12 Important Things to Know About your Electricity Meter

Traditional electricity meter

The electricity meter is an electronic device that determines the electricity costs consumed by the users. The efficiency of electricity meters is critical for both suppliers and end-users.

Meter manufacturers and suppliers commonly found in conflicts with the users due to inadequate monitoring and performance of the meters. You need a professional harness manufacturing company to help you out with the design process.

Traditional electricity meter
Traditional electricity meter

What is the most common issue that your manufacturing unit is facing right now regarding the quality and the design of the electricity meters? You need the best quality products from conception to the wires of the meter as an electricity manufacturer.

1.Accurate Billing With Electricity Meters

The electricity meter is the bridge between the electricity supplier and the consumer. The electricity meters fixed with the premises of the consumer. Meter readings and statistics determine the cost of billing and the units consumed by any consumer.

The accurate working of electricity is the essential thing for fair dealings between the supplier and the consumer. If the meter does not monitor the power consumption, the supplier may suffer from the loss. A tiny error or malfunction in the electricity meter can result in a significant loss for whether the supplier or the consumer.

For any electricity meter supplier, putting all the available resources into the quality of the meter is inevitable. No matter what, you should not cut corners on wires or the small components of the meters.

2. Electricity Meters Must Have 100% Uptime.

Consumers are using power 24/7, so the supplier cannot afford even 1 hour of the downtime for the electricity meters. If the meter is down, it means that consumers won’t be able to use any kind of power, and it will end with consumer complaints about your services.

No matter how good the power management is, when electricity meter goes down, everything is at risk. The use of poor wiring and no advanced wiring harnesses will keep you tangled with increased downtime and user complaints.

Electric meters with high power transmission
Electric meters with high power transmission

So, no matter it is a commercial electricity meter of residential power supply meter, 100% uptime is necessary for accurate measurements of power consumption.

3.Major Issues with Electric Meters

A faulty electricity meter can be a disaster for the supplier and the consumer too. In the case of lower readings, power suppliers will have to suffer, and if the error leads to more interpretations than the actual consumption, consumers will have to pay extra. There are several issues with electricity meters that need better cable management and wire quality, including:

• Melting of wires due to high temperatures

• Internal short circuit due to varying current levels

• Poor quality of the cables leads to limited control over maintenance

• Short circuit due to damaged wires

4. Varying Levels of Current Require Custom Wires

Current change can not eliminate, but it can reduce the impact. Many electric meter suppliers make the mistake of using ordinary market wires in their meters. As the current levels start getting out of hand, the wires start melting, and that leads to apparent electricity failure.

How to get rid of damaged causes by varying current levels? The use of custom wiring harnesses allows not only better cable management but also reduces the chances of melting, short circuit, and power failures. Wiring harnesses keep the performance of the electricity meter intact even in extreme conditions.

Electricity meter reading check
Electricity meter reading check

5. What can go Wrong With the Electricity Meter?

CLOOM Tech is a renowned harness manufacturing company, and we generally receive queries from the suppliers that why do they need custom wire harnesses? The electric meters already have high standard quality wires, so their meters are suitable to be used for longer times. The reality is quite the opposite as the standard market wire can never withstand the power abuse that meters go through. Ordinary commercially available cables can withstand conventional power consumption without any damage. When the meters have to deal with such abnormal power supply:

• Meter may burn

• The wires can melt

• The protective layer can burn and lead to a short circuit.

• The internal electronic circuitry can be damaged.

• Monitoring chip malfunction

You can see that any of these issues can lead to a damaged electricity meter, and that is a bad situation for any supplier. Using ordinary wires is just like creating a mess willingly.

6. What is a Smart Electricity Meter?

Why are companies switching traditional electricity meters with smart electricity meters? How can you start manufacturing the new trending meters to beat the competition? Many countries have already begun to the installation of smart electricity meters, and if your company has not rolled out the new smart meters, you need to take action right now. For intelligent electricity meters, you need to revise the whole manufacturing process from the design of the meters to the wire selection.

Ordinary wires and cable arrangements are not capable of handling the design requirements of the smart meters, so you need to consider the option of custom wiring harnesses.

7. What are the Benefits of a Smart Electricity Meter?

Millions of smart electricity meters are already operational in famous cities as these meters give better control to parties, consumers, and the supplier. The power consumption calculated every 30 minutes or according to the pre-programmed intervals. These capabilities offer better control and estimation of the power consumption to the consumers.

Smart electricity meters offer better power management to the suppliers and consumers with smart technologies. Bills generated as per the accurate readings, so you don’t need to worry about the estimated billing anymore.

8. Do Smart Meter Designs Require Smart Cable Management?

Smart electricity meters require exceptional wires and harness to follow the design and floor plans. Ordinary market wires are thick in terms of diameter, so they will not meet the design requirements of the smart meters for most of the electricity meter manufacturers.

The smart electric meters are too small in terms of size, so the optimized cable management is critical to get the desired results. If your manufacturing team faces limitations due to poor control over cable arrangements, using harnesses can be a good option.

9. How to Ensure Meter Safety?

The safety of the meter is directly associated with the security of your electronics. If the voltage keeps changing, your electronics may not be able to withstand these fluctuations. So, if you want to keep your consumers safe, you need to ensure the safety of your electric meters.

When it comes to the safety of the electric meter, the priority must be the safety of the wires and the internal circuitries. Using the wiring harnesses allows the manufacturers and suppliers to overcome the design and production limitations.

10. Cut Wire Costs With a Custom Wiring Harness?

It is a misconception that custom services and custom products cost high, but in reality, you can save a lot of side expenses with customized products. Without custom wiring harnesses, your meters are more vulnerable to damages and failures. In such situations, you will be spending a lot more money on maintenance than the actual cost of customized wiring harnesses.

Using wire harnesses allow the supplier to deliver the expected quality and durability to the consumers without risking the safety of the electronic devices across the premises.

11. Why Harnesses are a Must for Electricity Meters?

No matter what kind of electricity meters your company is manufacturing, there are always going to be some limitations that you will have to face due to ordinary wires. With problems like a short circuit, power failures, and inadequate monitoring, your manufacturing team needs extraordinary wires and other ingredients of electricity manufacturing. By using wire harnesses, you can get almost all the mentioned problems and limitations. We are seeing a massive boost in demand for harnesses by electric meter manufacturers and the suppliers. The stats indicated that the usage of smart technologies in electric meters lead to better monitoring of the power consumption and the lesser meter failures.

The electricity meter installed on the electricity pole.
The electricity meter installed on the electricity pole.

12. Eco-friendly Electric Meter Production

The use of custom harnesses not only benefits your company but also have a positive impact on the overall environment. With smart technologies, you can avoid possible power losses and failures. The use of energy-efficient appliances gives a sense of better power consumption to the users, and they consume the resources more efficiently. You need to save our planet if we want to survive here, no matter you are a supplier or the end consumer.

Conclusion

CLOOM Tech is the industry leader for custom meter cables and wire harness manufacturing. Whether you need smart assemblies for industrial units or want to optimize the electricity mater manufacturing process, CLOOM Tech can be your business partner. We offer the best wire harness manufacturing services for meter manufacturers and other industries.

8 Precautions for Crimping Wires in Wiring Harness Manufacturing

Crimper with red handles

Soldering wires in the wire harnesses are not only time consuming but costly method too. If you want to keep the project cost at minimal, then think of a smart solution. As wiring harness manufacturing is a more effective approach for wire management, crimping is also a better alternative for soldering.

Crimper with red handles
Crimper with red handles

Crimping wires in wire harness manufacturing requires quality testing as terminal connections define the durability of wire harnesses. CLOOM Tech wiring harnesses manufacturing teams use state of the art crimping tools. We ensure quality connections between all terminals in any wiring harness. Here are some considerations crimping wires:

1. Wire Insulation Should Fully Enter the Crimp Tab

The crimp tab is responsible for holding the wire tight and make sure that the wire fully covered with the crimp tab. When peeling off the wire, strip enough wire and twist the wire in such a way that tab can grip it firmly. Crimp tab must be fully over the wire, and if it touches the insulation, that’s fine.

Tools and tips of different sizes and colors for crimping stranded electrical wires
Tools and tips of different sizes and colors for crimping stranded electrical wires

In most cases, it is better if the crimp tab not only fully covers the stripped wire but also a slight portion of the insulation. It adds an extra layer of firm grip so that crimped wires can withstand rough use during installation and application. There are some more advanced crimping tools and connectors where you don’t need to strip the wires. The connectors can make contact with the strands without stripping the wire. This method is most effective and less time-consuming. When you press the crimp tab, it will automatically make direct contact with the wire. You can skip the long process of stripping wires for crimping. In case you insert stripped wires in these connectors, you will still get the same results, but why would you like to waste your time with stripping.

2. The Wire Should Be Flawless.

The crimping process ensures the firm grip of the terminals and connectors, but if the wire is flawed, you may not get the desired quality. In the wiring harness manufacturing, the quality of wire matters a lot. At CLOOM Tech, we have strict protocols to ensure the international standards of wiring harness manufacturing.

If you think that using damaged wire will get the job done, then you are not only wasting your time but your investment too. Nothing is more important than the safety of your project. So, make sure that you that the wires that you are trying to use in wiring harness manufacturing are flawless. Damaged wires may not work in the very first stage, and even if the miracle happens, the connection will break soon. Once the power supply cut off, you will end up paying even more money in the form of repairing costs.

Electrical crimp tools and wire
Electrical crimp tools and wire

3. Connectors Fully Retain the Wire

Lose connectors are the biggest threat to the smooth transmission of data and energy. While connecting terminals in wiring harness manufacturing, there are several ways to ensure the retention of wire. The end goal of using advanced tools and crimping technologies is to ensure firm connections. If that does not happen and you end up with losing terminals, there is no point in investing in these services. CLOOM Tech especially focuses on the quality crimping as part of better customer support. We continuously check every batch against different methods for wire retention. Every product from CLOOM Tech comes with quality crimping so that you can rely on our products and services.

4. Crimp Indentation Must be Right.

This precaution is not only about the quality of crimping but more about the aesthetics. For better management and presentation of wires, all components must be well-aligned. While crimping wires for wiring harness manufacturing, wires must be in the center of the crimping tab. If the wires are not centrally aligned, the tab will not properly grip the wires. The central indention is important for a firm grip, and it also presents the project in a better way.

5.No Signs of Tearing or Pulling on the Insulation

Wires that you are using in wiring harness manufacturing are somehow different from the typical energy wires. These wires are part of complex systems where quality matters the most. Unlike simple circuits, changing and replacing wires in the wiring harness can be a hectic task. If you have wires with poor or damaged insulation for crimping in the wiring harnesses, it may break from the weak points.

Tools for electrician and cables
Tools for electrician and cables

While using wires for crimping in the wiring harness manufacturing, make sure to connect reliable wires. If you feel that the slight damage can turn to be a disaster in the future, consider replacing that wire. You can use that slightly damaged wire somewhere else in the system, but wiring harnesses are not the option here.

6. Crimp Tab Should not Damage Insulation.

The use of crimping technology can alter the wire crimping process. In general, manufacturers use typical crimping methods for wiring harness manufacturing. Hence, wire with striped insulation goes into the crimp tab. The crimp tab slightly holds the insulation too for a firm grip. The crimp tab should not damage further insulation. While pressing the crimping tool, use enough force to grip the wire but don’t break the insulation. Striped insulation can because of corrosion due to damaged insulation. In a work setting with chemical exposure and humidity, perfect insulation is really important. Although the crimp tab will damage a small portion of the insulation, the impact can be huge.

7.No Broken Insulation

While stripping the insulation, you will have to be careful. Wrong stripping can break the insulation, and that is bad for project safety. Insulation is not only critical for project safety but human safety too. Exposure to the wire with broken insulation can lead to serious health damage.

Engineer crimping wires
Engineer crimping wires

At CLOOM Tech, we use custom wires and cables for wiring harness manufacturing. We take special precautions during the design and manufacturing process to deliver flawless products to our clients. While working with our team, you can have peace of mind as you will get professional crimping with flawless wires and components.

8.No Visible Cracks in any Component

Wire separation of damaged wires is a red flag for you. If you see any type of damaged insulation of other abnormalities in the wire, skip that wire and use the new one. These quality standards are not for wires only, but every involved component must be in perfect shape. From wires to the crimp tab, every component is equally important. Ignoring one component may lead to bigger damage later on. A professional wiring harness manufacturing supplier will consider all of these precautions. We have a long checklist for wiring harness manufacturing so that we don’t have to face any complaints from the clients.

Crimping tool component and cables
Crimping tool component and cables

Conclusion

If you want to save project costs with professional crimping in wiring harness manufacturing, you can have a detailed meeting with our team. CLOOM Tech offers affordable yet quality wiring harness manufacturing services to international and local projects. We can help you to scale your business.

7 Points to Know About Wire Gauge for Wire Harness Manufacturing

Wire gauge for thickness measurement

Right measuring standards are critical for the custom wire harness manufacturing. If you are not sure what measuring standard is suitable for your project, don’t go for the hit and trial method. Measuring standard is not something that you can alter after the production of wire harnesses. For accurate and precise wire harness manufacturing, you need to know about this everything.

Wire gauge for thickness measurement
Wire gauge for thickness measurement

1. What are the Measuring Standards for Wires?

Every wire harness manufacturing order comes with tons of information and requirements. Most of the manufacturing companies tend to ignore some points, and measuring standard can be one of those points. AWG and SWG are the recognized standards in the United States and other countries to measure wire gauges. The measuring standards are not universal and can change for different countries. These two standards are most famous in several countries, so manufacturing companies also follow these standards. While ordering bulk production of wire harnesses, don’t forget to discuss the details about measuring standards.

An engineer working on the measurements of the wires
An engineer working on the measurements of the wires

In case you have provided instruction in AWG, and the manufacturer deals with SWG; such a situation can make things critical for both parties. The end product may not meet your project specification due to the difference in measuring standards. The best way to avoid these issues is to discuss the standard measurements before starting the design process.

2. American Wire Gauge

The first measuring standard for wire harness manufacturing is American wire gauge or AWG. It is the American standard for the measurement of wires in wire harnesses. If you are dealing with an American client, there are high chances that you will get requirements in AWG. American clients and manufacturing industries use AWG for measurements. The same measuring standard goes for single wire measurement and wire harness measurements in the United States of America.

The diameter of the electrical wire is the base of AWG. The basic principle of American wire gauge is slightly different from typical measurements. In normal life, the larger measurements mean the larger object. Well, this not how American wire gauge works. This rule is different for not only the AWG but all other gauges too. The physical size of the object is something that matters the most. American wire gauge states that the larger physical size of the wire means small wire gauge.

3. British Imperial Standards Wire Gauge

Having a legalized measuring standard is important for industries and clients. Lack of standard can lead to conflicts and other technical issues later on. Like American wire gauge, the UK also introduced standard measurements in 1884. SWG is the measuring standard in the United Kingdom for wire harness manufacturing. These standards are also known as SWG or British Imperial Standard Wire Gauge.

Assemble wire harness, electrical wire
Assemble wire harness, electrical wire

As SWG and AWG are two different measuring standards, so what are the differences between these two standards? SWG defines all the measurements in metric size. The sizes of the wires rounded off to the full numbers in SWG. On the other hand, the American wire gauge standard does not follow this approach for the measurement of the wires. In terms of accuracy and precision, America wire gauge is way better than SWG. Most of the clients have complaints about the sizes of wires that come from the United Kingdom. AWG is a comparatively better standard for measurements in wire harness manufacturing.

4. Wire Harness Manufacturing Difference Between AWG and SWG

There are major differences between these two measuring standards. American wire gauge calculates the size of the wire harnesses in inches. On the other hand, SWG uses millimetres to calculate its size. These two different systems change everything regarding these two standards. You can compare the changes in the size charts of both standards due to a slight change in the measuring systems. The AWG is more accurate, so at CLOOM Tech, we offer both measuring standards. Our clients are from both regions, so we offer the flexibility of measuring standards.

Both systems have their applications, and no system is less effective. The application of the standards is associated with the geographical locations of both parties. In case you are outsourcing wire harness manufacturing to China or any other Asian country, don’t forget to discuss the measuring standards in the earlier stage.

5.Wire Harness Manufacturing Similarities Between AWG and SWG

Although both measuring standards are different and have a lot of differences, yet there are some similarities too. The basic principle of measurement is the same for both standards, and that is the physical size of the object. Both measuring standards for wire harness manufacturing use a metal measuring plate for measuring wires. But these similarities do not allow the industries of clients to use one standard instead of others.

The worker is packing a wiring harnesses
The worker is packing a wiring harnesses

6. Wire Harness Manufacturing How to Choose the Best Wire Gauge?

Wire harness manufacturing processes can be complicated, and you will need assistance. If you are confused about the selection of the right wire measuring standard, then here are some tips for you. The choice of wire gauge has a direct impact on your project, so do your homework about these standards.

  • Type of project

The nature of the project is the most important factor that determines the selection of the right measuring standard. Are you working with the robotic wire harnesses or industrial project? For every project, different wire harnesses required. Here are some general cases where you will have to use wire harnesses:

• Home wiring
• Robotics
• Computers
• Vehicles
• Appliances

Every project has unique gauge requirements, so one size does not fit all projects. Size, designs, electrical specifications of the project, and many other attributes influence the choice of the measuring standard.

  • Space required for wiring

With different sizes of the wires, you will have to manage different spaces in the appliance or the chassis. For accurate wire harness manufacturing, you should state project requirements. Once the manufacturing team has all the requirements on the table, they can suggest the best gauge. In industrial units, wire harnesses have to carry larger currents so that the size will be larger. In robotic wire harness, a minor amount of current is enough to power the functions of the robots.

  • Calculation of wire gauge

You must remember that with the increasing physical width of the wire, the numerical value of the gauge will decrease accordingly. In simple words, the increase in wire size will lead to a decrease in the numerical value of the gauge.

  • Use of large and small gauge

As there are different gauge sizes available, the applications of the small and large gauges are also different. Uses of smaller gauges include electrical lines, heavy-duty machinery, and industries. Home and office wiring also use the small gauges. Meanwhile, uses of larger gauges include computers, robotics, radios, GPS, and phones.

  • Amperage requirements

How much amperage do you need for your project? It is an important question that defines the gauge standard. There are many other attributes too that define the suitable wire gauge standard. The application of the wire, amperage requirement and the nature of the project also defines the right measuring gauge for wire harness manufacturing.

7.Custom Wire Harness Manufacturing and Custom Wire Gauge

In case of standards, wire gauge measurements don’t meet your project specifications; you can try custom wire harnesses. Custom wire harnesses allow the industries to have their unique wire harnesses manufactures as per the project specifications. The use of custom products allows businesses and project teams to scale their products in a better way.

Market wire harnesses have specific gauge measurements, so those measurements may not be according to your project specifications. While ordering custom wire harness manufacturing, make sure that your chosen supplier has experienced both measuring standards. In case you don’t get the right standards, what is the point of investing in custom services?

Conclusion

If you are also looking for accurate wire harness manufacturing for your project or industry, CLOOM Tech can offer the best services. We have state of the art design instruments to come up with unique and effective designs as per the project specifications. No matter which measuring standards you want to use, CLOOM Tech offers personalized measuring standards for wire harness manufacturing. So, let us collaborate for the betterment and growth of your business.

6 Critical Attributes of Medical Cable Assemblies in Healthcare Devices

Electrocardiograph machine with ECG

In the healthcare sector, a slight human mistake or malfunctioning device can cost someone’s life. No room for error requires all the instruments to perform all the time efficiently. We can help you if the medical equipment business or medical facility needs an effective power supply and data transmission solutions. CLOOM Tech is the renowned custom cable assembly manufacturer that can meet your expectations. If you feel cable management is restricting your operational capabilities, we can design custom medical cable assemblies for your business.

Electrocardiograph machine with ECG
Electrocardiograph machine with ECG

Here are some important points that you must notice in medical cable assemblies:

1.Medical Cable Assembly Durability

Medical cables are going to take a lot of beating. No matter how carefully you operate the devices or equipment, things can get complicated. Medical professionals have to handle emergency cases where they cannot waste time smoothly, moving the devices across the room. These cables must stay intact, and the power supply must be feasible every second in every situation. Medical cable assemblies are better and effective alternatives off the market cables. General power cables can stop working in case of kinks, but medical cable assemblies don’t consider these interruptions.

If the power goes off during an operation or some other medical treatment, imagine how it can affect the professional practice. It does not matter what kind of medical facility is using these devices; durability is critical not only for cables but for all components. A wise investment in medical cable assembly not only saves you from extra maintenance charges, but you can also stay assured about the reliability of your services and devices.

2.Medical Cable Assemblies Reusability

Hospitals pay special attention to the cleanliness of the environment and the devices. In ICUs and operation theatres, every device and equipment need sterilization. In the process of disinfecting the tools and equipment, professionals use special chemicals and sprays to sanitize these tools. Standard market cables can’t withstand chemical exposure so that insulation can break. Reusability is the missing feature in standard cables.

Medical used for heart testing and EKG machines used in the healthcare industry
Medical used for heart testing and EKG machines used in the healthcare industry

3.Medical Cable Assembly Adaptability

You cannot rely on a single type of wire to meet all medical equipment power supply demands. The medical environment can vary, so the cable designs should also be adaptable. Standard cables are static, and you can have these cables modified as per the demand. In the case of medical cable assemblies, you have the flexibility of custom design. If you feel that some certain restrictions and limitations are holding you back from achieving the best, give us a try. We analyze and design highly adaptable cable assemblies, and wiring harnesses for different sectors of life.

You don’t need to compromise on usability as we offer advance and scalable cable management solutions. CLOOM Tech has dedicated teams of professional engineers and designers who can meet your complex requirements. You don’t need to limit your practices as we are here to offer custom medical cable assembly manufacturing services. The only thing that you need to focus on is the quality of your medical practices. We are here to facilitate medical facilities with more agile and flexible cable management systems.

4.Medical Cable Assemblies Quality Components

Would you tolerate the damaged cables even after spending thousands of dollars on custom services? Well, no one would ever want to face such a situation. We all know that medical cable assemblies meant to last for longer times. What ends up destroying the cables and the power supplies?

EEG machine cables plugged-in to the socket
EEG machine cables plugged-in to the socket

Well, quality insulation or the use of premium material does not offer the assurance of reliable products. Apart from the medical device, medical cable assembly alone involves many components like the crimp tab, insulation, strands, harnesses, and many other technical components. The use of one low-quality component can sabotage the whole device or even project. Just imagine the crimp tab in the medical cable assemblies. This component is too small yet important. Your supplier used good quality material and premium quality insulation but did not focus on quality crimp tabs.

In no time, the cable started losing firm connections due to poor crimp tabs. Although the whole cable assembly was in perfect shape, equipment started facing power failures. Hence, a small component that did not matter to the supplier ended up damaging the whole system. Simply stating, from insulation to the crimp tabs, every component of the medical cable assemblies must be of premium quality.

5.Medical Cable Assembly Signal Integrity

These aspects of quality cable assemblies are not just limited to the power cables. If you are using data transmission cables, all of these standards still apply to those cables. Advanced medical equipment uses smart systems that based on pure programming, so continuous data transmission is critical. Lose of signal quality can impact the efficiency of automated systems. So, insulation of the data transmission cables must resist external interference to ensure signal integrity.

6.Medical Cable Assembly Resistance Against Chemical Exposure

Here comes the most important and critical attribute of the medical cable assembly. Quality market cables may make of quality materials by using advanced technologies but are not fit for medical facilities. Different medical units and hospitals use different chemicals for the sanitization process. Almost every medicine or drug has some chemical involvement, so the cleaning process also needs modifications accordingly. Eventually, the cleaning staff will have to use chemicals and detergents to clean the equipment and the floors. So, the final results will be dangerous for the cable assemblies. So, we have tackled this chemical exposure issues by introducing special insulations in the medical cable assembly. Our custom medical cable assemblies can withstand any chemical exposure.

Patient on cardiopulmonary bypass device in the intensive care unit
Patient on cardiopulmonary bypass device in the intensive care unit

Conclusion

If you have faced problems and limitations regarding the cable assemblies in the medical equipment manufacturing business, then trying out our custom services can be a good investment. We offer professionally designed medical cable assembly as per the product specifications. If you are tired of the poor performance of low-quality market cables, then custom medical assemblies won’t let you down. Join hands with CLOOM Tech for better medical practices and the safety of the patients.

9 Things to Know Stranded Wire VS Solid Wire in Electrical Applications

Wires used in electrical applications

As the name suggests, ‚ solid wire consists of a single metal core with an outer insulation layer. The stranded wire has many thinner wires. These wires called strands and twist around each other to form a single bunch.

So what wire is best for your project? To understand this, you need to know how stranded wires and solid wires differentiate.

That is why we put together this handy article on nine things you need to know about stranded wires and solid wires.

Wires used in electrical applications
Alt – Wires used in electrical applications

1.Stranded Wire VS Solid Wire Manufacturing Ease

The solid wire only has one copper strand and an insulation layer. It’s because of this that the solid wire is easier to manufacture.

Stranded Wire, on the other hand, has several thin copper strands twisted together to make it. Manufacturing these strands is more expensive when compared to solid wire manufacturing.

2.Stranded Wire VS Solid Wire The Thickness

In short, a solid wire is thicker than stranded wire.

For one, a solid wire has only one thick copper core. Stranded Wires consists of multiple thin wires. The thickness of these wires helps in giving different properties to the wires.

Solid Wire
Alt – Solid Wire

3.Stranded Wires VS Solid Wires of Durability

The thickness of the wire is a tell-tale sign of how durable it is.

In short, the thicker the wire, the more durable it is.

As solid wires consist of only one thick strand‚ it is much more durable than the stranded wires. The thin structure of the strands in the stranded wire has the opposite effect. The thinness makes them fragile and much less durable.

Being less prone to corrosion is also a benefit that occurs because of the thickness of the wire. The solid wire has the thickness, which results in an anti-corrosive effect. You can use the solid wire effectively outdoors. On the downside‚ the stranded wires are very prone to corrosion. There are air gaps in the stranded wire among the twisted strands. It makes the stranded wire vulnerable to corrosion. It is why we do not see stranded wires in applications exposed to the outside.

Solid wire also has the upper hand in damage resistance. It has only a single metalcore. As a result, the solid wire has fewer chances of getting damages. But‚ stranded wire has fragile, thin strands. It makes the wire prone to damages.

4.Stranded Wires VS Solid Wires Malleability

Flexible Stranded Wire
Alt – Flexible Stranded Wire

Stranded wires are much more malleable than that of solid wire. The twisted structure of the strands allows bending. So‚ the stranded wires are well-suited for applications that require flexibility and movement. Solid wire is much less flexible and only used in static applications that need no movement. Solid wire lacks the strength to endure motion.

So, when considering flexibility, stranded wires are highly resistant to damage. Solid wire is not made for flexibility and can break if bent.

5.Stranded Wire VS Solid Wire Costing

When considering the cost, solid wires are far less expensive. It is because it has a simple‚ straightforward manufacturing process. Stranded wire is an expensive investment. But in the long run, stranded wires are worth the investment. It is because of its strength and malleability.

Whether a wire is expensive or not highly depends on your requirement. So‚ to make a decision that cuts down costs, you need to consider your requirement first.

6.Flexing Issues

Flexing is the ability to bend into complex shapes. The single thick core of the solid wire is not made for flexing. These wires are highly likely to break when flexed. The solid wire may also break on the application of load and continuous vibrations.

Stranded wire, however, has a structure that facilitates flexing effectively. These wires are especially useful when connecting electrical applications in tight spaces. The stranded wire can withstand constant movement better. It’s why companies use the stranded wires in applications such as a robot arm or a car door. Stranded wires also used to connect most electrical applications in the household. They are also used in circuit boards and inside electronic devices.

Stranded Wire used in Household Applications
Alt- Stranded Wire used in Household Applications

7.Load Carrying Capacity

Dissipation is a common thing among any wire.

It is also one of the main challenges to the load-carrying capacity of a wire. Electricity goes through to a magnetic field when it travels through the wire. It causes electricity to dissipate into the air slowly. When the surface area of the outer layer is high‚ dissipation is more likely to happen.

The stranded wire consists of many strands and has air gaps among the wires. So‚, the surface area, is larger. But the solid wire uses only one strand. It significantly decreases the surface area where dissipation can take place.

So the load-carrying capacity of the solid wire is better than that of the stranded wire.

8.Impedance and Skin Effect

Impedance is the resistance of an electric component when introduced to a current.

When current passes through a cable‚ it induces a magnetic field around it. Sometimes‚ an electrical application can pass alternating current through the conductor. Alternating currents result in a changing magnetic field. The changing magnetic field induces an opposing eddy effect.

This effect forces the current to travel close to the surface of the conductor, known as the skin effect. It happens when alternating currents travel close to the surface of a conductor. It limits the area of the conductor available to carry the current flow. As a result, the resistance of the conductor increases.

You can naturally assume that the stranded wire reduces this effect. But this is not the case. All the strands of a stranded wire are short-circuited together and act as a single wire. The skin effect causes an increase of resistance where the skin depth is smaller. The small skin depth of the stranded wire causes higher resistance.

So‚ the stranded wire is more affected by the skin effect. It is the reason why stranded wires have a less load-carrying capacity than the solid wire.

9.Internal and Outdoor

There are some limitations to these wires because of their physical structures.

Stranded wires are fragile and have air gaps in between the strands. When exposed to outside elements, strands begin to corrode and get damaged. It affects the durability of the wire. But‚ in an indoor environment‚ stranded wires are the best choice. These wires are flexible and strong. For this reason, they are a staple in many electrical appliances indoors. These include the wiring systems in speakers and such electric applications.

When considering the outdoor application, solid wire is the best. The rugged‚ simple nature of the solid wire is effective for damage resistance. With the thickness of the core, these wires are immune to corrosion as well. It makes them capable of handling extreme weather conditions.

Solid wires are not used for intricate applications that require flexibility. But‚ the solid wire is perfect for tasks like carrying current through a building. You can use the solid wire when you need to pass high current. It is a wire that can only withstand little movement but is very durable.

Conclusion

Select the best wire for your project
Alt – Select the best wire for your project

The wire you need can change depending on the situation. To select the best wire, you need to understand each wire’s capabilities and drawbacks. Now you understand the difference between the solid wire and the stranded wire. And we hope this article helped in making your choice.

So‚ If you need customized cabling‚ CLOOM Tech have an expert team ready to help you. With our state-of-the-art labs, you can ensure that your projects get delivered on time. We can help with everything from PCB design to network cabling needs. Contact us today to get started with your project!

9 Things to Know About Coaxial Cable Assemblies vs Twisted Pair Cable

Coaxial Cable Assemblies

Are you looking for the right networking cable? There are some things to consider first. In order to make the best decision, it is important to understand the options available for you. When networking, you can use either Twisted Pair cables or Coaxial Cable Assemblies. There are pros and cons to each choice. The need for a network cable can change depending on the situation.

For example, when wiring a small space‚ twisted pair cable is the most effective. The coaxial cable is thick and is not flexible enough.So‚ what would be the best network cable for your organization?

This guide will give you the answer.

1.Coaxial Cable Assemblies vs Twisted Pair Cable Variations in Shielding

Find the right coaxial cable
Alt – Find the right coaxial cable

First, Let’s talk about the anatomy of each cable.

Twisted pair has two types of cables. Those are; Unshielded Twisted Pair (UTP) and Shielded Twisted Pair (STP). The two cables differentiate when it comes to shielding. STP uses a metal shielding around each twisted pair. It is helpful to provide extra protection from noise‚ crosstalk and EMI. STP is more expensive than UTP because of this added protection.

UTP does not have any shielding method to prevent EMI. Yet‚ UTP can reduce the effect of EMI using the twisted pattern of the cables. STP cables have some shielding in place that can protect the data from EMI.

According to the level of shielding UTP and STP can divide into further categories. Higher-level shielding gives the most protection.

Coaxial cables transmit high-frequency signals such as video signals. It mainly uses for computer network connections‚ TV transmission and so on. This cable has a round copper conductor and three layers of insulation and shielding. Coaxial cables much more protected than Twisted Pair cables due to this.

The Twisted pair cable is a patch cable that has been around for a very long time. Like the name suggests‚ this cable has two twisted insulated wires. These run parallel with each other. This pattern helps reduce crosstalk and EMI to some extent.

You need to choose the right twisted pair for your business need. It could also be getting twisted pairs that have foil shields that. This type of cable also has an overall braid shield. Finally, some twisted pairs have foil shields. It also includes an overall foil shield and a braided shield.

Coaxial cable or coax uses an inner dielectric insulator and a woven copper shield. This shielding provides superior protection against disturbances.

2.Coaxial Cable Assemblies vs Twisted Pair Cable Advantage in Cable Length

Coaxial cables have better shielding. So‚ this cable is extremely reliable for long length transmission of data. The centre core can carry signals for up to 500m before it starts to attenuate.

Twisted pair cables can successfully transfer data if the cable length is below 100m. If the cable is longer‚ you would need repeaters and amplifiers to carry on the signal. It is because the signal will start to attenuate.

So‚ if you are looking to cover a long distance‚ coaxial cable is going to be more effective.

3.Coaxial Cable Assemblies vs Twisted Pair Cable Crosstalk

Finding networking cable right for you

Alt – Finding networking cable right for you

Twisted pair or coaxial‚ every cable is susceptible to crosstalk.

Sometimes a signal can get mixed up with a signal from another cable. This incidence is crosstalk. Crosstalk happens when many cables are running close to each other.

The parallel twisting pattern of the twisted pair cable can help reduce crosstalk. This method is somewhat effective. But‚ twisted pair cables are still very vulnerable to crosstalk.

The coaxial cable, on the other hand, is much more effective at reducing crosstalk. It has an efficient shielding in place, and this provides better protection to the data.

Do you have a lot of cables carrying different signals running around? Then, a coaxial cable may be a better choice.

4.Coaxial Cable Assemblies vs Twisted Pair Cable Signal Transmission Rates

Coaxial cables offer much higher transmission rates than that of Twisted pair cables. Twisted pair cables can only transfer up to 1000 Mbps(1 Gbps).

Comparatively‚ Coaxial cables offer almost 80 times more bandwidth than Twisted pair cables. The maximum transmission rate of the coaxial cable goes up to 100Mbps.

5.Coaxial Cable Assemblies vs Twisted Pair Cable Costing

Twisted pair cable is extremely affordable. Coaxial cables are more expensive in comparison. It is because Coaxial cables offer more bandwidth and better protection.

6.Coaxial Cable Assemblies vs Twisted Pair Cable Ease of Setup and Installation

Check how easy it is to set up the networking cable
Alt – Check how easy it is to set up the networking cable.

Are you looking to use the networking cable for a while? You need it to be sturdy then. Because of the thin physical structure, a twisted pair cable is easier to install. The installation process is quick and affordable.

Coaxial cables are difficult to install. The installation process is also expensive.

7.Coaxial Cable Assemblies vs Twisted Pair Cable Sensitivity to EMI‚ Noise Elimination

EMI is a disturbance caused by external sources such as thunderstorms or cell phones. It can cause errors and affect the transmission quality of cables.

Noise happens when stray signals generated inside the cables affect the data transmission. External sources can affect the cables and produce noises randomly.

In coaxial cables, EMI and Noise interference is low. It is because of the proper insulation and shielding available on the cables. In Twisted pair cables‚ the susceptibility to noise and EMI is very high in comparison.

If the environment has low interference‚ Twisted pair cables are a good pick.

Are there some EMI sources that can potentially disrupt the transmission?

Then coaxial cable might be the right cable for you.

8.Coaxial Cable Assemblies vs Twisted Pair Cable Data Security

Data security for networking cables
Alt – Data security for networking cables

Coaxial cables have better shielding than Twisted pair cables. Because of this, they naturally provide better data security from external sources.

But‚ coaxial cables are still susceptible to tapping. You can tap into a coaxial cable simply by piercing the sheath of the cable. The physical setup of twisted pair cables can make it a little trickier to tapping.

When connecting computers to computers, coaxial cables are the norm to use. But‚ Twisted pair cables normally connect computers to hubs‚ switches and so on. Therefore‚ tapping into a Twisted pair cable can make the network more vulnerable.

Coaxial cables give better security when compared to twisted pair cables. But‚, the best thing you can do is keep your data protected is to provide protection physically.

9.Coaxial Cable Assemblies vs Twisted Pair Cable Data Video and Audio Transmission

Coaxial cable generally uses to transfer high-frequency signals. They generally carry around 80 times the data transmitted by Twisted pair cables.

But‚ the twisted pair cable is effective in audio transmission. Telecommunication companies generally use Twisted pair cables for telephone transmission.

If your organization has a high volume of calls‚ the Twisted pair cable may not be sufficient. But‚ the Twisted pair cable is more than enough to handle moderate amounts of voice data.

Conclusion

Choose the right network cable
Alt – Choose the right network cable

When choosing the right cable for your network, there are some facts you need to consider. Your needs may differ depending on the factors we mentioned above.

We hope you enjoyed getting to know a thing or two about coaxial cables and twisted pair cables.

Cabling is a very important part of networking. Finding the right fit cable is going to be effective in cutting back unnecessary costs. With right cabling, you can ensure that your network is at its best performance.

That is why you need an expert manufacturer for your custom cable needs. We at Cloom Tech are here to make sure you get the best cabling materials. Cloom Tech is a custom wiring harness and cable assembly supplier. We are ready to launch your business on the fast track to success.

To find the best solution for your cabling needs‚ contact Cloom Tech today!

5 Common Types of Wire Insulation for Wiring Harnesses Manufacturing

cored wire wrapped in plastic

Wiring harnesses an effective piece to combine several wires and conductors in order. Without proper wire insulation, the connection of different cables and strands within the wire harness can cause damage. You get to choose from different materials for wire insulation. The selection of the material depends upon the work environment and layout of the wire harness.

cored wire wrapped in plastic
Copper-cored wire wrapped in plastic

For industrial and commercial projects, CLOOM Tech offers five different types of wire insulations for custom wiring harnesses. Here is a brief introduction of every wire insulation type the technical specifications of the materials.

1.Polyvinyl Chloride

PVC has a wide range of applications in electric cable manufacturing as bedding, insulation and sheathing material. PVC was an advance and better alternative to rubber insulated wires as PVC was easy to process than the rubber sheathing. As you are not going to replace or repair custom wiring harnesses any sooner; hence, PVC offers an excellent lifespan. The cost of PVC is less than many other wire insulation materials.

PVC is one of the most flexible and versatile thermoplastics due to its fantastic flexibility. The original properties of PVC make it rigid and challenging, but it is useable in different applications after easy modifications. The processing of PVC is easy, and it is also recyclable. During the selection of material for wire insulation, fire resistance is an important consideration. Most of the industrial applications require such fabric for wire insulation and cable sheathing that can withstand higher temperatures. The use of PVC for wire insulation in wiring harnesses allows the harnesses to perform effectively despite the rise in temperature.

Wire insulation for different applications
Wire insulation for different applications

Apart from high-temperature resistance, PVC insulation can protect wires against oils and chemicals too. The chemical exposure is too regular in many industrial work settings, so you can opt for PVC insulation if there are any chances of chemical exposure.

Examples of PVC Applications

In many wires and cables, you will find PVC as the main insulation material. CLOOM Tech also offers modified PVC insulation for custom wiring harnesses according to the requirements of the client. Here are some significant examples of PVC insulated wires:

• As jacketing and insulation for low voltage wires

• Cable jacketing for medium and low voltage appliances

• For local telecommunication cables

• In wiring harnesses for automotive

• Flexible wires for better protection against tearing

2.Fluorinated Ethylene-Propylene

FEP is the blend of hexafluoropropylene and tetrafluoroethylene. FEP materials are modifiable after melting. This material type is a perfect insulation material for temperature sensing wires, but its use for wiring harnesses also has some benefits. FEP has countless applications in industrial units as insulation and jacketing material for wires and cables. In coaxial cables, this material can perform as a dielectric too. The outstanding resistive properties for chemicals make it a suitable option for wire insulation in wiring harnesses.

Insulation of wire in different colours for several applications
Insulation of wire in different colours for several applications

When it comes to temperature resistance, FEP offers great resistance temperature ranges. Due to amazing electric and physical properties, manufacturers use FEP in many industries and projects. In TEC cables, manufacturers use FEP as filler material. These TEC cables are perfect for the gas and oil industries. FEP is an excellent option for wiring harnesses for military installations and applications. Due to the excellent temperature and chemical resistance properties, FEP has countless applications in commercial and industrial projects.

Whenever you need wiring harnesses with flexible yet tough insulation material, you can choose FEP as protective material. If you are concerned about changing weather conditions, FEP can withstand all weather conditions with effective water resistance properties.

Applications of FEP Insulation

Almost every industry has some space for FEP as insulation for custom wiring harnesses. Typical industrial applications of FEP as wire insulation include:

• Military installation and military-grade equipment

• Oil and gas units where chemical exposure is a common problem

• Chemical industries with harsh work settings

• Medical facilitates that need sterilization of wires and wiring harnesses

• Aviation and aerospace sector

• Cars and vehicle manufacturing units

3.Polyethene

Polyethene insulated wires are best for projects where high voltage is involved. From electrical properties to resistance against different levels of temperature, Polyethylene is suitable for harsh conditions. In various applications where general sheathing materials would fail, manufacturers use Polyethylene as an insulation material. From freezing conditions to boiling applications, Polyethylene can withstand both extremes.

The wiring harnesses with a coating of Polyethylene are rigid but offer better resistance against abrasion. The original chemical properties of Polyethylene make it a rigid and solid material. In the original form, Polyethylene may not be suitable for wires where you need flexibility. But with some further modifications of additives and fillers, you can make it flexible according to the project specifications.

Close up of electric cables with insulation
Close up of electric cables with insulation

Polyethene insulation is the perfect choice to minimize power loss. The leakage of current or data from wires with Polyethylene coating is almost negligible. From low or high voltage current-carrying wires, you will get a maximum efficient supply of current with Polyethylene insulated wires. What makes Polyethylene a better choice as compared to other insulation materials?

The additional properties of Polyethylene make it a suitable coating material for high frequency signally carrying wires and transmission lines. All the appliances that involve audio data and radio frequencies, custom wiring harnesses with Polyethylene coating can perform better than other typical coating materials.

Different Types of Polyethylene

There are different types of PE, depending upon the chemical properties of the material. Polyethene is originally lightweight, chemically inert, and water-resistant. Here are different types of PE:

• Low-density PE

• Linear low-density PE

• Medium-density PE

• High-density PE

• Chlorinated PE

• Cross linkable PE

4.Nylon

Thermoplastic materials for insulation of wires in custom wiring harnesses are less expensive as compared to thermosets. There are realities of wires and cables that feature different insulating materials according to the project specifications. Each material has some benefits over the other, as some are soft, and some exhibit rigid attributes.

When it comes to soft materials for wires in custom wiring harnesses, manufacturers look forward to PVC or Nylon. Both are highly flexible and adjustable according to the project specifications and harness layout. In some industries like automotive and aerospace industries, Nylon seems to be a perfect choice. Although this material is flexible, yet the toughness of Nylon can protect the wires against external factors and abuse. At some point where a lot of bending and mechanical movements are involved, custom wiring harnesses with Nylon insulation can perform better. The strain relief and flexibility of Nylon insulation are way better than many other insulation materials.

Macro detail of some cables
Macro detail of some cables

Benefits of Nylon for Wire Insulation in Wire Harnesses

Apart from the easy availability of Nylon as insulation material, the price of Nylon is also less than other materials. Many clients prefer to have custom wire harnesses with Nylon insulation due to low cost and effective properties. The following are some unique advantages of Nylon.

• Nylon is a highly flexible and soft material that is perfect for insulation.

• The rigidness of Nylon makes it tough insulation in the original form

• It has a string of abrasion resistance properties.

• Nylon provides better protection against tearing and cut through.

• The chemical resistance of Nylon makes it excellent insulation for industrial projects too.

5.Thermoplastic Rubber

Thermoplastic rubber is the primary focus of custom wiring harnesses manufacturers. The fantastic properties of Thermoplastic Rubber make it a better option for the insulation of wires with the least investment. The processing of Thermoplastic Rubber does not require a lot of processing, making it an affordable option for industrial applications.

Electrical tester wires tying cables bolt cutter pliers
Electrical tester wires tying cables bolt cutter pliers

The use of Thermoplastic Rubber for cable insulation and jacketing is nothing new as this material has been around for a long time. The unique physical properties and low processing costs make it a desirable material for custom wiring harness manufacturers. If we compare Thermoplastic Rubber with other thermoplastic insulation materials, it is the most flexible material out there. Even after stretching the material to a sufficient elongation, Thermoplastic Rubber will return to the original shape. Hence, improved flexibility leads to the enhanced lifespan of the wires and cables.

Properties of Thermoplastic Rubber

Here are some unique physical and chemical properties of Thermoplastic Rubber that make it a perfect choice of wire insulation in custom wiring harnesses:

• Higher processing speed leads to faster production

• Temperature resistance against extreme temperature levels

• Excellent resistance against weather and heat ranges

• Enhanced lifespan with the better ageing process

Conclusion

No matter what are your project specifications and work environment requirements, CLOOM Tech can manufacture custom harnesses with any insulation material. You can contact us for bulk production of custom wiring harnesses with different protective coatings and insulations.

5 Common Issues About Connectors in Custom Wire Harness

Wire Harness Connector

A vital issue with low-quality wiring harnesses is the “push back” of wires of contact retention. There are different options available for connectors like insert-able contacts and crimp on. If you are facing power failure due to ongoing issues with connectors, you need to try custom wire harness.

Wire Harness Connector
Wire Harness Connector

For high standard custom wire harnesses, CLOOM Tech designers deploy quality connectors. The intricate designs of custom wire harness highly depend upon the connectors. Custom wiring harnesses with premium connectors and terminals can prevent these issues, let’s take a look.

1.Custom Wire Harness–Unprotected Contacts

Contacts are critical for the successful working of the connector. Unprotected connections can initiate corrosion that will not only affect the current supply but will lead to supply failure later on. Connectors in custom wire harnesses fail due to poor contacts. Contacts consist of small metal parts and pins that imitate the current flow in the harnesses.

As these metal pins are smaller in size hence are more vulnerable to moisture, corrosion, and other external factors. These contacts for custom wire harness connectors come with a limited lifespan. The continuous use without proper layout will lead to premature failure of the connections and connectors. Contact must have an appropriate coating and protective layers for improved quality.

Automotive male and female connectors
Automotive male and female connectors

Poor quality contacts will exhibit a “push back” phenomenon too. Whenever you insert the references in the right cavity, due to poor quality, it will push back the contacts. Due to a broken circuit, connectors will interrupt the power supply. These things must be under consideration while testing connectors and wire harnesses for practical applications. CLOOM Tech engineer not only uses premium quality materials for the contacts, but they also put contacts and connectors under rigorous testing. Every product that we ship to our client comes with the approval of our testing department. State of the art testing labs and strict quality standards help us to meet user demands and expectations in a better way.

2. Custom Wire Harness–Poor Crimping Techniques

Crimping is the most common way to create a connection between wires and terminals or connectors. For the electrical supply, connectors need to join different cables in a cable assembly or wire harness design. Crimping referred to as the process of connecting wires to the connectors or terminals by using special techniques and tools. The name of the method suggests that a bond is created for different wires by compressing connectors on the wire. You don’t need to perform any kind of complex soldering process to connect two wires or connectors.

In the case of poor crimping technique or use of the low-grade tool, the connector will not hold the wire firmly. As there will be enough space for the moisture to penetrate on the joint, it will initiate the corrosion in the joints. Decay is one of the biggest threats to the safety and efficiency of custom wire harnesses. As the decay starts covering the links, it can result in power supply failure. Most of the time, decay can lead to short circuits too. So, we ensure that we follow the international crimping tools and crimping standards for the best quality connectors for the custom wire harnesses.

An engineer performing crimping on wires
An engineer performing crimping on wires

3.Custom Wire Harness–No Strain Relief

Strain relief is critical in connectors for custom wire harnesses. No strain relief can lead to a connector breakdown during any kind of mechanical movement. Low-grade custom wire harness teams tend to overlook the importance of strain relief. Hence, a small missing mechanical property of connectors can cause total power failure.

Enough strain relief for the connectors allows the flow of force in any direction due to mechanical movement during the installation of working. Due to a lack of strain relief, the wire can push back from the terminal or the connector. A lot can go wrong with connectors in custom wiring harnesses, and lack of enough strain is one of those issues.

Strain relief for wire harness connectors
Strain relief for wire harness connectors

You will have to choose custom wiring harness manufacture that uses professional tools for accurate design layout. Precise design and layout of the wire harness will ensure the balanced strain relief to transfer force due to movement. Extra strain relief will also create problems as the wires may not stay firmly tight with the connectors. With the loose wires in connectors, sooner or later, the system will collapse.

4.Custom Wire Harness–Poor Wire Harness Layout

From the vehicle industry to the aerospace sector, custom wiring harnesses have become an essential part of almost every field. The increasing demand for custom wire harnesses requires the manufacturers and designers to work on something extra and something unique. The electrical routing in the wiring harnesses highly depends upon the quality of connectors. Intricate wiring harness designs and layouts may require exceptional connectors. The limited space and weight reduction can affect the performance of the connectors in custom wiring harnesses.

As the design does not meet the project specification, continuous alterations in the connectors will damage the contacts. The contacts are tiny metal parts that cannot take much abuse. Hence, the changing requirements of the project lead to loos contacts. If the custom wiring harness is up the mark according to the project specifications, you won’t have to undergo the stressful modifications in the harness design.

Quality of the wiring for cars at a modern plant
Quality of the wiring for cars at a modern plant

As the harness layout changes, connectors may fail to deliver the desired results in the new design. A professional custom wiring harness manufacture will get the layout right in the very first stage. More revisions and modifications mean less lifespan of the connectors due to poor contacts. CLOOM Tech custom wire harness team especially emphasizes the importance of the design process. Without getting the designing part right, you cannot scale your project. Accurate and precise design is the backbone of the custom wiring harness process.

5.Custom Wire Harness–Missing Hardware

Just imagine that contacts are gone missing during the shipment or the installation process. This situation is the ultimate failure of the whole wire harnesses. A custom wire harness is a unified whole, which means that every part matters equally for the success of the entire project. Although Connectors are usually small in size yet even if single contact is missing, that joint won’t be operational. Poor crimping can loosen the wires, and if the connector goes missing due to poor crimping, you will have to repair that joint. If you want to avoid any of the given problems with custom wire harness connectors, then focus on every component of the harness.

Assemble wire harness, electrical wire
Assemble wire harness, electrical wire

Dealing With Contact Retention Failures

Once you have inserted the contact in the cavity, it should stay there so that the current can continuously flow through the circuit. If the connection is loose, then it can push back with breaking the course. In the worst situation, contact retention can lead to short courses too. These small connectors and terminals can sabotage the whole project. Especially in the automotive sector, connectors are the most important. Detecting and repairing the damaged connector due to contact retention failure can be a hectic task. Here are some ways to deal with contact retention failure for custom wire harness.

• Push-click-pull

It is a really simple yet effective method where you don’t need to use any type of complex tools or equipment. Make sure that you don’t apply too much force as there are no specific standards for the method. Pushing or pulling the wire with additional force can break the joint. So, there is a lot of human error involved in this method.

• Verify using tools

This method use tools to verify the retention of the contacts in the connector. You can measure the force applied for the connections, and these tools are not expensive. Although this method based on the application of tools and equipment for verifying the retention, yet it can be costly in terms of labour cost. Your technicians will have to verify each pin against testing tools. Errors may occur after the assembly process instead of during the assembly.

• Electrical testing

It is the fastest way to verify contact retention by using the advance electric method. Electric tools can analyze almost everything that can go wrong with the connectors. Instead of testing one by one, a complete batch of contacts can undergo the electric testing process.

Conclusion

Even with all of these precautionary measures, inadequate quality wire harnesses will ditch you at some point. The best way is to invest your money in the services of a professional company. CLOOM Tech not only detected these issues with connectors in custom wire harnesses, but we also resolved these issues. If you want high-quality custom wire harnesses with reliable connectors, CLOOM Tech is the best custom wiring harnesses manufacturers in China.

10 Risks of Choosing Unsuited Custom Cable Assembly

Manufacturing Process of a Cable Assembly

While custom cables are the better option, creating a cable assembly without keeping the application in mind can also lead to a slew of problems. That said, in the worst-case scenario, the apparent issues of not creating an adequate cable for the application may surface in front of a customer. It may be an instrumental question that could affect your team’s final product in serious ways.

So to help you make a more educated decision, we will tell you ten risks that come with choosing an improper custom assembly.

Manufacturing Process of a Cable Assembly
Manufacturing Process of a Cable Assembly

Risks of Choosing Unsuited Custom Cable Assembly

1. The Quality Might Not Match The Application

One of the biggest risks that come with using an improper custom cable assembly is that the quality of the cable might not fit the application at hand.

So even though you may have the right assembly for the job, its quality may not match the application at hand. It can lead to a multitude of issues, like mechanical and technical delays in your project. Moreover, the wire may have very weak insulation, which can cause its fair share of problems.

2.Custom Cable Assembly–Environmental Harm

If your particular application involves working in weather-sensitive or risky areas, using any improper custom cable assembly can result in serious ecological damage. Due to the rising concerns of global warming, most customers are very conscious of applications that may do ecological damage.

Environmental damage does not just affect the customers who buy the appliance in the first place, but your company’s overall brand image as well. Upon finding out that your business decided to use inferior quality wires for your products, customers may not choose any of your other products.

3. Custom Cable Assembly–Reputational Harm

Another major risk that comes with not using the right cable assembly is reputational damage. Due to incredible competition in the market, customers often dictate the life cycle of a company. And with them having so much choice in the market, their tolerance for failure is often very low.

Therefore, using the wrong cable in your application can result in serious reputational harm. It will not only affect dedicated customers but will also result in new customers not coming towards your business.

4. Custom Cable Assembly–Does not Fit Your Application

Other than running into an issue with quality and lower performance, not making the right custom cables assemblies can also be much larger than what your setup requires. It can cause frustrating issues to deal with, as projects have to work with rigorous measurements. The difference can be of an inch or even smaller, but you will still have to order a new one. And if it does not fit the machine properly, your team may have to make compromises in the overall design.

Checking Wiring System At A Control Desk
Checking Wiring System At A Control Desk

Luckily, the best thing about custom cable assemblies is that they take into account measurements for the machine or project. Therefore, they fit perfectly inside, allowing your team to work on other aspects of the device besides fixing its fitting problems. They are also able to check various extra things like insulation and better conductors in the same measurements.

5. Custom Cable Assembly–No Product Testing

Custom cables assemblies undergo a rigorous and stringent manufacturing process. And once it is ready, manufacturers will conduct various tests on the cable to see if it meets project requirements. This product testing is essential, as it ensures that the wires you will receive are ready for the conditions of your particular project.

By not conducting these tests, custom cable assemblies can be susceptible to all sorts of damage. This damage can make for serious issues within the appliance. Ultimately, you can expect malfunctions or a complete shutdown of the product altogether. Of course, that is the best-case scenario. In the worst-case scenario, the malfunction could cause injury to the customer, which is an entirely different set of problems includes reputational, financial, and legal hassles.

Cable Assembly against White Background
Cable Assembly against White Background

6.Employee Morale Dropping

Throughout the production cycle, your team may undergo some failures, seeing how it is widespread. No matter how small the application may be, every cable plays a vital role in the appliance’s functionality. If one falls, the entire device can follow.

Employee morale can drop due to poor quality cables, seeing how this is a limitation that is not in their control. Therefore, they may have to rework the appliance to cater to a single wire completely. It can be very redundant, and doing the same thing multiple times can make the team feel like they are making no progress at all.

7. Custom Cable Assembly–Lawsuits

When a company does not use the right cables in their appliance, reputational damage is the best-case scenario. In the worst-case scenario, a company can face serious legal issues due to their lack of foresight. Legal proceedings can drag out for quite some time, which involves a massive financial load in lawyers’ fees.

Colourful Assembly with Various Other Cables
Colourful Assembly with Various Other Cables

Legal trouble can also mean severe reputational damage on a significantly larger scale. All these factors have led to the dilemma of rising costs and decreasing revenues of the company. In some cases, lawsuits can do enough damage to dissolve a company or lead the owner to bankruptcy.

8.Custom Cable Assembly–May Cause Delays

Of course, a malfunctioning product is not the only thing that is capable of causing reputational damage. Delays in customers receiving your product can also leave a bad impression on them. Delays are possibly one of the few things that both customers and businesses equally despise.

Even if the delay is not significant, it can get on a customer’s bad side. It can lead to the cancellation of the order itself or are duction in payment. Either way, a delay is not a favourable situation to be in, especially with a particularly picky client.

9.Custom Cable Assembly–Recalls

If the products you sell to your customers do malfunction, you will have to issue a recall of your products. However, recalls can lead to a massive drop in revenue, as you scramble to fix the issue at hand.

If a wire causes the problem in the product, then you may need a costly repair. Not only is such an issue financially expensive, but it can also be draining for your employees; they have to do the same thing over again. It can also lead to a drop in employee morale.

10.Productivity Downtime

While a delay certainly hurts the clients and customers, your employees also take a substantial hit in terms of productivity. Solving redundant problems and issues that they have worked on before will undoubtedly bring down their overall productivity. But more than that, if the wires take a longer time to reach the employees, you can expect production levels to decrease.

It can be very dangerous, as employees may not work as hard or perform as well. It has its fair share of problems.

Wiring System on Control Desk
Wiring System on Control Desk

Conclusion

In conclusion, these risks are to remind you that you should put a lot of thought into making custom cables.

And since the risk of using an improper custom assembly is immense, you should not take the risk. CLOOM Tech provides some of the best and highest quality custom cable assemblies that you can find. All equipped with premium components and professionals that will help throughout the manufacturing process. If you have any needs, please feel free to contact us.

Custom Cable Assembly–8 Important Considerations Before Production

Colorful wire harness and connector housing

The custom cable assembly design process demands most of your attention. Identifying all the requirements and specifications at the very initial planning stage can lead to better scalability of the project. Are you looking for a bulk product of custom cable assemblies for your industrial project? Evaluating your requirements can be very helpful if you don’t want to face any complications after the shipment has arrived.

Colorful wire harness and connector housing
Colourful wire harness and connector housing

To obtain satisfactory customized cable assemblies. The following are some important items that must consider before producing custom cable assemblies:

1.Electrical Requirements

Custom cable assembly production results and design process highly depends on the electrical requirement of the project. The varying levels of current and voltage must be important considerations regarding the cable assembly design. Electrical specifications, like the number of contacts, operating voltage, and operating current, must be clear before the design process. The resistance of wires and connectors can also impact the performance of the project.

While choosing the appropriate wires according to the work environments, make sure that you are not compromising on the electrical specifications. There are many other electrical specifications too that may not be under your consideration but are important. The separation of signals and power will also have an impact on the custom cable assembly design. So, make sure that all of the specifications and requirements are clear to the manufacturer. Miscommunication between the supplier and the client can lead to wrong cable production. Every single factor that you think is not related to electrical requirements must be under consideration for the effective delivery of shipment.

2.Cable Type

The cable design is another critical factor to consider in custom cable assembly production. The cable-type can vary according to the requirements of the appliances. Mostly, flat ant round cables are two common options for industrial and commercial use. In residential applications, round cables are applicable for almost appliances. But for industrial appliances and other machines, cable type matters a lot. In complex appliances where space is limited, round cables cannot fit in. So, flat ribbon custom cable assemblies are better suitable for such applications.

Precision work on the production line
Precision work on the production line

Depending on the exposure of chemicals or moisture, the type of shielding will also affect the project. In hot and extreme work environments, jacketed cables are a better option, and for mass termination, flat cables are more effective.

The round cables are too common in the industry due to compactness and durability. As compared to the flat cables, round cables can perform effectively in long runs. The twisting and bending also have the least impact on the round cables. So, if you are not sure about the appropriate cable type, try communicating with the designer team. CLOOM Tech custom cable assembly designers are best in the field. From analyzing the project requirements to suggesting the right cable type, they have exceptional skills.

3.Safety of Cable Assemblies

The safety standards of the manufacturing company are important for different regions. Make sure that your custom cable suppliers follow the industry safety standards for the production process. Determine if the manufacturer is compliant with the safety regulations or not.

And the use of different jacketing materials also refers to the safety of custom cable assemblies. The shielding and jacketing of the assemblies will ensure safety against external and environmental factors. The wrong choice of protective materials may lead to the early tearing of the wires. For better performance and safety of your project, invest your money in reliable manufacturing services.

Safety of electrical cables
Safety of electrical cables

4.Custom Cable Assembly–Durability of Material

Project teams usually make a mistake at this point. The better quality of wires will come at a higher cost. For keeping things under control, project teams tend to choose cheaper cables. Ignoring the durability of the material can cause poor performance and risks of short circuits. Before the bulk production of the custom cable assemblies, ensure that the chosen material suits your project specifications.

Use cases to define the right material for the project. If you are going to install the custom cable assemblies at extremely high temperatures, choose the wire material with high-temperature resistance. For oil and chemical industries, choose a material that can withstand chemical and moisture exposure. In mechanical industries, a lot of bending and movement are involved so, more flexible cables can perform better? The durability of cables defines the success and efficiency of your project.

5.Custom Components and Jacketing

Do you have specific project requirements that demand the use of special materials and components? In such scenarios, discuss the details with your supplier. Some suppliers may take extra time for delivery in case of customs requirements. For medical cable assemblies, special materials and coating materials are required. Typical cable manufacture may not be able to meet your demands. So, always choose a professional custom cable manufacturing company that can deliver your desired products.

At CLOOM Tech, we have been dealing with industrial project teams for a long time. We cover a wide range of custom products, including custom cable assemblies and custom wiring harnesses. While ordering bulk orders for custom cable assemblies, you don’t need to worry about the availability of the material. Leave that part to us, and we will make sure you have exact custom products as per your project specifications.

Man cutting the custom cable
Man cutting the custom cable

Protective materials and jackets my look normal thing but the impact of shielding are very critical. So, spend some time analyzing the project for better material and component choices.

6.Custom Cable Assembly–Design Specifications

Here comes the most important factor to consider for bulk production of custom cable assemblies. The design process of cable assemblies must be clear and understandable. Any kind of ambiguity or doubt can lead to conflicts after the delivery of the order. The availability of the space, mechanical movement of the components, and environmental conditions define the design of the cable assemblies.

For a project where cables need to transmit power at longer distances, round cables perform better. So, the cable design must ensure that the durability of round cables stays intact, but assembly also fits in the appliance. In a project where weight reduction is a primary concern, assembly design will use flat ribbon cables. Flat cables are perfect for appliances with low space. The design process will take account of all of these aspects.

7.Custom Cable Assembly–Performance

No client would ever want to miss this important point while ordering bulk production of custom cable assemblies. Materials, cable design, connector material, and shielding are a few factors that determine the performance of a custom cable assembly. The optimized custom cable assembly design will cover every aspect of project specifications, including the performance of the wires.

The cable design must maintain the efficiency and performance level over time. The choice of material matters the most when it comes to the performance and quality of the custom cable assemblies. The use of technology can boost performance. The cable assemblies are becoming more compact and smaller in size. So, these new requirements must not affect the quality and performance of the custom cable assemblies.

8.Custom Cable Assembly–Operating Environment

Do you think medical cable assembly can meet the requirements of automotive production units? Each custom cable assembly has some distinct electrical and design properties. Not following the work environment restrictions and limitations may lead to project failure.

Electrician worker checking voltage of the electric power switch
Electrician worker checking voltage of the electric power switch

For medical facilities, we need custom cable assemblies that are easy to clean and can resist the tearing due to sterilization. So, the oil refineries and chemical units require cable assemblies that withstand exposure of chemicals and moisture. Projects with high-temperature demand high-quality materials with high-temperature resistance. So, the operating environment determines cable design, cable type, and cable quality. The list of considerations can be very long. Don’t hurry while ordering the custom cable assemblies. Do your research and try to discuss the project goals with your supplier.

Conclusion

Do you need affordable custom cable assemblies without worrying about all of these mentioned points? CLOOM Tech team is always ready to help businesses and projects with custom wiring harnesses and custom cable assemblies. If you want a cost estimation of your project or want to discuss the project details with our team, please write to our team, and a team representative will get back to you soon. You can rely on CLOOM Tech custom cable assembly services.

Get A QUICK QUOTE

Fill in your details and we’ll get back to you in 24 Hours.