How

What is it that you need to look for in an SDI cable? Should you go for an HDMI connector or an SDI one?

We look at the SDI interface, the different types of SDI cables, and how these can be a better choice in many instances.

Do cables such as SDI or HDMI confuse you? Don’t worry. This article will help you pass through the turbulent waters of cable.

Chapter 1: What is SDI Cable?

Now, what is SDI? SDI stands for serial digital interface or SDI cable for short. It is a standard used for transmitting digital video over long distances.

It is the most common cable found; all the broadcasters prefer SDI and use it.

The cable that connects your TV set-top boxes or TVs is probably an SDI cable. SDI cable belongs to the family of digital video interfaces.

The Society of Motion Picture and Television Engineers [SMPTE] named it in 1989. Compared to HDMI, display port, DVI, or VGA connector, it is pretty old.

You can think of SDI Cable as a grandfather, while the others as grandchildren.

SDI cable was first standardized in 1989, but it’s 2019 now. SDI cable has gone through many upgrades over the decades.

The enhancements are mostly done to increase signal quality and transmit more data.

About SDI Cable

Whether watching a live show or regular television, SDI cable brings you that feed. The reason for the SDI cables preference over other cables is:

• Transmission of audio and video over the long-range [300ft]. Amplifiers and repeaters increase this range even further.
• Has a BNC connector which has a lock-in mechanism.
• Cheaper compared to other cables as it is mass-produced.
• It’s reliable, robust, and sturdy.
• Works wonders while sending uncompressed audio and video signals.

Types of SDI Standard

Now, there are various standards of SDI cable. Here is a look.

• SD-SDI, with a bit rate of 270Mbit/s, was introduced in 1989. It can transmit a video format of 480i and 576i.
• HD-SDI, with a bit rate of 1.485Gbit/s, was introduced in 1998. It can transmit a video format of 720P/1080i.
• 3G-SDI with a bit rate of 2.970Gbit/s introduced in 2006. It can transfer a video format of 1080P 60F/s.
• 6G-SDI with a bit rate of 6Gbit/s introduced in 2015. It can transmit a video format of 4K 30F/s.
• 12G-SDI with a bit rate of 12Gbit/s introduced in 2015. It can transfer a video format of 4K 60F/s.
• 24G-SDI is already in development, with a bit rate of 24Gbit/s.

Video Payload and Blanking

Now time for some technical stuff. Do you know how data goes through?

Here is a simple rundown. The data go in packets called payloads.

At the same time, the information about the destination is in the header.

Video payloads in the earlier versions of SDI were a far cry compared to the new ones.

The higher the video payload, the higher will be the video definition.

Have you ever wondered how the secondary data, such as subtitles, stock files, etc., come into your live feed?

This answer is blank. Blanking is the interval between the end of the last line of the frame to the first line of the next frame. 

There are three types of blanking – Horizontal, Vertical, and Field.

Blanking is used earlier for better video quality during CRT TVs.

Nowadays, it’s more to carry secondary data and audio-video synchronization.

SDI cable uses a real-time transport protocol [RTP].

It helps in the real-time transmission of data on multiple channels.

That also helps in better payload and hence, better video quality.  

Chapter 2: SDI Check and SDI Status Display

 SDI checking is important. Some tests are a must for ensuring that SDI is performing satisfactorily. Some of those checks are:

• SDI check field
• In-service testing
• Eye pattern testing
• Jitter testing

SDI cables go through these checks. It results in the brilliant transmission of audio and video.

SDI status display also gives a summary of several physical layer measurements.

For one, this helps in better configuration. There is an automatic change of the filter settings according to the signal.

During configuring the settings for the transmission, these work wonders.  

Chapter 3: Do You Need SDI Interface – moving from Analog to Digital?

What many people worry about is signal integrity. That is, whether or not your signal will reach its destination without alteration.

I’ll be honest here. No matter what cable you are using, there will be some loss during transmission.

You only need to worry about whether that loss will significantly affect you. If you can’t understand, then let me make it simple.

Let’s start with the basics. All of you know signals in analog or digital carries data.

Analog transmission was the standard in the early 60s, 70s, and before.

Now the digital signal is the undisputed king [no kidding].

The earlier coaxial cable used analog cables.

However, the transmission loss was pretty high. Analog signals transmit data in a waveform.

And when alteration happens, it is progressive and continuous.

In simple words, the more noise, the more the degradation in signal.

Digital signal stores and transmit data in the numeric value of 1& 0.

That is not just easy for transmission but allows less alteration as well.

Due to this, most cable nowadays uses a digital signal, and SDI is no exception.

So, if you want to transmit data, the digital signal is the best.

If you still use analog signals, you should consider moving to digital.

Chapter 4: Selecting the Proper Manufacturer for SDI Cable Assembly

Looking for the best SDI Cable assembly services?

You can find the SDI port in every major camera. If you’ve ever been to a stadium during a live event, you can see many camerapersons holding cameras.

If you look closely, you can see a lot of black wires. Those are none other than SDI cables.

It may seem a bit crazy. However, here is the thing.

The total length that you see while live streaming is several Kilometers.

It’ll probably burn your pockets if you use HDMI or any other cable – and I am not kidding.

It would help to have a custom SDI Cable manufacturer you could trust.

At CLOOM Tech, you’ve got the right experts to help you.

Have high-bandwidth applications that need a 125 meters transmission distance?

We can help you get the SC-DZ type RG7 cable to help you out. Want to go the economical way?

Try out our choices of RG6 cable.

We can help you design SDI repeaters that can accept two signals together.

Or even convert copper SDI signals into optical SDI format.

That will help for extra-long cable runs of over 300 meters. 

Our cable rating is according to the frequency [Giga Hz].

The higher the Giga Hz, the higher will be the bandwidth. Higher bandwidth equals better video and audio quality.

Many manufacturers make SDI cables, but you need professionals you can trust.

We can custom-assemble SDI cables according to your needs.

Choose from Triax, coax, fiber, or audio cables.

Each comes with its cable and connectors. Talk to us to know more about how we can help.

Chapter 5: HDMI vs. SDI: What’s the Difference?

I am sure many of you want to know the million-dollar question.

What is the difference between HDMI and SDI?

HDMI stands for high-definition multimedia interface. SDI stands for serial digital interface.

Both are for the transmission of audio and video signals.

There are a few differences between them, such as

• SDI cable uses BNC [British naval connector], whereas HDMI uses the HDMI connector.
• HDMI uses high bandwidth digital content protection [HDCP] for protection, whereas SDI has no such protection.
• Speed in HDMI cable is a bit slower due to HDCP than SDI.
• HDMI cable has 19 pins, whereas SDI cable has only one pin.
• HDMI cables are more expensive than SDI cables.
• SDI cables are reliable, and their connectors don’t break easily compared to HDMI cables.
• HDMI cable is more oriented toward consumers. SDI cable orientation towards professionals.

Chapter 6: SDI Cable vs. Coax

Coaxial cable is the simplest type of cable found. Coaxial cable has a central core, either aluminum or copper, clad in a dielectric constant.

A braided copper mesh surrounds it for shielding, and finally, the insulator over it. 

• Coaxial cables have a male connector at the ends, which connects to the female connectors. They are the most common use in cable television.
• SDI is a transmission format. It uses coaxial cables along with BNC [Bayonet Neil Concelman] connector.

The reason for using coaxial cable is that it is very cheap compared to other cables.

All the major institutions, whether the military, bank, or telecom, use SDI.

So, you can think of a coaxial cable as a part of SDI transmission.

Chapter 7: SDI Cable vs. BNC

As you already know about SDI, I will discuss the BNC connector.

BNC connector has a male-mounted connector with a pin connected to the central core.

A ring is there with the male member to fasten it to the female member.

This lock-in function is one of the best reasons BNC connectors are sturdier than their peers.

• You don’t want HDI Connectors Always.

You wouldn’t want wires pulled from the ports whenever someone trips over them.

SDI cable uses a BNC connector, which is very reliable and does not break easily.

HDMI connectors are a pain in the neck precisely because of their fragile nature.

• It’s Inexpensive

SDI cable is one of the most versatile and useful cables.

Professionals all over the world love it. Its ease of handling, reliability, and inexpensive nature add to the charm.

But no one is perfect, and SDI cable is no exception.

Though it can transmit a signal over long distances, it can’t compare to Fibre.

• You save on costs

To compete with Fibre, you need repeaters and amplifiers.

It will significantly increase the cost. It has a lower bandwidth compared to HDMI.

And as of now, it can’t send a signal with a bit rate above 12Gbit/s.

However, what is the best selling point of SDI cables? It can alter video characteristics.

You can change the ISO or white balance in real-time.

Conclusion

You wouldn’t want your live baseball game to stream late due to video editing.

The broadcasting and TV industry uses SDI cables on a large scale.

They got popular during the 1980s and have become the go-to cables since then.

A new transmission medium, Fibre, has recently gained ground.

But it has a long way to go before disrupting the SDI foundation.

If you want a signal over the long-range at a friendly cost and good quality, SDI cables are the way to go.

With CLOOM Tech, your search for a good SDI cable manufacturer ends too.

Talk to us about how we can help you do more for less.

The gauge of the wire tells how much electrical current a wire can carry without heating up.

Suppose you accidentally pass a current higher than a particular wire gauge’s rated current carrying capacity.

The electrical wiring may heat up and generate heat leading to wire deterioration. It may further affect its insulation which may cause an electrical fire.

Then, how to tell what gauge wire is?

There are two ways. Let’s get into the details of both methods.

With a Wire Stripper:

Recently, electricians have been using cable colors to know the polarity of the wire (whether neutral or hot).

The wire insulation indicates the American Wire Gauge sizes of the wires. 

However, if something is wrong with the indications, you should look for a wire stripper.

Step 1: Expose the wire

First of all, shut the power off at the electrical circuits. Ensure the power is off by turning on the light, checking the plug with the plug-in appliance, or using a voltage tester. 

Remove the cover or the faceplate from the electrical box.

You will see multiple wires inside attached to a light socket, switch, plug, or electrical connector.

Use screwdrivers to loosen the connector and take the wires apart.

Don’t touch the wire with your bare hands. Use long nose pliers with insulated handles to hold the wires.

Step 2: Determine the wire size:

You can use a wire stripper to determine the wire’s diameter or AWG size.

As wire strippers have round holes with AWG sizes mentioned over them, you can quickly determine the diameter by inserting the wires in their corresponding holes.

Once you know the wire diameter, you can refer to the AWG wire gauge chart and list the wires according to their AWG size.

Caption: wire strippers

How To Tell What Gauge Wire Is: By Measuring Cross-section

If you don’t own a wire stripper, you can calculate by measuring the cross-section of the wire.

Step 1:

Firstly, observe the electrical cable insulation. Look for any text written on the cable.

The last number written on the cable indicates the AWG of the wire.

If no text is written, jump to the next step.

Step 2:

Cut the wire perpendicular to its run with the help of wire cutters.

Step 3:

Now, measure the diameter of the wire’s cross-section.

Don’t add wire insulation while measuring the diameter.

Step 4:

Now, divide this wire diameter by .46. Calculate the logarithm of this result with the help of the “log” button on the calculator.

Now, divide this logarithm value by -.050305. Subtract three from the resulting value. The final value is the AWG of the wire.

Caption: voltage tester

Conclusion:

Determining wire gauges requires minimal equipment, which works virtually for all wires and cables.

The cables are the main functional component of any electrical device.

Always look for high quality and the right gauge.

Cloom is the world’s leading manufacturer of top-quality wiring harnesses and customized cable assemblies, which you get after the toughest quality assurance tests.

You must attach trailer lights to your vehicle if you’re towing a trailer for public safety.

While every state in the U.S. has laws and regulations governing everything of the tailor lights, from size to weight restrictions, they all have one thing in common.

They must be wired for taillights, brake lights, and turn signals.

For that, you can connect the trailer to the electrical set-up of the vehicle.

However, you will find an unending variety of cables with sheathing of different colors and connectors.

What’s that? And how do hook up trailer wire harnesses?

Trailer wiring diagrams can help.

How do you attach the trailer lights?

Using T-One connectors is your best solution.  

T-connectors, also known as custom wire harnesses, are designed to work with a specific vehicle while providing simple output, with no additional wiring or splicing necessary.

4-way flat trailer harnesses are commonly used.

There are also 5-pin, 6-pin, and 7-pin trailer harnesses available in flat, round, and square. 

It has multiple plugs that ‘T’ into the vehicle’s taillight assembly so you can draw power directly from the taillights or the battery. 

Taillights, turn signals, and brake lights are essential for any trailer.

Markers and flashing lights are also necessary for some roads.

In addition, electricity is needed for some brakes, such as when you want to reverse and engage the electrical brakes or turn off the hydraulic brakes.

No matter your condition,  T-One connectors are the most convenient option because they have an OEM-style link that fits into the car’s current wire harness. 

Why is the color code for trailer wiring important

Every wire in your trailer wiring has a purpose; one for the tail light, one for the left brake light,  one for the right, and so on.

Following the color code is important because mismatched wires can confuse the road if the trailer lights aren’t working properly.

When do you apply the 4-pin trailer connector?

A 4-pin trailer connector is common in most trucks since it is the industry standard for trailer wire harnesses.

Thus, utility trailers use this plug to keep the vehicle safe while towing.

Four wires are connected: green to the right or brake, yellow to the left turn or brake, brown to the taillight, and white to the ground. 

When do you use the 5-Pin Plug?

You might not see a 5-pin plugin in many trailers since it is less common than the 4-pin.

However, this added pin has a major significance in many cases.

The fifth wire is usually blue and helps connect the reverse lights.

Since not all trailers have reverse lights, you will not always need the 5-pin plug.

For example, in boat trailers, 5-pin plug wiring is necessary. 

When do you apply the 6-Pin Plug?

Many companies use the gooseneck trailer to deal with heavy-weight objects.

These are usually placed on the truck’s bed. For such situations, the 6-pin plug system works perfectly.

It has the same color scheme as the others, with an added feature of black or red auxiliary wire.

Also, most wires in 6-pin are round. 

How about the 7-Pin system?

RVs and other big loads typically require the 7-pin system.

You can find many kits to help you with 7-pin wiring in the market.

Their color and function may vary; hence check what the colors mean before connecting the system.

Also, our favorite is the 7-pin spade and 4-pin flat connectors, which provide round and flat pull from one location.  

Trailer taillights

Conclusion

Trailer wiring is not so complicated if you have the right kind of equipment and skill with you.

You only need to look for the schematic and wire it up in an actual way.

If trailer wiring isn’t your thing, let Cloom handle it. 

When installing a new car stereo, the first step is to make sure how to connect radio wire harnesses with the adapter you intend to plug into your vehicle.

Making proper and durable wire connections is one of the greatest concerns you must deal with.

Thus, using one or more methods can ensure your connections remain intact and effective for years.

It will guarantee your new stereo works as it should.

How to Splice Two Wires

Most connections involve interweaving the ends of two wires together.

We can look at some aspects users should consider when undertaking this task.

And it is up to you to decide which method works best.

1. Soldering Two Wires

Soldering wires is the most effective way to ensure a solid connection.

You can do this by heat shrinking the tubing that insulates and protects the connection.

In most cases, the process will begin with you using a wire stripper to remove the insulation at the ends of the wires.

The following steps should help you navigate your way through the soldering process:

• The first step is stripping about half an inch of the insulation material from both ends of the wire using strippers, which will expose the copper strands beneath.
• Next, twist the wire strands together to prevent fraying and simplify your work.
• Now place some heat shrink tubing over the end of one wire. Ensure you slide it far enough to prevent it from heating while soldering.
• Proceed to twist the two wires together. This step isn’t to make a secure enough connection but to pave the way for the soldering process.
• Next, heat the wires from beneath using a soldering iron. Allow the solder to flow through the wires from above.
• This step ensures you get to the temperature, and the solder flows through the connection.
• Then test your connection and slide the tubing on the open wires. 
• Always apply only a little heat to prevent the wires from melting into the tubing.

2. Making use of Posi-Product Connectors

One of the best things about Posi-Product connectors is that they are easily attached and firmly placed.

Most users also prefer this method because of the integrity of the connectors and the simple process involved with the technique.

Below are the steps to connecting two wires using a Posi Connector:

• First, strip off half an inch of the insulation material to expose the copper strands beneath.
• Take your POsi tap made of three parts and unscrew the top smaller part.
• Next, twist the wire strands and slide the Posi tap end over the naked wire strands.
• Proceed to screw the remaining Posi tap body back into the top piece to crimp the wires. 
• Once it’s secure, you can unscrew the bottom part of the Posi tap connector, exposing the piece that pierces your existing wire and the piece that holds the existing wire in place.
• Next, slide the bottom part over the existing wire you want to tap into, then screw the remaining Posi connector with the newly attached wire you want to tap into to get a secure connection.

3. Crimping wires

Contrary to what some believe, crimping wires can help create a fairly solid connection.

However, it would help if you had crimp caps and a crimping tool to undertake the task.

Nonetheless, one of the potential drawbacks of this process is that the caps can shake loose if you don’t crimp them tightly enough.

Therefore, you should give them a good tug before installing your stereo.

To crimp two wires, follow the steps below:

• First, expose the copper strands beneath by stripping off half an inch of the insulation material on each wire.
• Take the two wires and twist the ends together. Ensure you don’t leave any loose copper strands.
• Next, slide a crimp cap over the twisted wire stands. Ensure the cap covers all the wires.
• Finally, squeeze down over the metal sleeve inside the crimp cap using a crimp tool to create a secure connection.

Caption: Crimping Tool

Ways of Tapping into Existing Wires

Sometimes, you also need to tap into an existing wire.

And linking a new wire to the middle section of an existing one is what we call tapping the wire.

There are also several ways to safely and securely carry out the process.

Based on your preferences, you can opt to go with either one of the following:

1. How to Connect Radio Wire Harnesses: Using Posi-Tap connectors

In the same way, you would handle other wire connectors; the Posi-Tap connectors are straightforward for anyone trying to create a secure tap with another wire.

Follow the steps below to tap into a wire using Posi-tap connectors.

• Begin by stripping off about half an inch of the insulation material to expose the copper strands beneath.
• Use your Posi tap made of three parts by unscrewing the top smaller part.
• Twist the wire strands together and slide the Posi tap end over the naked wire strands.
• Next, screw the remaining Posi body part back into the top part to crimp the wires in place.
• Proceed to unscrew the bottom part exposing the piece that pierces the existing wire and the piece that holds the existing wire in place.
• Now slide the remaining part over the existing wire you want to tap into and screw the rest of the Posi tap connector along with the newly attached wire onto the wire you want to tap into, creating a secure connection.

2. How to Connect Radio Wire Harnesses: With a soldering process

If you are familiar with the various aspects of wire connecting, then you know that soldering is considered an old-version methodology of getting the job done by most.

Nonetheless, it is still relevant today and often gets the job done.

Follow the steps below to tap into a wire using the soldering process

• The first step is to strip off about half an inch of the insulation to expose the copper strands below.
• Next, twist the strands together to prevent fraying and make working with them easier.
• Now using a pair of strippers, cut through the jacket material to expose the wire strands beneath. Be careful not to cut through any of the wires.
• Next, pull off the wire jacket to expose about a quarter inch of the copper strands. 
• Proceed to twist the wire strands of the new wire and existing wire together. 
• Now heat the wires from beneath with a soldering iron and flow the solder through from above. This step will ensure you get to the right temperature and fill the connection with solder.
• Finally, cover the portion of exposed wires with electrical tape to tap into your wiring harness.

3. How to Connect Radio Wire Harnesses: By a T-splice but no solder

T-splicing is also known as a mechanical splice.

It is one of the methods used to create a solid connection with the wires.

Sometimes, it can be the only way to ensure the job is done right.

It is one of the ideal processes to get good practice.

The steps below will assist you in tapping into a wire using a T splice and no solder.

• First, strip off about three-quarters of an inch of the insulation material to expose the copper strands beneath.
• Next, find the wire you want to tap into and slice open the jacket. Be careful not to cut through the wires. B bends the ire to start splitting the jacket to make it easier.
• Now try to separate the wire strands from the jacket material. Ensure about an inch of the inner wire strand is exposed because you’ll need to cut off the remaining jacket material to make it easier.
• Proceed opening up the middle of the naked wire strands, creating a space for a new wire to slide through.
• Take the new wire and slide it into the existing exposed wire.
• Follow by taking the wire end and dividing it into two halves to allow you to wrap both ends in different directions around the existing wire to create a tap without solder or any mechanical connections.
• Cover the exposed wire with electrical tape to create a secure connection.

Conclusion

For those undertaking their first installation, connecting wires can be intimidating.

However, the process is not that hard when you think of it.

One thing you need to do to ensure a successful outcome is to take your time and exercise caution when making the connections.

Contact Cloom Tech for the best wire harness services if you encounter any problems or inquiries.

Manufacturers have had to find a way to reliably transmit data from the screen to the motherboard without taking up too much room in their quest to develop ever-thinner gadgets.

That’s why “flex cable assembly” is commonly used. Smartphones today are a prime example of this.

The flex cable’s structure and adaptability allow it to execute the job, but the trade-off has a higher potential to be damaged.

Let’s dig into the complications and how to avoid them using professional help.

What is flex cable?

The flex cable, or FFC (Flat Flexible Cable), is a crucial component of any electronic device, such as a mobile phone or tablet computer.

The flex cable’s primary function in mobile devices is to interconnect the motherboard to the LCD monitor, while its potential applications are far broader.

How to suspect a broken flex cable?

A broken or intermittent display is the most telltale sign that you have a compromised flexible cable.

Naturally, this kind of gadget is useless.

Therefore, any procedure requiring opening the device must be carried out cautiously.

Most common causes of damaged flex cable

 It takes only one broken flex cable to render an entire screen and gadget useless.

So, the flex cable needs careful handling, or it will fail to work.

• Incorrect installation of flex cable in the apparatus.
• Damage to the flex cable due to carelessness
• Pinch or pressure damage to the wire
• Failure to recognize the uselessness of one’s current methods
• Making adhesive contact with the flex cable

Caption: FFC with computer component

How to fix flexible “flex” cables that are broken or torn?

When it comes to completing the repair, poor handling is directly linked to its completion.

Suppose you’ve effectively replaced the monitor and are ready to reattach it to the CPU via the flex connection, which is when the cable is most likely to be broken or otherwise damaged if you store it in the wrong spot and then close the device. 

If it is your first time making this repair, it’s a good idea to snap a photo of the device while it’s open so you have a reference for putting the cable back in its original spot once you’re done.

Tools

• Solder paste remover 
• Adjustable heat gun
• Small scissors or surgical solder iron with miniature failure
• Desoldering braid
• Weld roller for electrical equipment
• Masking or sticky tape
• Razor blades with one edge or a surgery scalpel
• Flat blades
• Screwdriver

Instructions

Step 1

First, using the scissors, cut the torn piece cleanly along the two straight edges using the scissors.

or

Cut or rip as straight as a feasible non-torn section to get equal halves if the cutting takes too much time while tougher.

Then, please read the steps below.

Step 2

Scrape the insulation off one side of the cable with the single-edged blade to reveal the bare wire for the connections, which should be about 3 to 4 mm long.

Take your time and avoid damaging or removing the copper if possible. Getting anywhere is a slow procedure.

Then, please return to the cable’s back half and scrape it similarly to reveal the copper there.

The lacquer insulator is not as easily scratched as it appears in images.

Step 3

The third step is applying a thin solder paste eraser and coating all exposed copper sides.

If it spills over, that’s okay.

Heat the dough with the soldering iron to stick it to the cable’s copper section.

Take care of both sides. You should use a solvent or cleanser to remove any lingering dough.

However, be careful not to destroy the plastic insulation after placing the solder on each tin contacts.

To reconnect the cable, apply this to the connections of the two “flex” portions.

Use a desoldering braid to remove excess solder or to split two tracks that have become accidentally connected.

Step 4

Use a mask or sticky tape to attach the two cord ends ‘flex securely’ layered one on top of the other, with the ends aligned as precisely as possible and overlapping by about 4 mm.

Hence, the contacts are entirely in touch (without an electrical circuit).

Put a dab of solder solution to the connection point between the two pieces.

To rejoin the cables, heat the top sheet (using the heat gun at the welding station) gradually, avoiding overheating the insulator of the cable “flex” while melting solder uniformly enough to pull it over all of the contacts.

Step 5

The next step is to apply pressure between the 2 layers of cables using a flat-bladed screwdriver or a stiff metal plate and then perform circular motions with the heat gun to strengthen the weld’s hold.

Wait until the solder has cooled before removing the screwdriver (or metal plate) for approximately 30 seconds.

Remove all tapmmeter connections from end to end to ensure that there are not any loose connections.

You should weld the connections again with heat if you find any faulty ones.

Precautions

• There is a risk of worsening a bad situation if you try to fix a malfunctioning electronic card, as these cards typically have integrated components vulnerable to static discharge.

• Also, there is no way around learning how to precisely operate electrical solders on the card and typical parts to repair cables that ‘flex.’ Welded (and desoldering) equipment (iron tiny conventional welder and hot air cannon to heat and flowing factors) should also be available.

Conclusion

Flex cables are best when adjusting more wire in smaller spaces.

However, you have to handle them carefully and fix them in places with expert techniques.

After all, mishandling or incorrectly using a flex cable’s associated tools is the leading cause of this part becoming damaged.

If you want to handle it well, use only the provided professional tools and never touch it with metal instruments.

Here at Cloom, we offer flexible cable assemblies with careful handling so you get signals with minimal interference.

For getting services, contact us now.

A large number of radio frequency connectors are working with coaxial cables.

These connectors help maintain the shielding of coaxial cables and have a fastening mechanism of different types.

BNC connectors are common among different types.

How does the BNC connector cable assembly benefit us?

What are BNC connectors?

BNC connectors are small RF (radio frequency) connectors connecting with coaxial cables.

These connectors first came into existence in military radio equipment in the year 1940, and since then, they have been widely used in radio systems.

These connectors help maintain the characteristic impedance of the cables at either 50 or 75 ohms.

You can use them for radio and video frequency connections with frequencies ranging up to 2 Giga Hertz and up to around 500 volts. 

Disassembled BNC connector

BNC connector construction

The female connector in the BNC connector has two bayonet lugs, while the male part has a slot.

You can ensure complete mating by turning the connector a quarter from the coupling nut.

Both male and female connectors have an outer conductor with slots with plastic dielectric.

Due to this dielectric, the connector experiences signal losses at high frequencies.

For frequencies up to 4 GigaHertz, the outer slots radiate signals and thus make the connector usable.

However, for frequencies higher than this, like about 11 GigaHertz, these connectors are not stable.

You can find the interface-related specifications of the BNC connectors in MIL-STD-348.

BNC connector uses

These connectors were mainly planned for military applications.

Nowadays, along with the radio, you can use them with miniature or subminiature coaxial cables in television and various other RF equipment. 

Additionally, manufacturers used them in early computer works, such as the IBM Personal Computer network and ARCnet. 

So you can see BNC connectors on thin 10BASE2 Ethernet cables and network cards.

Further, you can use them on commercial video devices for mixed video. In such conditions, use consumer electronics with RCA jacks and commercial video equipment with BNC jacks only with the help of an adapter. 

You may also notice BNC connectors in studios where recording equipment uses BNC connections to synchronize various components. 

In BNC connections, the male part fits the cable while the female part attaches to a section of the equipment for signal connections like

• Radio antennas
• Nuclear instrumentation
• Test equipment
• Analog and serial digital interface video signals
• Aerospace electronics

The coaxial cable on panel telecommunications

BNC connector types, formats, and variants

Apart from these types, 50 ohms and 75 ohms, there is a variation of BNC connectors, i.e., RP-BNC or BNC Connectors with Reverse Polarity.

As the name indicates, in this connector, the polarity of the BNC connector reverses.

Here, the female part you usually see in the jack is in the plug, and the male is in the jack.

The reverse polarity connector does not connect with the common interface connector.

An example of this reverse polarity BNC variant is the SHV (Safe High Voltage) connector.

In addition, some miniature versions of these connectors are Mini BNC, and another is high-density BNC.

These connectors retain the original characteristics but have reduced footprints with high pack density on their circuit boards.

Such connectors have 75 ohms impedance, so you can use them with High-Density video applications.

Also, there are some straight and right-angled variants of BNC connectors.

Of these, the straight ones are more common.

You can use the right-angled connectors, where a cable separates with the plug at right angles.

Right-angled connectors are suitable for various applications like this so that the cable detaches from the connector in a tidy manner.

There is a drawback with right-angled connectors, i.e., these connectors lead to higher signal losses than straight ones.

For many applications, signal loss is insignificant for operational limit frequencies, and the difference becomes higher.

There are several BNC connector variants based on the different female sockets.

In a basic BNC connector, the socket has a panel mounting assembly having a solo connection for the coax cable.

For Earth, you can use the panel and do it with the help of a single nut. Some other connectors have bolts and four nuts to allow them to fix the panel.

However, this arrangement is suitable only for low-frequency applications and not for radio-frequency applications where you must match impedance.

For such applications, bulkhead mounting connectors are available for different cable dimensions.

You may also find adapters and attenuators beside the plugs and sockets.

Compatibility

The best part of BNC connectors is that all their different versions can manage without any doubt.

The 50-ohm and 75-ohm versions are compatible with the 2007 IEC 60169-8 and can mate with each other. 

When the frequencies are very low, i.e., below 10 MegHertz, there is some impedance mismatch between a 50-ohms cable/connector and a 75-ohms connector bit with insignificant effects.

There were 50 ohms versions of BNC connectors that you could use with cables of any impedance.

Thus, frequency mismatch becomes significant and may lead to reflections in signals.

BNC vs. SMA

Consumers may be more familiar with SMA connectors because television cable connections in homes mainly use them.

The difference is that SMA connectors are threaded, and BNC connectors are not.

What is the BNC connector cable assembly?

In the BNC connectors, the male part attaches to the ends of the coaxial cables.

It has a metal tube or ring-like structure that surrounds a pin.

This pin connects to the coaxial cable and acts as a transmission between the cable and the device connected to the cable.

BNC connector cable assembly method

The BNC connector cable assembly method has four.

Twist on 

As the name suggests, these connector types twist onto the cable.

So it is easy to use and does not need special tools.

You may need a wire stripper only to remove the cable’s insulation.

However, some people do not find twist-on connectors as reliable and secure.

Crimp-on

These crimp-on connectors have two styles: two pieces and three pieces.

Between these two, two-piece connectors are more common.

And this type of assembly requires a particular type of crimping tool for proper crimping.

Follow the below procedure for making a two-piece crimp-type assembly:

• First, slide the ferrule (a hollow tube-like portion of the connector) over the cable. Slide it a few feet so that it gets out of the way.
• Second, cut the cable end neatly and cleanly.
• Third, strip the cable with the help of a stripping tool. Make sure you strip the outer jacket about ½ inch back of the cable, strip the braided sheath about ¼ inch, and then strip the insulation about 3/16 inch from the cable end.
• Now, insert the solid central conductor of the cable into the connector’s center pin. Try to slide the center pin downwards to cover the inner insulation.
• Take a crimping tool and crimp the center pin.
• Now, slide the body of the connector on the center pin and the insulation under the braided shield. Once you start pushing, you will hear a clicking sound.
• Next, move the ferrule forward to touch the connector’s body. Finally, crimp it also with the crimping tool.

For the  three-piece crimp-type assembly:

• There is a center pin that you have to crimp to the central conductor of the cable. 
• After that, you can push this crimped pin into the correct location of an inner ferrule which separates the internal insulation and cable braid. 
• Once pushed, you can crimp the outer ferrule to the braid and external insulation to fix the cable firmly to the connector. 

Cable assembling with these connectors can take longer than the others, but finally, you will get a secure connection that will not become loose over time.

Generally speaking, these connectors are suitable for large production runs.

However, you cannot use them for rework once crimped.

F-compression

Attaching an F compression connector to the coaxial cable and then fixing it to the BNC connector.

In this method, the connector has a center pin known as a solder pin.

You can expand this compression gland to hold the sheath or braid of the cable.

You can use this type of connector with limited cable sizes.

Thus, this method and connector are suitable for small quantities of production. 

Most people prefer the second method as it does not require estimating the coax cable length as the core is visible. So there are lesser chances of error.  

F-crimp

 Like the F-compression connector, the F-connector crimps onto the cable first, and then you can screw it to the BNC connector.

Caption: Three main components of a BNC connector 

Conclusion

BNC connectors have become standard RF connectors as they are easy to use, durable, cost-effective, and easy to assemble.

However, the crucial point is knowing which connector type to pick among many variants that suit your Coaxial Cable Assembly.

If you need any help, contact Cloom.

With four key factors affecting cable assembly performance—mechanical, electrical, environmental, and application-specific—manufacturers must ensure that cable assemblies can withstand harsh conditions and operate reliably over the system’s life.

Cable assemblies with durable, compact, and flexible designs help that, whether used in systems operating on land, subsurface, sea, or space.

However, as applications vary, so do the design and cable assembly types. Today, we’ll take a closer look at some of them.

What is a Cable Assembly?

A cable assembly is designed to consolidate the functionality of multiple cables into a single, more manageable unit, making it simpler to set up, move, and repair.

Many wires and cables are color-coded or labeled for quick identification.

The wires in certain cable assemblies are exposed, whereas those in others are completely covered.

A cable assembly typically has a single component connecting each end and plugging into an outlet.

While the final assembly may be concealed, it is usually constructed so that the individual components can be seen for at least a few inches before joining the part plugging into the power source.

Cable assemblies simplify designing, buying, testing, and installing cables.

They cut costs and streamline supply networks.

Optional electronic components and features like bend reliefs and sealing caps can make them active while providing flexibility and lightweight benefits.

Common Application of Cable Assemblies in Specific Industry

Transmission of either information or electricity is the usual function of an assembly.

Usually, you can see them in the following industries.

Automotive Cable Harnesses

Most manufacturers provide a variety of automotive sectors program requirements, such as automation grade cables, assessment submissions, and a lengthy development cycle.

It is common practice for manufacturers of custom wire harnesses to demand either an SAE-approved or special dust and waterproof caps and connectors.

Hence, you will use silicone seals, gaskets, and bespoke over-molds and grommets in automotive cables.

Medical Wire Assemblies

Multiple types of cables carry electricity and high-definition video between medical devices.

Sterilization, bio-compatibility, and ISO 13485 certifications are all prerequisites for many medical cables.

Many wire-sleeve and over-mold methods exist because of their resistance to ethylene oxide, autoclave sterilization, and isopropyl alcohol.

MilSpec Cables

Mil-spec standard 38999 is a comprehensive standard for electrical harnesses for military applications.

Moreover, manufacturers offer expert designs for these cables, which often have mil-hardened parts.

You need intricate connector systems and specialized materials for the wire jackets to put together several of these cables.

Connector systems that adhere to Mil-spec 38999 typically call for specialized tools.

For example, insert/extract tooling, back shell torque wrenches, HIPOT test equipment, crimpers, and multimeters to achieve the program’s goals.

Military-grade cable assemblies are typically used for aerospace, tactical, and marine applications. 

Caption: Wire processing for connecting machine

7 Types of Cable Assemblies You May Need

The various cable assembly types may be grouped by application, the number of wires (core), desired shape, and material, including complex military, multi-conductor, round coaxial/RF, wire and cable harnesses, flat ribbon, custom electro-mechanical, and more.

Data & Video Cables- D-Sub, USB, HMDI, DisplayPort

Multiple variations within each family are just some of the industry standard cable formats manufacturers support.

This applies to the male and female varieties, the full-sized and miniaturized forms, the “A,” “B,” and “C” varieties of the USB connector, RJ45, RJ11, and other Ethernet cable and phone jack types.

Power Cables

Power cables can employ various cable technologies for general usage and normally run at voltages lower than 30VDC or 120VAC.

You might use PVC coatings, tinned copper wires, thermoplastic over-molds, and connectors in manufacturing these cables.

For several common connector types, such as DC power barrels and AC power plugs like NEMA 5-15P and 5-15/20, in-house tooling is available.

Low Voltage Hook-Up Wire Harnesses

A wide range of wire harness constructions meet UL and industry standards and need 300VDC or less.

Companies can offer solutions for single-wire and multi-wire cross-sections with 1 to 100 conductors.

You can find these wire harnesses inside consumer devices, mechanical systems, medical equipment, and most of our daily tech.

RF/EMI Cable Assemblies

The world is already very noisy, and each of your cables undoubtedly contributes to that.

If there is interference in the radio spectrum, we call it RFI or radio frequency interference.

There are EMI or electromagnetic interferences as well.

However, if the disturbance persists, the circuit’s performance may suffer or stop working altogether.

Any data path may suffer consequences, from a rise in failure rate to complete data loss.

Depending on the context, you may wish to use these signals.

Hence, you should consult with the cable assembly person to determine the optimal course of action.

Molded Cable Assemblies

You have likely encountered molded cable assemblies outside of your professional life.

In most cases, manufacturers might prefabricate the HDMI cables in a mold.

A molded cable assembly might be the best option if your application demands increased durability and a cleaner look.

You can also use plastic or metal to create shells; both types, protected and uncovered, have their uses.

Assembled Coaxial Round

Coaxial cables are special electrical wires in which the inner conductor is encased in an insulating tube, and the outer conductor is encased in a shielding tube.

A jacket is typically around the outside of a coaxial wire to provide insulation.

The word “coaxial” refers to the core conductor and the external shield lying along the same geometric axis.

Coax cables have several uses in vehicles, airplanes, medical devices, and radios.

Flat Ribbon Cable Assemblies

Ribbon cables that are flat and sleek are awesome.

The cables are neatly arranged in a flat ribbon rather than packed together within a sheath.

Ribbon cables, which you have probably seen in old computers, are flat cable assemblies that are just as functional as round cables.

However, they can be more useful in some situations due to their smaller footprint.

Ribbon cables make viewing and classifying each wire easy and can have color-coding to indicate their function.

Moreover, their primary use is bulk termination at IDC connectors with a sharp forked row of contacts.

In some cases, ribbon cable assemblies are superior to round cable assemblies when the cable’s width is a critical design factor.

Caption: Bare wire stranded

Cable Assembly Design Considerations

You need to follow some key considerations before designing the system.

• Identify the requirements and application area so that you design the protection accordingly.
• Determine the correct length and size of the conductor
• Also, determine the proper conductor and insulation material for your wires
• See that the cables are flexible enough to endure the abrasions
• Decide the stranding pattern of the cable so that it offers good flexibility
• Moreover, determine the correct shielding and plating types of the conductors so that they work in humid environments
• In the end, use the correct connector types and termination methods.

Caption: Power connector

Conclusion

Cable assemblies play a significant role in the manufacture of any system.

Also, there are many types for each industry type.

Thus, designing these harnesses requires extra care and consideration to work perfectly.

Here at Cloom, we offer wiring harness and cable assembly solutions, so you don’t have to worry about perfection.