According to ISO standard 10487, there are about four types of connectors.

A-Group connectors

These connectors, also known as Power Connectors, join the vehicle’s head unit to the power supply unit.

B-Group connectors

These types of connectors are used to connect the speaker around the vehicle.

C-Group connectors

These types of connectors are optional and used to connect peripherals.

D-Group connectors

These types of connectors are optional similar to C-Group and are used to connect the navigation system.

Wiring harnesses under the dashboard

Standards of the automotive connectors

Automotive electrical connections are prepared, tested, and installed in the vehicles per global standards and specifications. It includes ISO:

10487 for passenger car radio connections.

7736 for Road vehicle front radio installation.

 9458 for Passenger car motor connections.

Challenges faced in the automotive connector industry

With technological advancements in heavy-duty vehicles, many connectors are used to overcome excessive stress and strain experience. However, manufacturers tend to rely heavily on connector equivalents or component availability. Therefore, it creates multiple problems since this connector equivalent is less durable than the real connectors.

Another challenge faced in the automotive connection industry is sourcing wire harnesses in today’s market. Several distributors either do not deliver the connectors and wire harnesses on time or don’t have the desired quantity.

Wiring harnesses

Conclusion

There is a rising need for more durable wiring and connectors as modern automobiles become increasingly networked and microprocessor-controlled. Do you need help with them? Here at Wiringo, we offer wiring harness and cable assembly solutions so that you do not have to worry about perfection.

It would help if you had wires and cables for all types of electrical systems as they make the system function. Also, they have a considerable role in maintaining safety in wiring. Thus, you must pick the correct type of wire for a particular application. Wire diameter or gauge is the most crucial among so many different features. How? Let’s learn how the gauge affects the different technical specifications of the wire and have the AWG Wire Size Chart in detail.

What is the American wire Gauge?

In North America, AWG is the standardized wire gauge system denoting the wire sizes. In this system, as the AWG number increases, the wire diameter and thickness become smaller. The smallest standard size in AWG is 40 AWG, and the largest is 0000. You can also call it the Brown & Sharpe wire gauge or just the wire gauge. They are for solid, round, conductive, and single-stranded electrical wires.

The AWG system came into existence in the year 1857. Before this standard, manufacturers used different methods to measure very confusing wire. The AWG system is similar to the Standard Wire Gauge system used in Britain. Several other countries use international metric standards where wire cross-section is represented in square millimeters, as mentioned in International Electrotechnical Commission 60228. The AWG system does not include the insulation size in the diameter dimensions. 

Caption: cross-sectional wire area

Importance of American Wire Gauge

As the wire’s cross-section area increases, the wire’s resistance decreases. At the same time, the amount of current that a wire can carry safely also increases with the increase in the cross-sectional area. Also, a small gauge or larger diameter wire can have more power than the wire with a larger gauge.

AWG holds importance for wires which carry electrical current like home or business wiring, high power wires in automobiles, extension cords, etc. Using too small a wire, i.e., a very high AWG, can melt, overheat, and catch fire. Thus, to ensure safe electrical wiring, you must consider the wire’s current carrying capacity.

As larger wires use more metal, they are more expensive than smaller wires.

For wires that carry signals, such as video interconnect or audio hookup wires, the AWG is not as essential as it is for power wires. It is because the electrical signals in these wires have low power, and thus you do not need smaller AWG wires. Cable pair twisting and efficient shielding are more critical in these wires to maintain the integrity of the signals.

Caption: Gauge Wire

Relationship between the AWG thickness and other technical specs

The gauge affects the wire’s different technical specifications, which is why we say it has a considerable role in maintaining safety in wiring.

AWG to diameter

In this system, 0000 AWG indicates a wire diameter of 0.46 inches, and 36 AWG indicates a wire size of 0.005 inches. There are 39-gauge sizes between these two sizes which you can get through logarithmic calculations. The ratio of different sizes is 1 to 92 in diameter. So, you can say that each AWG step is around the 39th root of 92, which is approx. 1.12293 times changes in diameter.

You can calculate the wire diameter with this formula:

D(AWG)=.005·92((36-AWG)/39) inch

For gauge numbers 00,000, and 0000, you can use -1, -2, and -3 as gauges as they make more sense mathematically.

In the AWG system, the wire diameter doubles with every 6 gauge reduction, and the cross-section area doubles with every three gauge reduction.

AWG to Cross-sectional area

Commonly, when you refer to the size of a conductor, you talk about its cross-sectional area, which is expressed in mm2. To calculate the cross-section of solid round wires, you can use this formula:

Area = πr2, where r is the radius (1/2 of the diameter)

The gauge is ten times higher than the diameter in millimeters in the metric gauge scale, meaning a 50-gauge metric wire is 5mm in diameter. You must know that in the AWG system, the diameter increases with the decrease in gauge, but this does not apply to the metric gauge scale. Metric size wires are mentioned in millimeters instead of metric gauges to avoid confusion.

AWG to load current carrying capacity

The ampacity of the wire refers to its maximum current carrying capability of the wire. The table below mentions the copper wire current capacity. However, these are just rules of thumb. In reality, insulation, voltage drop, temperature limit, thermal conductivity, thickness, and air convection should also be considered.

Based on the AWG system, a smaller gauge or larger diameter wire conducts more electricity than a wire with a larger gauge or smaller diameter. As you decrease the AWG size of the wire by six, its cross-sectional area and the electric current amount increase doubles when AWG reduces by three. When you change the AWG size by ten, the cross-sectional area also changes tenfold.

As aluminum is not as good as copper in its conductivity, we consider aluminum as two gauges larger than copper when we compare the conductivity of both.

AWG to Maximum frequency for 100% skin depth chart

You can use this data for high-frequency AC applications. When alternating current flows through the wire, the current tends to flow along the sides of the wire. As a result, the effective resistance increases. The table below mentions the frequency at which skin depth equals the wire radius, which means above this frequency, you have to consider the skin effect while calculating the resistance of the wire.

Breaking force for copper wire

The table also shows the breaking force for copper wire. Here the estimation is based on the nickel-free soft annealed copper wire with a tensile strength of 37000 pounds/sq inch.

Caption: AWG Wire Size Chart

What is the American wire Gauge for Multiple Conductors Stranded Wires?

The AWG system primarily describes the size of single-stranded solid wires. However, when there are multiple conductors stranded wires, you can use AWG to get the cross-section of all the strands and then add them together. 

In stranded wires, you usually use three numbers to define their measurements, representing the AWG size of the wire, the strand number, and the American Wire Gauge size of each strand.

For example, 23 AWG 5/30 means a stranded wire of 5 strands of 30 AWG or 0.0509 mm2 which is equal to the 23 AWG or 0.258mm2.

twisting two electrical wires

Applications for Different AWG Diameters

Wires have different physical and electrical properties, making them suitable for various applications. The wires with thin gauges are ideal for lightweight applications, and the thicker wires are suitable for heavy-duty applications.

Here are some uses of wires with different gauges.

• Gauge 4 wire: suitable for large heaters and furnaces.
• Gauge 6 wire: ideal for heaters, large air conditioning units, and the clothes dryers
• Gauge 12: small air conditioning units and outlets in residential areas
• Gauge 14 wire: suitable for electrical circuits, devices, and lighting fixtures
• Gauge 16 wire: ideal for light-duty extension cords
• Gauge 18 wire: suitable for low-voltage lighting and cords

AWG wires

Conclusion

Hopefully, with this information, you will choose the correct wire size for your applications. If you need more help regarding high-quality cable assemblies and harnesses, contact Wiringo. We are a leading manufacturer of superior quality.

When you connect bare wires to equipment, they become loose and curly and rust over time. Electrical equipment needs safe and secure connections to keep the equipment functional. Banana plugs are an easy solution to form a solid connection. How do they work? This article will discuss the banana plug cable assembly in detail.

What are banana plugs?

Banana plugs are cylindrical connectors that you use for electrical wiring. It got its name from the fruit banana because of a protruding prong that bulges out from the center. This protrusion has a spring-mounted fin which can expand once you insert it into the equipment socket. Thus, it results in a firm and almost permanent hold. You can also call them 4mm connectors; the 4mm refers to its standard diameter.

Uses of banana plugs

With banana plugs, you can safely, easily, and quickly connect or disconnect electrical wiring to equipment through matching banana sockets. If you do not use a banana plug, you may need to attach and reattach the bare wires on equipment, resulting in short circuits and equipment overload.

You can use banana plugs in a wide range of audio equipment, such as:

• Sound systems and speakers (wired)
• Audio wires and cables
• Hi-Fi receivers
• Loudspeakers
• Aux jacks for standard headphone connections
• TV aerials 
• and testing equipment from laboratories.

Gold plated banana plugs 

Types of banana plugs

The screw type is the standard banana plugs, and there are different designs to hold wiring.

Open screw banana plugs

In open screw banana plugs, there is a lug connector or a protruding bolt where you can attach the length of insulated equipment wire. You can do this through crimping, soldering, or an easy-to-use built-in screw.

Closed screw banana plugs

In these types, you can hold the wire in place through a metallic cylinder into which you insert the wire from the rear end. Following this, you can screw an upper cylinder with a prong on its top.

Open screw banana plugs vs. Closed screw banana plugs.

The similarity lies in the cable termination in both types. There is a rear section that you can remove to allow the cable entry and then clamp it internally. 

The main difference is that in the closed screw types, there is an enclosed chamber; on the other hand, in the open screw, there is a side entry point providing a versatile solution along with an enclosed chamber.

 Open screw banana plugs

Closed screw banana plug

Additional Features of Banana Plug Connector

The banana plug comes in different varieties.

Locking banana plugs

In these plugs, there is a mechanism through which you can expand the prong more than the typical spring-mounted fin once it inserts into the socket. As a result, it forms a stronger bond.

Gold banana plugs

These plugs provide a high electrical conductivity level and are very attractive. It has a gold plating that combines with other conductive metals like brass.

Banana plugs with covers

You can also call them shrouds. These covers are tube-like structures that surround the prong to protect them. These covers automatically retract once the prong inserts into the socket. Some sockets also have been shrouded. Generally, these plug covers are more used in high voltage equipment such as test laboratories.

Double banana plugs

As the name clears, these plugs have two in one housing, which may feature a different cable connector on another side. As a result, it helps form a sturdy connection between two other audio cables.

Angled banana plugs

These special banana plugs have a pin at a 90-degree angle to the cable. With this, you can insert the cable in the top-down position, giving a more robust and more secure connection than the side insertion. The side connections often become loose due to wire stress or accidental tugs. Typically, you will find them with a multimeter or other electrical test equipment.

Different types of banana plugs

Banana Plugs Genders

You will find electrical connectors in female (i.e., enclosing) or male (inserting) designs. The banana plugs are male connector types that you can insert into their female counterparts, i.e., banana sockets or jacks.

The presence of insulation affects the compatibility between banana plugs and banana sockets. When insulation is there, the sheathed male plugs will not fit appropriately into unsheathed female banana sockets. Unsheathed banana plugs may fit into both sheathed or unsheathed sockets. The speaker plugs have uninsulated endings.

Angled banana plugs

Banana plugs sizes

Banana plugs can have pins that vary in size and diameter. However, you will commonly find metal pins 4mm in diameter or 5/32 inch as the standard size. Other than this, there are miniature plugs of 2mm in diameter. Also, there is a 3mm plug which you can refer to as a mini banana plug or small banana plug.

The standard length of the banana plugs is 20mm or 3/4inch; however, some shorter sizes are also prevalent. Especially in the US, banana plugs of length 15mm or 5/8inch are more common. Sometimes, people refer to them as short banana plugs, and you get a discreet connection with these plugs. Other than these, there are 25mm or 11mm plugs. However, they are less frequently seen.

Banana cables for the electrical laboratory

Do I need Banana Plugs for my Speakers?

Banana plugs offer several benefits, but connecting the amplifier to your speakers is not essential. However, with plugs, you can benefit a lot. 

• Using banana plugs will keep your speaker wires tidy and prevent them from damaging. 
• The two ends of the speaker do not mix when you use banana plugs. 
• Also, with banana plugs, you can easily connect or disconnect your speaker wires. It is tough when you use the bare wire of the speaker to connect with the amplifier. Ensure the wires are exposed, and you must place them in a grip to ensure their contact with the metal surface. However, when you use banana plugs, you only need to connect the plug to the corresponding port.
• An additional advantage, though not very prominent, is that they improve the sound quality.

Speaker wiring without plugs

How to Install Banana Plugs on a Speaker Cable?

Follow the steps for a successful banana plug cable assembly.

Preparation

Most of the audio systems are inside any entertainment unit. Thus, you cannot expect too much light in that area. Therefore, please carry a compact torch with you before the installation begins.

Besides this, you need to take a stripper to strip off the insulation from the wire to insert inside the connector. You can also use a blade or a scissor if a stripper is unavailable. However, make sure that you do not cut the inner strands.

Don’t forget a screwdriver (according to the banana connectors type) so that you can tighten the fasteners that lock the screw to make a secure connection.

Next, you need not follow any rules for the tracer wire. However, we suggest you maintain consistency with the color to which the tracer wire goes through your installation, which will help you wire your speakers correctly.

Select the correct banana plugs

It would help if you chose the plugs with the right size, quality, angle, and so on.

• Banana plugs come with different measurements based on the thickness of the speaker cable. You can find speaker wires in different gauges. However, the common gauges of wires that you use for connecting speakers to a receiver or an amplifier are between 12-16 gauges, and that’s what you pick with banana plugs too.
• The angle of approach of the speaker cable to the speaker terminals is also critical. In general, you can use a banana plug having a rear entry point; however, you may also need to pick a side entry point.
• Banana plugs are available in different metals and alloy options. Some of them come with 24K gold plating, which ensures that the connection will be more durable and will not rust over time.
• Other than these main factors, you may also look for manufacturing materials and general artistry.

Installing banana plugs:

Closed and open screw banana plugs have rear entry points, so both installation processes are the same. However, the open screw banana plug also has an entry point from the sides, and the installation differs slightly.

Installing closed and open screw types through the back entry point:

Method 1:

• First, strip the required length of the speaker wire from every conductor.
• Second, fold the cable over the halfway point so that strands double to fix onto the plug.
• Now, unscrew the banana plug’s top section from the lower side.
• Next, insert the speaker’s cable into the bottommost section on the rear side until all stripped cable protrudes.
• Now, form a tiny ball shaped from all exposed strands so that the plug clamp effectively.
• Now, screw back the top part, so it stands for the speaker’s cable you made in the last step.
• Finally, insert plugs into the connectors on the amplifier or the speaker.

Method 2:

• First, strip the required length of wire (approx. 30mm)
• Now, remove the upper section of the plug from the lower side.
• Now, insert the speaker’s cable from the rear bottom until you notice the cable of the speaker cable protruding out up to 3-5mm.
• Next, expand the wire and fold it around the bottom piece’s circumference.
• Put back the screw piece of the top so that it works as a stand for the speaker’s cable.
• Finally, insert the banana plug into the connectors of the amplifier or the speaker.

Note: for cables under 12 American Wire Gauge, you must use method 1 to terminate securely.

The side entry point is for open screw type only.

• First, strip the required length of the wire (approx. 12mm)
• Now, twist the wire strand of the cable to make them tight.
• Now, make an L-shaped from the twisted wire at around ⅓ of the bare wire. 
• Now, remove the top part about half of the way.
• Next, insert the cable into the entry point towards the sides. Make sure that the L-shape points toward the bottommost section.
• Put the top piece back to work as a clamp for the cable prepared in the last step.
• Finally, put banana plugs into the binding posts on the amplifiers or the speaker.

Note: if you use this entry point, you can also use the back entry point to connect other banana plugs for bi-wiring.

Installing screw-locking banana plugs

• First, strip the required amount of wire (approx. 12mm) from each conductor.
• Remove the banana plug’s outer section to reveal the inner chamber.
• Now, make the screw locking fasteners on each plug loose.
• Next, insert the speaker’s cable into the plug while applying minimal force until the wire touches the chamber’s end.
• Now, tighten the fasteners.
• Conceal the inner chamber by placing the outer section again
• Finally, insert the plugs into the binding posts.

Speaker wires

Conclusion

Although banana plugs are not necessary for your audio system, they have a wide application. Before you pick a plug for your use, make sure that you choose the right size and type. You can get professionals to help from Wiringo. We are a leading manufacturer of wiring harnesses and cable assemblies.

Automobile batteries frequently die in the bitter winter, but the problem may not lie with the battery. The battery cable assembly could be at fault. Today, we will have a clear picture of the ideal cable.

What are Battery Cables?

They are a pair of thick cables connecting the battery to the electrical system. The positive charging cable is the red-sheathed wire that runs from your car’s battery to its onboard computer. Additionally, you will connect the battery’s negative terminal to the vehicle’s chassis through a black-sheathed wire known as the negative dc cable (sometimes called the ground strap or ground cable). They form an autonomous circuit that allows for constant energy transmission.

Red and black battery cables with 6mm hole connectors

Where Are Battery Cables Used?

The most effective method for connecting the batteries to a starter is with a battery cable. Boats, trucks, buses, vehicles, RVs, and tractors use battery cables. Boats, trucks, buses, vehicles, RVs, and tractors use battery cables. The battery cable’s strength and longevity shine through straight lines with minimal battery cable 90-degree bends.

Compared to other types of wire, like welding cable, battery cable is a simple and inexpensive way to connect batteries. Hence, there are numerous cable types to choose from, and the one you use will depend on your unique requirements. In general, the voltage rating of this cable is 60V DC, and the gauge sizes available are somewhat varied. In general, the voltage rating of this cable is 60V DC, and the gauge sizes available are somewhat varied.

Copper battery cable

How do Battery Cables Work?

The wires connecting your car’s battery to the electrical system are in plain sight. Additionally, the starter solenoid is often the immediate target of the positive cable. Then the route proceeds to the starter’s positive lead. Also, the negative battery wire of the vehicle is connected to the vehicle’s chassis, so electrical components like the starter can operate when the relevant switches are engaged.

Jumper cables

Symptoms of Bad Battery Cables

• The illumination inside your car gets dimmer.
• Your engine cranks slowly.
• Your engine won’t turn on.
• When you press the key, you hear a clicking sound, but the engine won’t start.
• Your car’s electrical system is down.
• Without moving the car, the engine stalls.

How to Check Your Battery Cables

For a deep examination of your battery, follow these simple steps.

• Check the terminal and battery electrical connection; they should be in perfect condition, and the work environment can expose the wire’s conductor.
• Clean the corrosion on the terminals, if any
• Check the negative battery cable for any grime on it.
• Look for any wear and tear that loosens the cables or expose the conductor.

When to Replace Battery Cables

Unlike oil changes, there is no standard for how frequently damaged you should replace battery cables. Moreover, you should regularly inspect the battery cable sheathing for cracks since a crack could expose bare wires to corrosion and other factors.

Pay attention to the signs of a bad battery cable described below, such as difficulty starting the vehicle, dimmer interior or exterior lighting, or stalling while the vehicle is running.

The lithium battery pack in electric car

Things to Double-Check When Choosing Battery Cables

Let’s analyze their functionality, inspect their condition, and determine the following characteristics of battery cables.

Wire Gauge

Electricians can meet power requirements with the help of the many different wire gauges available in battery cables. Also, power capacity increases with cable size. Hence, its intended use, location, and surrounding temperature determine the maximum current that can safely flow through a cable.

• 10 gauge is for low-power alternators, accessory leads, and trigger wires
• 8 Gauge is best in Low-power alternators and accessory leads
• 6 Gauge is for most stock alternators and accessory leads. It also works for battery cables on small engines.
• 4 Gauge is mostly for battery cables. Also, it works well for wiring the alternator and other accessories.
• 2 Gauge wire is best for four small 6-cylinder engines, power converters, and other things.
• 1 Gauge is best for big 6-cylinder engines, small V8 motors, and high-output alternators with a current rating of 200A or more.
• 1/0 Gauge is for simple V8 motors and 6-cylinder engines
• 2/0 Gauge is for engines that are hard to turn, battery banks, electric cars, and large power converters.
• 3/0 and 4/0 Gauge is best for the high-power energy banks and big diesel or marine engines

Stranding

Battery cable assemblies’ adaptability is significantly affected by the wire’s stranding. So, when a wire’s current is more likely to travel along its outer surface, a greater strand count will have slightly better conductivity and power distribution than a lower one.

Connectors

Standard battery terminals, which fit over lead posts, and ring lug terminals are two of the most popular connectors used for battery hookups. They are available in straight and right-angle shapes to accommodate a wide range of wire diameters. These can be found in both plated and unplated copper forms.

Insulation

It is common for the oil and toxins present beneath the hood to increase the temperature of a car’s battery cable assembly. Battery cables of SAE type SGT and SGX are designed for usage in cars and other vehicles. A standard SGT battery cable will suffice for most uses, but it lacks the advanced capabilities of the SGX battery cable. 

SGT： A common battery cable with several uses is the SGT variety. Because of its resistance to moisture, oils, acids, and cracking, SGT is great for electrical work like replacing batteries and other similar operations.

With its thick PVC insulation, your connection will remain intact and trustworthy. According to a general opinion, this cable is the most cost-effective choice for many common tasks. The SGT battery cable is rated for temperatures up to 80 C (176 F) and complies with SAE (Society of Automotive Engineers) standards J-1127.

SGX： SGX distinguishes itself from its rival by using XLPE insulation as its insulation. As a result, there is resistance to coolant, ethanol, diesel fluid, fires, gas, ozone, acid, alkalis, abrasion, acid rain, power steering fluid, transmission fluid, and oils. In addition, as they can endure up to 125°C/257°F, it offers more heat protection than SGT. 

Engine compartments are the best for SGX battery cables because of the enhanced protection. Boats, buses, trucks, RVs, tractors, and other large vehicles can all be supported by SGX cable. This cable typically costs more than the SGT power cable since it is more dependable and long-lasting.

Length

The voltage drop, or the voltage lost across the length of the automobile wire or cable, must be considered while deciding on the length. Also, electrical resistance increases with wire length, reducing the voltage to an unsafe level if the wires aren’t short enough. 

As the resistance of a wire depends on its cross-sectional area over distance, thinner wires with a larger gauge will have a greater drop rate than thicker wires with a smaller gauge.

Conductor material

The conductor material of the wires is also a significant influence. 

OFC (Oxygen Free Copper): To connect speakers or a high-powered amplifier, stereo shops frequently sell OFC (Oxygen Free Copper) wire. As for the benefit, OFC has a purity level of 99.5% or higher, which is 0.05% more copper than a simple one. However, it costs twice the standard cable, making it an expensive option.

CCA (Copper-Clad Aluminum): Copper clad is just aluminum that has been coated in copper. With only 60% of copper’s conductivity, a CCA wire would need to be around 2 times larger to match the performance of a standard copper wire. As an alternative, a CCA wire of 2 gauge would be required to replace a 6 gauge copper one. Hence it’s better to stick to the plain old copper battery cable.

The battery in an electric car

Custom Battery Cable Assemblies according to your needs

Wiringo continues to be a cable assembly manufacturer that leads the way in conventional and custom battery cable assembly.

Marine rating Battery Cable

Many different kinds of wire go by the name “Marine.” The “wet” or marine environment is where it shines. Another requirement is to be a “self-extinguisher” in the event of a fire. That is why all products intended for use at sea must have a special marine rating, as required by the manufacturers.

Fuse Link or Fusible Link Battery Cable

The high-temperature shielding of the fuse link will keep the cable secure if it overheats and fuses open. The most typical use is in automobile alternator wires. Common applications include harsh environments, relay wires for heating systems, and diesel engine plugs.

Tapered Post-Battery Cable

The terminals of the tapered post cables might be made of lead, brass, or forged bronze. Furthermore, it can be with various coating options and features lead cast heads made from 8-gauge wire. Additionally, it offers numerous choices for covering connections, such as heat shrink tubing, to ensure their safety.

Ring to Ring Battery Cable

Ring-to-ring battery cables enable you to crimp many wires onto a single lug. In addition, you can dip it in tin, which increases its corrosion resistance and gives it a powerful pull.

Booster Cables

Finally, the booster cables are useful when you have limited space yet still need to charge the car’s battery. In addition, it is built with purpose-built components for certain applications.

Ground/Flat Straps

Connecting to the ground with a flat strap takes up very little room. Additionally, it offers various crimp alternatives, such as lugs, open-barrel, and lead cast battery terminal connectors.

Battery Cable Repair Splices

Batteries with built-in cable repair splices allow for speedy and easy replacement of worn or broken connectors. Moreover, fixing a damaged battery terminal is easier than changing the entire battery cable harness.

Just unplug it, strip back the insulation, splice in the new terminal, and reconnect the connection to the battery. Since you can replace the terminal end of a battery cable independently, battery cable repair splices are more convenient and cost-effective than replacing the entire cable.

Booster battery cable assemblies

Conclusion

It would help if you replaced the battery cables before any further problems. Hopefully, with this information, you will choose the correct one for your lasting battery connection. Also, here at Wiringo, we offer wiring harnesses and cable assemblies to make your connection reliable and safe.