Multi-Strand Wire – The Ultimate Guide to How to Choose a High-Quality Product

Wires are everywhere, whether it’s a power light or a TV. Yes, you need to use wires whether you are connecting devices or connecting boards. But do you know that the cable types for different applications will change? Do you know the difference between single and multiple strands? Do you see the welding technology used for multi-strand cables?
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In this guide, we will provide you with a comprehensive course on multi-strand cables and related aspects so that you can become an expert immediately!

 CHAPTER 1: What is Multi-Strand Wire 

1.1. Multi-Strand Wire Meaning

Multi-strand wires come with a bunch of small wires bunched together to form one thick conductor. Multi-strand wires are more malleable than single strand wires with the same cross-sectional surface. The multi-stranded wires come handy when you need a higher resistance to metal fatigue.

Multi-strand wires are used when the rigid nature of single strand wires are not suitable, such as for circuit boards.

Single strand wires are prone to power loss due to skin effect, where the current travels on the outer surfaces of the wire. Multi-strand wires can reduce the skin effect, as the surface area of all the strands is more significant than single strand wires. It may not be true in case of ordinary stranded wires where the strands are twisted together to form a single core.

Multi-strand wires also come with higher resistance because the cross-section is not made entirely with copper. There are also air gaps between the strands which contribute to the high resistance.

1.2 Multi-Strand Wire Sizes

Multi-Strand wires can come in different sizes to suit various applications. American Wire Gauge or AWG is taken as the standard and represents the wire diameter. The diameter is calculated based on the conductor with the insulation removed.

A multi-strand wire has an overall larger diameter than a single strand wire of the same current capacity and electrical resistance because of the gaps between the different strands.

The thickness of the diameter is more in lower AWG wires, and they keep on decreasing as the number goes up. For example, AWG 12 or 14 is used for general household wiring while AWG 22, 24 or 26 is applicable for telephone wiring.

1.3 Multi-Strand Wire Specification

Multi-strand wires come with similar specifications like standard wires. The wires have multiple strands which are bunched together to form a single core.

The strands can be made of different materials such as copper or aluminum. They are covered by outer insulation made of plastic, rubber or other items such as PVC. Sometimes, the individual strands of the wire are provided with separate insulation which goes a long way to reduce the proximity effect.

1.4 Multi-Strand Wire Current Capacity

The current carrying capacity of wires represents the amperage the conductor can carry before the core or the insulation melts. The heat produced by an electrical current in the conductor determines the amount of electricity it can carry.

The current capacity depends on some factors such as the size of the conductor, the ambient temperature, the type of conductor insulation and the number of strands. The installation conditions will also affect the current capacity of the multi-strand wire.

A 6 AWG multi-strand wire with 7 to 24 cores will have a current capacity of 38 amps. A 10 AWG multi-strand wire with 25 to 42 cores will have a current capacity of 18 amps. The current capacity of 24 AWG multi-strand wire with 7 to 24 cores will be 1.4 amps.

Both single strand and multi-strand wires are used for both commercial and residential purposes. We will take a look at the differences between the two types of wires in the next chapter.

 CHAPTER 2: Multi-Strand Wire Vs. Single Strand Wire

 You have to make some crucial considerations when choosing a wire for any application. A load of amperage and application will determine the correct gauge of wire you will need. The type of metal used in the wire is also important and will need consideration.
Apart from selecting between copper or aluminum wire, you also have to choose between single strand wires and multi-strand wires. Both the wires can be used for residential and commercial applications, but each comes with its unique bunch of advantages and disadvantages. It would help if you had an idea about the differences to make the correct choice. First, we will take a look at single strand wire as you already know what a multi-strand wire is.

2.1 Single Strand Wire Definition

Single strand wire is also known as solid core wire and comes with a single piece of metal wire. The wire is rigid and stable and used for conditions where durability is an essential factor. The wire comes with a single conductor and suitable for outdoor uses and rugged applications.

Single strand wires are commonly used for mounting CCTVs or outdoor lights where the wire is exposed to external weather conditions and corrosive elements.

Now we will explore the differences between the two types of wires.

2.2 Differences between Single Stand Wire and Multi-Strand Wire

You will find many differences between the two types of wires. Single Strand wires are rigid and used for applications where movement is minimum.

Multi-strand wire, on the other hand, come with a bunch of conductors or wires put together inside a rubber or plastic insulation. For this reason, multi-strand wires are suitable for complex application such as in a circuit board and electronic device. Multi-strand wires are more flexible and can withstand the twisting and bending that needs to be performed while connecting the wires.

The single strand wire has a few advantages- it is durable, cheap and straightforward. The wire comes with only a single core and is very easy to manufacture. It is also resistant to damage and can last for a good many years.

A multi-strand wire is ideal for applications which involve a high level of movements, such as in vehicles and robotics. You can also use them for situations where you want to shape them into complex shapes, such as in the case of circuit boards and electronics. Single strand wire is unsuitable for such applications as they don’t have the malleability and strength to withstand motion and reshaping.

Multi-strand wires are perfect for the conditions which require reshaping and flexibility. However, they are prone to electronic interference as the air pockets between the strands spike up the skin effect due to the magnetic field acting on the surface of the wire.

Multi-strand wires have a larger surface area, and as a result, any signal or current passing through it experiences less resistance.

Single strands are more accessible to weld because only one core can handle. Multi-strand wires can be a bit challenging to solder as you have to secure all the smaller strands. For this reason, the strands are tinned before they are soldered. You can also put the strands in crimps and connect it to a crimp connector.

Single strand wires are simple to make and come at cheap rates. Multi-strand wires require a high level of stranding and extrusion, which results in the increased cost.

If you are choosing the wires based on cost, then you also need to consider the long-term durability factor. A single strand wire will last for many years to come, but they may crack or rupture if exposed to motion or bending due to the metal fatigue. In that case, multi-strand lines are more suitable,because they can run without the risk of metal fatigue.

As already discussed the difference between single and multicore. Now we will find out how you can adequately solder multi-strand wires.

 CHAPTER 3: The Correct Way to Solder Multi-Strand Wire

 A multi-strand wire is flexible and contains multiple strands of wires. It can be difficult to solder them properly if you don’t use the proper technique. We will tell you how you can adequately solder multi-strand wires first by carrying out a tinning process if that is necessary.

3.1 Things You Will Need

You will only need a soldering iron and some resin-core solder for the process. Of course, keep a wet sponge and wire stripper to help you out.

3.2 How to Solder Multi-Strand Wire

The tinning process helps you place molten solder on the strands of a multi-strand wire so that you find it easy to solder it to other wire or terminals. The tinning helps the strands to hold together so that you can effectively make an electric connection.  Do remember that we are not going to use any actual tin in the wires. We will only use the solder that fills the gap between the strands to form a solid core. You can quickly move or bent it and connect it to other terminals. The process removes any risks of losing connection, and no wires stick out from the end of the terminal screw. We will be using electrical application rosin-core solder which comes with flux in the solder core. It would help if you prevented using any acid based solder which can damage the wire. Let’s check out the tinning process below:

Multi-Strand Wire Tinning Process

1. The tinning process has to be carried out on the bare wire. Use the wire stripper to strip the wire to about 3/4 inch to 1 inch by cutting the insulation. The length of the wire is ideal for connecting to screws or terminals. 2. Connect the soldering iron to a power outlet and allow it to heat up. 3. The soldering iron tip should be free from oxidation which takes place while it heats up. Just wipe the tip of the iron on a wet sponge to make it clean. 4. Now unfold the solder from its spool in a straight line. You can use heat-resistant holders to hold the solder for convenience. 5. Take the tip of the solder and place it on the tip of the soldering iron. Wait for the solder to melt and accumulate on the solder iron tip. 6. Now place the solder iron tip on the bottom part of the wire. Work your way around the wire ends and apply molten solder. Continue the process until you achieve a uniform coat of solder on the wire making it a single core. 7. Let the solder solidify and inspect the wire. The solder should be applied in a thin coat around the wire without forming any lump or uneven surface which results in electrical resistance. We have completed tinning of our multi-strand wire. Now we will get along with the actual process of soldering the wire to other surfaces.

Multi-Strand Wire Soldering Process

1. Plug in the soldering iron and wait for it to reach its operational temperature. 2. If you haven’t tinned the wire, you will need to twist them to a single formation. Also, you may need to strip the wire down a bit to get access to the strands. Make sure that the wire surface is free from dust or other contaminants. Use sandpaper or knife to clean the wire surface. 3. You have to carry out the same tinning process if you haven’t done it earlier. Use the same method to tin the other wire which will be soldered to the multi-strand wire. Let it cool for the solder to solidify. 4. Now apply the soldering iron tip to the tinned solder on the multi-strand wire. It will melt the solder after which you need to place the other wire on top of it. Apply another beautiful coat of solder on the wires so that they are fused. 5. Let the surface of the wires to cool down. The solder will become solid joining the two wires together. You can slightly pull the cord to make sure they have the proper welding. Voila! Your work is now complete. Now let’s go over a few tips to keep in mind.

3.3 Tips and Warnings

• Be sure to clean the wire to remove any contaminants before you solder it.  • The soldering process should be carried out as quickly as possible to reduce the chances of damage to the insulation. Also, prevent overheating the wire. • Don’t breathe the fumes produced by the solder. They can be poisonous in nature.  • The soldering iron can heat up to 400 degrees Celsius and cause severe burns. Be sure to operate it away from the body and avoid contact with skin. • Place the soldering iron on heat-resistant surfaces. Don’t keep anything flammable nearby.  • We have covered how you can solder a multi-strand wire properly and the precautions to take. Now comes the turn to check out the gauge chart of multi-strand wires.

 CHAPTER 4: Multi-Strand Wire Gauge Chart

 The gauge rating denotes the sizes of multi-strand wire. Here is a table of standard measurement:

Gauge      No Inches      Millimeters      1             0.2893                 7.348      2             0.2576                 6.544      3             0.2294                 5.827      4             0.2043                 5.189      5             0.1819                  4.621      6             0.1620                 4.115      7             0.1443                 3.665      8             0.1285                 3.264      9             0.1144                 2.906     10            0.1019                 2.588      11            0.09074             2.305      12            0.08081             2.053      13            0.07196              1.828      14            0.06408             1.628      15            0.05707              1.450      16            0.05082             1.291      17            0.04526              1.149      18            0.04030             1.024      19            0.03589              0.9116      20            0.03196              0.8118      21            0.02846              0.7229      22            0.02535              0.6438      23            0.02257              0.5733      24            0.02010              0.5106      25            0.01790               0.4547      26            0.01594               0.4049

You must be aware of the different sizes of multi-strand wires. In the next chapter, we will cover the uses of the wire.

 CHAPTER 5: Multi-Strand Wire Uses

 Multi-strand wires are used in situations where you need to bend and move the wire frequently. They are used in circuit boards of electronic devices and PCBs where the wire is bent for connection. You will also find their use in power cords for different appliances, extension cords and musical instrument cables.

Multi-strand wires are also used in computers and peripherals such as mouse and keyboards. Various machines like mining equipment with moving parts use multi-strand wires for their flexibility. You will also find multi-strand wires in different vehicles and engine compartments where malleability is the priority.

You have learned many new things about multi-strand wires till now. We will cover the prices of this type of wire so that you can make an informed decision while purchasing. 

 CHAPTER 6: Multi-Strand Wire Prices

 The price of multi-strand wires depends on many factors. Different manufacturers charge different prices for their products, and it also varies according to the core material, the type of insulation, size and length of wire and so on.

To give you an idea, 100 meters of multi-strand wire can cost you anything from $20 to $25. If you want to buy a 500 ft roll, be ready to spend around $100. It all depends on your need though, so it is essential that you take into account the job you need to get done first.

 Conclusion

 Multi-strand wires are perfect for an application which encounters a great deal of movement or bending and twisting. You can use them for commercial and residential applications where flexibility is required. You also know how to solder them properly so that an active electrical connection is possible.

If you want to purchase high-quality multi-strand cables, you can get in touch with our team. We can manufacture the perfect type of wire you need matching your size requirement and other specifications.

Medical Cables – The Ultimate Guide to How to Improve Quality

A place where life or death situations unfold needs to be equipped with highly durable and reliable equipment. The equipment needs to be in top shape at any time in preparation for any emergencies that might require their use. Hence, a medical cable must be manufactured with strict adherence to industry standards. Industry standards hold that a medical cable must have high degrees of properties such as flexibility, durability, and resistance to sterilization methods. Also, medical cables must be capable of repelling airborne chemicals and particles, as well as EMI interference. Also, the medical wires you use around MRI machines must be free of any trace of magnetic materials like iron. Such cables must be made from medically transparent resins. This dossier sheds insightful light on these medical cable properties and much more, exploring the world of medical cable inside out.

CHAPTER 1: Medical Cable

 A medical cable is a sophisticated cord made from the highest grade of materials due to the sensitivity of its applications. Medical cables are usually made of silicon and low-friction coating, which imbue them with excellent capabilities and long-standing durability.

Medical cables can also be made from other medical grade materials such as TPE and polyurethane.

Medical cables are critical to the safety and performance of medical devices. As such, they’re critical to a medical device’s chances of success in FDA tests.

They help facilitate proper interconnections in medical facilities. Medical cables also facilitate potting and pressure tests, as well as the control of statistical process and serialization.

A medical cable is usually highly flexible to prevent kinking. Medical cables are also normally temperature-resistant because you’ll most likely subject them to sterilization on a frequent basis.

However, many medical cables are disposable, depending on the application they are using. Moreover, there are medical cables for hundreds of various healthcare applications.

These include patient monitoring, electro-surgery, bionics, cardiac therapy, nuclear medicine, optical enhancements, ultrasound, and lots more.

Each of these applications has different requirements for medical cables. Hence, a medical cable assembly manufacturer must be able to meet various specifications according to the peculiarities of its application and devices.

They must be capable of creating excellent cable designs such as connectors, custom over-molding, moisture proof, and disposable and reusable, lots more. In general, reusable cables are usually resistant to chemicals and sterilization techniques such as steam, gamma, ETO, and many others.

Wiring configurations, as well, as intermittent connections, can make or mar the efficiency of a medical cable. As such, many manufacturers subject medical cable assemblies to electrical tests to eliminate the possibilities of these defects.

Medical cable manufacturers deploy thorough-going inspection processes at various stages of the fabrication processes as quality checks.

Now, let’s give you a closer look at the various applications of medical cables and their unique medical cable requirements.

CHAPTER 2: Medical Cable Application

 

Cosmetic Surgery

Medical cables are critical to the successful use of ultrasound, RF, microwave, and other medical technologies to execute cosmetic procedures. These applications have intricate energy delivery and process monitoring requirements. Due to the nature of their application, cosmetic surgery medical cables usually come in ergonomic aesthetically-pleasing packaging. Also due to the nature of their application, many medical cables come with applicators that can be changed quickly and easily.

Defibrillation

For cables used in emergency response medical facilities, durability and reliability are the two most critical qualities. Medical cables for emergency response facilities are used both within the hardware and the paddle assemblies that come in contact with the patient. They also provide safe, reliable and straightforward energy delivery solutions for such applications.

Electrophysiology

Medical cables for this application facilitate the collection of data points that facilitate the monitoring of low electrical pulses in the heart.

In order to do so, these medical cables usually support excellent signal integrity. They generate signals that help identify the site where the occurrence of arrhythmias must be eliminated through ablative energy.

You’ll find that they usually come with high-density connectors. They’re usually sturdy and reliable, as they must be used repeatedly for precise heart mapping intelligence.

Electrosurgical Applications

Due to the nature of this application, medical cables for this application are usually single-use, disposable types, for cost-effective risk management.

Imaging

The use of imaging is gaining more use in diagnostics, surgery, therapy delivery, and so on. It is especially true in applications such as fluoroscopy, MRI, X-ray, PET, CT, and many more.

This proliferation of use is, in turn, giving rise to a growing need for medical cables that enhance image quality cost-effectively.

Minimally Invasive Surgery

Medical cables are critical to image delivery in minimally invasive surgical procedures, such as those involving the use of endoscopes. They help minimize trauma in surgery patient, helping accelerate healing by extension.

Medical cables for endoscopy are usually made of fiber optics and fiber materials.

These cables must facilitate the delivery of high-quality images on numerous iterations after several sterilization cycles, as efficiently as they deliver on first-time use.

Patient Monitoring

Medical cables for patient monitoring are designed to facilitate reliable transmission of patient information to those looking after patients. They’re critical to the verification of the efficacy of the treatment you administer to a patient.

Patient monitoring medical cables are usually designed with ergonomics and aesthetics as critical considerations. Moreover, since you’ll most likely be using them frequently, they usually very durable, safe and easy to deploy.

Now, each of the applications mentioned above uses different types of medical cables. The following chapter delves into the various types of medical cables.

CHAPTER 3: Medical Cable types

Single-Use Medical Cable

To minimize the risks of spreading infections, you need to dispose of a medical cable that’s attached to a patient after a single use. Disposable medical cables are cost-effective risk-minimization measures that come in handy especially in public medical facilities.

You’ll find disposable medical cables used regularly in electrosurgical devices, ultrasonic scalpel, surgical monitoring, and so on.

Since they’re to be disposed of after the first use, they usually come pre-packaged and sterile. Some disposable medical cables are designed to withstand autoclave sterilization so that they can be suited to repeated use (only just a few times, though).

Power Supply Cables

The UL regulation 60601 stipulates the acceptable standards for power supply medical cables. The provision holds that power plugs must be made of solid brass, and exhibit strain relief, with minimal current leakage.

The provision also states that the cords must pass the proper grounding tests.

Every equipment operates with a unique circuitry, hence the variety of power-plug blades of hospital equipment. There’s a particular blade configuration that’s the most appropriate for each unique circuitry.

Coiled Cables

These types of cables are the most appropriate for use in equipment where mobility and foldability are crucial factors. These include equipment with sliding and rotating components, including X-ray machine heads, MRI and CAT scan machines.

Retractable cords can also help you avoid the dangers of working with dangling power cords on portable mobile equipment. Unlike long cords, you won’t have to deal with entangled and knotted cords when using coiled cords.

It can significantly enhance the convenience of use of equipment. It is even more beneficial in the use of machines that run with large bunches of cords.

Patient Monitoring Cables

Devices that monitor patient information such as blood pressure, respiration, EEG, ECG, and vital signs, need cords with plenty of connectors. Since you’ll most likely make use of numerous electrodes on a patient, you’ll need various connectors.

Also, for a number of reasons, including for coming into direct contact with the patient, many monitoring cables are disposable by design. For starters, connectors are used to connect individual leads. Moreover, the leads are susceptible to wear, so you need to replace them regularly.

However, the lead components are usually the only responsive element in patient many monitoring cables, hence the low maintenance needs of these cables.

All in all, patient monitoring cables are usually made of flexible, durable materials with excellent strain relief qualities. They come with a slender finish that prevents abrasion or adhesion to a patient’s skin.

Ultrasonic Cables

Due to the need for mobility in the use of ultrasonic equipment, ergonomics is at the heart of the designs of ultrasonic cables. Because they’re carried continuously around by technicians during use, ultrasonic devices require cables that are lightweight and flexible.

The flexibility of high wires is usually a result of the multiple copper wire strands components.

Now, to shed more light on all of these medical cord types, we’ll show you details of how they assembled. The next chapter covers medical cable assembly.

CHAPTER 4: Medical Cable Assembly

 Medical cable assemblies are primarily used to connect medical and laboratory equipment. A medical cable assembly comprises of a band of individual cables attached to connectors on at least one end.

They’re usually designed to transmit power, data, and electrical pulses.

In order to minimize the risk of scratching and sticking on patients, they usually possess low surface friction qualities. In addition, they usually come with anti-abrasion jackets that also enhance their durability.

Other standard features of medical cable assemblies include high flexibility to prevent kinking. Another is temperature resistance that allows them to last through several turns of autoclave sterilization.

However, note that it’s advisable to check for the biocompatibility of a medical cable if its outer jacket is to contact the patient’s body.

Types of Medical Assemblies

Equipment and Sub-assembly Interfaces

These types of assemblies come installed in equipment from the factory. However, you can replace them to make upgrades and retrofits.

You’ll find these types of assemblies in nuclear imaging devices.

Communications Interfaces

These cables are usually made from fiber optics, serial or local area network.

Patient Interfaces

Although they have good durability, these types of medical cable assemblies come in need of replacement multiple times during an equipment’s lifecycle.

You can provide performance upgrades for certain patient interface components instead of completely replacing them. However, you’ll eventually need to replace them due to age-related and use-induced degradation.

There are many sub-categories in the patient interface category. There is the long-life patient interface, used mainly in ultrasound imaging and ECG diagnostics.

There’s also the limited-use interface, used mainly in ICU and CCU monitors. They come with a limited shelf-life because they’re frequently exposed to mechanical stress and sterilization procedures.

There’s also the use-only interfaces used majorly in neural simulator lead sets, fetal monitoring cables, catheters, and electro-surgical devices. They’re designed to be discarded after a single use.

All in all, these cable assemblies are usually produced in line with medical cable industry security standards and certification criteria.

CHAPTER 5: Medical Cable Security and Certificate

 The main factors that differentiate medical cables from those of other industries include the provisions for bio-compatibility, sterilization, and lumen generation.

Medical cables are usually manufactured in compliance with application-specific safety and regulatory provisions. An example of such regulations includes the ISO 10993-1.

Another typical example is the requirements set by the FDA for the 510 (k) submission of medical devices. There are also the ISO 13485 and ISO 9001 standards.

Nonetheless, every country has unique sets of regulations for the production of medical cable assemblies. These regulations are usually much more elaborate when it comes to medical cables for connected devices.

All in all, these regulations help safeguard both the patient’s recovery as well as the working environment wherein the recovery takes place. As such, compliance with these regulatory standards requires validation, testing, and inspection of medical cord assemblies.

Many public health facilities also implement their own in-house medical cable safety and security measures. Examples of such measures are cable tethers.

Cable tethers help prevent patients from taking expensive bedside monitoring leads with them from high-traffic units to other places in the medical facility. They secure the cables by affixing them to other components.

With the cable tethers, monitoring leads can only be removed from a room by authorized staff who have the keys to loosen the security screw and detach the cables. This measure can help hospitals save up on the costs of replacing expensive monitoring leads frequently.

Another frequently used safety measure is the mounting pads. These provide excellent solutions for attaching equipment safely to a wall.

To use them, you need to fix the mounting pad on the targeted area using an adhesive of your choice. Moreover, then, fix the tether eye-loop to the mounting pad together with the security screw.

Still curious about the processes involved in the production of medical cable assemblies? The next chapter delves into medical cable manufacturing.

CHAPTER 6: Medical Cable Manufacture

 As stated earlier, there are stringent regulations in place to ensure that manufacturers always provide you with high quality, wear-resistant products. These standards ensure that manufacturers provide you with highly reliable interconnection solutions for your medical devices.

Regardless of the application which you want to use a medical cable for, there’s a constant need for reliability and durability.

Even if the medical cable’s only flaw is the failure to withstand cleaning chemicals used for sterilization properly, it still exposes users to risks.

Sterilization, which is the process of eradicating biological contaminants such as bacteria, fungi, viruses, and so on, It is a key consideration for medical cable manufacturing.

Most medical manufacturers use similar measures for ensuring their medical cord assemblies stand up to sterilization procedures.

Key Requirements for Medical Cord Manufacturing

A Deep Repertoire of Application Knowledge

There are vast interconnection needs required by the various applications for medical cords. Medical cable manufacturers need to be well-informed about the interconnection needs of your medical cable.

They must design your interconnection solutions with wonderful insights.

Material Expertise

A medical cable manufacturer must also be very conversant with the various qualities of medical cable materials. They must be able to provide you with veracious advice on which material is best-suited to your intended use.

A Deep Understanding of Manufacturing Principles

The manufacturer must be conversant with the industry-best methodologies for manufacturing medical cable assemblies. They must also be well-versed in the integration of interconnects and cable bundles.

Cable Bundle Optimization

Manufacturers must be able to assemble cables accurately based on your unique propositions.

In-house Testing

The manufacturers must test cable assemblies consistently at various phases using test tools such as force measurements, medical grade disinfectant washers, TDRs / VNAs, and so on.

Expertise in Hybrid Cable Assemblies

Manufacturers need to be highly knowledgeable in the production of hybrid assemblies that comprise electrical, fluidic, pneumatic and optical components.

Conclusion

 Cleanliness, quality, and handiness are the most crucial qualities of any medical equipment. Regardless of the volume of the assembly produced, these three attributes must be keenly considered.

We leverage our state-of-the-art equipment and our wide breadth of experiences to provide you with excellent interconnection solutions for your medical devices.

We help you simplify the nature of your medical cable assembly, and enhance the user experience of your medical devices. Reach out to us whenever you’re ready to acquire a medical cable, and let’s help you simplify everything.

 

China Wiring – How to Make Ideas Come True

Wiring requirements vary from individual to individual. Your wiring application area and functionality will dictate the design, voltage, and current capability, size, colors among other variables. Therefore, it is essential to deal with a China wiring company that takes your needs seriously. Apart from a meeting customer’s requirements, China wiring is under certain standards on safety, design, and installation. The rules and regulations are formulated by GB standards (GuoBiao Standards), China Compulsory Certification (CCC) and the International Electrotechnical Commission (IEC). The IEC tries to harmonies the wiring standards globally. It has proven difficult as every country varies environmentally and structurally regarding electrical appliances, machines, and automobiles. This article will provide detailed information on China wiring. From wiring and cable harnessing, color codes, designing, testing, and other wiring processes.

CHAPTER 1: Cable Harness

 Cable harness is combining of two or more conductors that are insulated with a more intensive exterior product. Mostly, a cable will have a positive wire to carry current and a neutral one to complete the electrical path and finally a grounding wire. After that, the whole combination is covered with heavy-duty materials such as shrink-wrapped thermoplastic, rubber or vinyl sheath.
Cable harnessing is mainly a custom-designed assembly to ensure the overall product meets your specific logistic and structural requirements. Also, other factors are put into consideration, for instance, temperature, humidity, size, shape, chemical substance exposure, fiction, colors and area of application. We deal with highly qualified electrical engineers in designing cable harnesses thus ensure quality from the start. After that, it is our sole responsibility to test that every harness will provide its optimum function. We confirm its durability under different environments, desired functionality and the place of application. In the end, we come up with quality-defined standards of manufacturing a cable harness. Aside from acquiring standard processes, we also develop a methodology in which we develop some of our tools, plastic, dies, and glass, metal, and synthetic materials. To bring all the materials and tools together, we have a highly designed and developed process with qualified technicians to see that the manufacturing process goes on smoothly and efficiently.

1.1 Cable Assembly process

The cable design process entails:
  • Cutting and shaping cables to the required lengths
  • Installing the wires, cables, and components (subassemblies) on the assembly or pinboard
  • Routing and attaching subassemblies with terminals and through other connector housing or sleeves
  • Attach the subassemblies to the board with wraps, weaves, ties, or tapes
  • Where possible, soldering of wire ends with a solder machine
Nevertheless, this is just a general process of what cable assembly entails and not the specific step to step process. Also, automation of the whole process has proven difficult as manual cable harness is more cost effective considering the numerous activities involved. However, initial parts of harnessing and kitting can somehow be automated. In the end, we have a complete functioning and high-quality product for your use. The whole china wiring harness involves a balance of accuracy and speed ensuring every item meets the standard protocols.

1.2 Cable Harness Testing

Before releasing the wire harness to you, we ensure the cable harness meets the geometric and electrical requirements by thorough testing and evaluation by our experienced team. Repeat purchase of similar products over the years has allowed us to develop standard product and save time in harnessing process, testing, and installation.

What is Automobile Wire Harness?

Automobile wire harness can simply be described assembling of electrical cables for transmission of signals (wire harness) in automobiles. Wire harness plays an important role in some functionality of automobiles and space/air-crafts considering the amount and length of wires involved in their construction. Wire harness ensures the wires are more bound thus safe from damage through abrasion, vibrations, and moisture.

Also, the constriction of the wires saves much space, and since they are bound into slave resistant-sleeves, the possibility of electrical fires occurring is minimized.

CHAPTER 2: China cable Harness Heat Shrink Tubing

 Cable harness unlike wire harness as you will see later requires more great insulating materials. It involves bundles of wires and cables, and the connections are made for sensitive machines, automobiles or aircraft. Therefore, caution and precision are mandatory.
 

2.1 Protecting Cable Harnesses

Heat-shrink tubing: This is an efficient insulation technique especially when the cable harness is used in an environment with diverse temperature levels. Plus, it can be useful in handling chemical erosion, abrasion or even water damage. Spiral-wrap tubing: This is a technique that allows the flexibility of the cables and wires in the harness. It involves a wrap tubing with openings that provide passage for the assemblies to join or separate from one group to another. Split loom tubing: The loom tubing is a method that ensures the connections remain intact. The tubing has small openings along its length. Through these slits is where the wires and cables are installed and after installation, they close keeping the assemblies surrounded. Sleeving: This method deals with sleeves especially those made with braided-like material such as polyethylene, these allow flexibility at severe low temperatures. Also, some sleeves expand in situations where a lot of wrapped wires are involved. Tape:Use of tapes in designing cable harness is among the standard parts of the process. However, it can also be automated. The tapes can be of different backing such as cloth, foam, PVC or felt. In the above techniques of insulation in China wiring, the heat-shrink tubing has proved to more effective at providing cover against damage. It is a recommendable method for a cable to either a manufacturer or you.

2.2 Features to Consider in Heat Shrink Tubing

 

The heat-shrink tube as a product has different brands. Some offer one unique feature while some have combined benefits, and it is up to you to choose one that suits your needs best. Here are separated characteristics a heat-shrink tube could offer:

Temperature tolerance: This is suitable tubing if the cable harness is to be used in an environment of extreme temperatures, cold or heat. For example, in an automobile or a factory machine where much heat is likely to be emitted.

Chemical resistance: You should know what type of chemicals and the level of concentration they are in, your harness will be exposed. They can either be acidic or basic, after that, you can choose a tubing that provides the proper protection against that chemical damage.

Strength:

This is a feature to consider especially when your cable harness will be exposed out in public. The tubing material should, therefore, be brawny enough to make it difficult to impregnate the wires.

Abrasion resistance: Friction will majorly be as a result of movements in the area of application of the cable harness. Consequently, erosion and heat will be the result. Therefore, other than being abrasion resistant, the tubing material ought to be able to withstand heat. It is significant considering the damage and loss that can occur if the wires got exposed in a condition of extreme heat.

Electrical insulation: How much voltage will pass through your cable harness wires? The number of voltages is essential because it helps Chinese wiring manufacturing use wires that can handle the current.

Flexibility: Flexibility depends on the size of your insulated wire harness and the area in which the cable harness is installed. Flexibility in tubing ranges from very elastic to rigid, and it is up to you to choose which one suits you.

Water resistance: Assuming you need a cable harness for a watercraft, water-resistant tubing is what you should go. However, in consideration of what type of water the harness will be in contact with, is it fresh or salt water?

Shrink factor: No, this is not similar to flexibility. It understands the degree of shrinking that can occur and finding the material that has the ratio to withstand the change.

UV protection: If your cable harness were exposed to sunlight for a long period, UV- resistant tubing would be very useful.

Flame resistance: In a more severe environment with flames involved, apart from the temperature-tolerance feature, tubing that is flame resistance can come in handy in protecting the cable harness.

CHAPTER 3: China Wiring Color Code

 IEC has been trying to standardize wiring color codes. However, colors still vary from region to region. The variation is especially in jurisdictions where some wires are codified with an allowance of alternative wire colors to use.

Most of China wiring follows the International Electrotechnical Commission (IEC). With AC wires such as flexible cables (lamp cords and extensions) and fixed wires (behind or on the wall cables), the protective earth or insulation is green or green with yellow strips. Neutral is indicated with blue. China wiring of live wires is indicated as brown, black and grey labeled as L1, L2, and L2 respectively.

DC China wiring such as in solar power and computer data centers follows similar standards as the AC wiring.

CHAPTER 4: China Wiring Harness

 Unlike cable harness, china wiring harness deals with connecting single conductors. Wire insulation has little effect in protecting it unless in a situation where the wires are thick as they are at higher risk to damage from a burned fuse. Also, jacketing is mainly employed on wires to be used under conditions of dust, extreme temperature, moisture and friction for example in a remote or housing shell.
Wiring harness integrates wiring components into a single unit thus simplifying the manufacture of a huge complex writing system. Also, it allows for an easy-fix installation and modification in case of damage to some components. Therefore, China wiring involves assembling of different wires that may or may not have the exterior covering. Wire harness is a cost-effective means in creating an orderly and carefully fitted wiring system. In order to achieve an effective harness design, there is a need for evaluation of different types of cables you use, style and materials.

For example:

For example:
  • Insulating colors
  • Color codes
  • Shielding and heat-shrinking coats
  • Lacing and wire-tires
  • Labeling and barcodes
  • Polypropylene, nylon, and paper fillers
Additionally, the area of application of the wire harness should be known and considered. It includes factors such as size, chemicals that will get in contact with the harness, temperature, humidity, and friction. These variables will facilitate the creation of the design model regarding size and components the harness will use. We aim to build our customer a long-lasting, durable, affordable and quality product. Thus, we employ our best technician, tools, and technologies in assembling cables, connectors, pins, and other materials.

4.1 Wire Harness Design

After building the harness design model, designing begins with the development of a blueprint for manufacturing and a pin board for hosting the harness. The pin or assembly board is a representation of the harness. It indicates all the components; their location as well serves as a working table for the wire harness.
The wires to be assembled come in a master reel then cut into the desired lengths and printed for labeling and bar-codes where required. With the required lengths, the wires are stripped off at the end to fit the terminals and connector housing where necessary. The wires are placed on the assembly board and attached to it with the suitable lacing, wire ties, tapes, strings, weaves or straps or a combination of the components. Over time there have been attempts to advance manual wire harness designing to automation, but as the process involves many activities, most of the stages of the process remain to be manual. Nevertheless, some parts of the process have been automated for speed and accuracy.

4.2 Wire Harness Testing

Once wire harnessing is concerned, the process is not complete until testing for the real world application is done. Testing is usually conducted with our expert staff who employ the help of a test board.

A test board evaluates the electrical functionality of the wire harness. It is preprogrammed with electronic features, and once the complete wire harness is connected, it provides results of its performance or in comparison to certain values.

CHAPTER 5: What to look for in China Wiring Manufactures

Wire or cable harness may seem like a typical job until you come to think of it regarding what and how much you could lose in case there is an application of poorly manufactures cable harness. Damage or failure of a wire harness could have an impact on the devices connected to it. Consequently, it is essential that you have sufficient information on choosing the right manufacturer for your harness.

Tips for Evaluating Wire Harness Manufacturers

The quality, durability, and life of your wiring harness will have a lot to do with the manufacturer. Below are tips you can put to considerations to enable you to choose the suitable manufacture as you do your research.

The company history

A manufacture’s longevity in China wiring is an assurance of a well-versed provider in the wiring harness. More time spent in the industry means there is an accumulation of knowledge, skills, practices, better methodologies and acquisition of quality materials.

Also, it would help if you did not have to worry about finding out that your manufacture closed the business without getting the job done. Like every industry, businesses start and get closed; a more rooted china wiring manufacturer will advantageously have you at peace.

Skill level and experience

As earlier discussed, it has become impossible to automate the whole wiring harness process. Therefore, standardization is less achieved with manual working thus making it easy for you to identify a quality finished product. It will depend on the level of expertise of the designers and manufacturers.

Quality control is also an aspect you can consider about you manufacture. It is mainly implemented during testing. Therefore, the company should have invested in high testing technology. Efficient and optimal testing is a guarantee that your requirements of a quality and reliable wiring harness will be met.

Does the company cost complement the quality?

It is human nature to relate expensive with quality. However, your wiring harness manufacture should be able to meet your component, and product quality needs such that you will be happy to pay for it. Low cost of the service and the product could seem like a great deal but look out, it does not come to bite you in the back.

Proper communication and interaction

Apart from working to achieve a quality product, the manufacturer should be attentive to your specific needs and put them in action. Additionally, when you reach out, the manufacturer should respond immediately and address your concerns. Communication should not be frustrating.

Conclusion

 Wiring whether wire or cable harnessing, it is a task that requires expertise and experience for a quality end product. We at Wringo, we are committed to providing outstanding wire harness solutions. Through our expert technicians who understand and are familiar with the required standards of China wiring, we deliver nothing short of the best.

With years of experience at wiring and manufacturing of related materials, we have mastered the skill and perfected the art of understanding your ideas and making them come to be. Contact us any time; we will be glad to serve you.

Automobile Wire Harness-Growing Demand in the Automotive World

From harsh environmental factors too numerous abrasions, automobile wire harnesses need to weather numerous storms. The automotive industry utilizes wire harnesses like no other. As electrical links connecting various components in an automobile, wire harnesses are indispensable to automobiles. The range and quality of functionalities in modern vehicles are on the rise, and this is bound to expand the demand for wire harnesses in the industry. Most modern cars have integrated wire harnesses that are more sophisticated than standard wire harnesses. In this dossier, we explore automobile wire harnesses from the inside out.

 CHAPTER 1: Automobile Wire Harness

 

What is an Automobile Wire Harness?

An automobile wire harness is an electrical cables assembly that facilitates the transmission of signals in electrical devices. It’s a well-structured unit bundle of conductive wires.

As such, it facilitates cross-connections and interactions between various electrical components of an automobile. Wire harnesses are integral parts of a vehicle’s electrical system.

The automobile industry’s demands for wire harnesses eclipse those of nearly every other industry. As such, the variety of wire harnesses deployed in the industry is more productive than those used in any other industry.

Automobile wire harnesses serve as transmission systems combining the wiring of various electrical and electronic components in a car. As such, they coordinate and empower the various functions of a car’s components.

They lend themselves to use in electrical and electronic systems of automobiles, including electrical circuitry. Hence, they can adapt to a wide variety of conditions and applications.

However, for them to do so, their material composition should chose with great care. The next chapter shows you the first wires that make up an automobile wire harness.

 CHAPTER 2:Primary Wire for Automobile Harness

 Electric cables serve an uncounted number of purposes in the car industry. Every wire harness comes with a unique material composition that makes it best-suited to a specific purpose.

Each automobile wire harness deals with a unique combination of environmental factors like heat, emissions, vibrations, and so on. Moreover, that’s all the more reason why their physical makeup requires conscientious selection.

The material composition of wire harnesses categorize into two:

The Insulating Materials

This material part of the wire harness serves up a layer of protection against heat, chemical compounds, and vibrations. It usually consists of various halogen-free polymer bases (PVC, chlorinated polymers, polypropylene, and so on.)

Usually, we select the insulation materials for a wire harness based on the purpose for which the harness is designed to serve.

Insulation materials best-suited for resisting temperatures of varying degrees include polyesters classes ranging from T2 to T61. These insulation materials are usually the aptest for use in cables for batteries and electric vehicles.

Insulating materials best-suited to mitigating abrasions include polyesters of classes T3 and T4.

Conductor Materials

Copper is the most widely used conductor material for wire harnesses. When alloyed with magnesium, copper serves as a more reliable conductor and provides a lot more capabilities with a smaller diameter.

However, aluminum, being a much cheaper and lighter conductive material than copper, is also gaining full acceptance by the day. Due to its excellent thermal capacities, aluminum has been the most widely used conductor material for battery cables.

Moreover, now, its alloys are being put to use in an increasing number of applications. However, copper cables have the advantage of yielding greater capacities with smaller diameters, and therefore outperforms aluminum regarding flexibility.

And now, you know the most commonly used types of wires for an automobile wire harness. However, what types of wire harnesses can these materials be used to create?

 CHAPTER 3: Automobile Wire Harness Types

 

Standard Wiring Harness

This type of harness can be found in nearly every automobile. They’re usually plugged into the factory plug of a vehicle.

Hence, they can remain intact even after the successful installation of new devices like a radio. As a result, they allow you to install and uninstall different components more quickly and neatly.

Reverse Wiring Harness: This harness comes in a reverse setup of the standard wiring harness, plugging into the factory radio. With this harness, you’ll be able to restore your car’s factory radio plug when it gets damaged.

Hence a damaged factory radio plug cannot prevent you from installing an aftermarket radio.

Stereo Relocation Harness

In many vehicles, the radio connects and interacts with some other devices in the vehicle. With this relocation harness, you can efficiently manage and transfer your stock radio without disrupting other functionalities.

It also allows you to replace your stock radio for an aftermarket radio easily. It allows you to do so without disabling any of the car’s functionalities.

Amplifier Integration Harness

The factory amplifier uses an amplifier Integration harness to support the speakers or subwoofer. When you install an aftermarket radio, it’s the integration harness that helps you connect the new radio to the inbuilt speaker system.

Amplifier Bypass Harness

A vehicle with an inbuilt amplifier that supports your speakers or subwoofer also comes with a bypass harness. It helps you deactivate the inbuilt amplifiers to install an aftermarket amplifier.

With this harness, you can also replace the inbuilt amplifier with the aftermarket receiver’s inbuilt amplifier.

Chime Retention Harness

These harness powers the car’s inbuilt warning system that chimes to alert you of vehicle issues. Such issues range from lights that are mistakenly left on to an insufficient oil reserve, and more.

This alert system can be deactivated when you replace the stock radio with an aftermarket radio. However, with the chime retention harness, you can install a new radio without disabling the chime alert system.

Premium Harness

This harness powers the specialty services for a car. The premium harness system also empowers warning chimes as well as the factory amplifiers.

All these various types of wire harnesses can be confusing. However, to gain more clarity about them, you may need to prune the bunch of wires in the harness. That helps to remove unnecessary wires to make the wire harnesses neater and more manageable.
Want to learn about how to rid a wire harness of extraneous wires? The next chapter shows you the steps.

 CHAPTER 4: How to Remove a Wire from an Automobile Harness

 Many wire harnesses come with additional wires that make them look clumsy or unnecessarily bogus. It’s a common practice to cut and insulate extraneous wires in a wire harness.

However, the best way to deal with unused wires is to disconnect the external pins keeping the unused wires in place. You can also come in need of replacing the wire harnesses when they’re damaged or suffering from electrical issues.

There is a wide variety of tools for removing pins from various types of plugs. These tools simplify the removal of the unwanted pins. Hence, they allow you to do the pin removal by yourself.

How to Remove Wires from an Electrical Harness

Open the hood and trace out the fuse block. The fuse block is usually found in the upper right corner of the engine compartment, close to the windshield. 

Disconnect the fuse block from the center bolt holding it in place. After that, separate the fuse box from the transmission and chassis harness as well as the entire engine.

Trace out bolts placed sideways along the windshield and remove these using a socket wrench. These bolts differ in lengths and sizes from one vehicle to another.

Moreover, in some vehicle, they’re replaced by the seam around the dashboard. In such cases, use a flat head screwdriver to rip open the seam around the dashboard carefully.

Next, remove the AC and ductwork by holding the tubing and severing it from the point where there’s a seam.

Two bolts run along the steering column around the wheel. Trace them out from underneath your dashboard, then remove them. Trace out all the other bolts fastening the dashboard and remove them.

After that, take down the dashboard to reveal the wiring running through the back.

Turn to the firewall hole and run a fragile, strong thread between the firewall hole and the engine compartment. Knot the end of the thread and attach it tightly to the end of the fuse block to enable you to pull it to disconnect the wiring with greater ease.

To make it easier to reassemble the wires, take pictures of the wiring or write down how the color combination of the wiring. Alternatively, you can also mark each wire with regards to their position.

Next, disconnect every wire from the back of the wire harness, and then pull apart the fuse block from the point where it connects with the wire harness. You need to remove any bolts or rubber sheath around the wire harness if there are any. If you don’t do that, you’ll not be obliterating the harness.

Alternatively,you can insert a pin extractor in the plug’s open end where you have the pin you want to remove. Press down the barbs that are fastening the pin by pushing down the pin extractor. Hold the wires as tightly as possible around the back of the pin. With the barbs still pressed down, carefully pull out the wire together with the pin.

So far, you’ve learned about managing automobile harnesses and keeping them neat and crisp. However, Use neat harness what benefits? Find out in the next chapter.

 CHAPTER 5: Benefits and Applications of Automotive Wire Harnesses

 

Applications of automotive wire harnesses

There’s hardly any vehicle where you can’t find an automobile wire harness. You’ll most likely find an automobile wire harness in either the engine, body, or chassis of the vehicle.

You’ll find the body wiring harnesses in the dashboard, interior electrical components, power windows, boot and bonnet locks, and so on. You’ll also find body wiring harness as parts of the air conditioning system, connectors, and dimmer switches.

The engine wiring harness usually runs through cruise control systems, lock braking systems, and speed sensors. Other parts where you can find the engine wiring harnesses include the battery cables, engine fans, and ignition systems. 

Moreover, the chassis wiring harnesses are usually comprised of the front, rear, and main harnesses.

However, each vehicle’s wire harness comes with a unique design that takes into account the electrical and geometrical peculiarities of the vehicle. For instance, heavy vehicles such as trucks and buses require different harnesses than those used in cars.

The Benefits of Automobile Wire Harnesses

Minimal Installation Time

With wire harnesses, you can install multiple wires in one go, instead of installing a wire at a time. Not only does this help reduce installation time, but it also eliminates the possibilities of errors.

When installing multiple wires prearranged in a single unit, the margin of error is reduced compared to attaching one wire per time.

Reduced Possibility of Short Circuits

An automobile wire harness combines multiple wires into a bundle unit. There’s, therefore, a lowered risk of short-circuiting in an automobile wire harness when compared to loose wires.

Greater Resistance to Extreme Conditions

One of the most outstanding advantages of wire harnesses is their enhanced durability. Wire harnesses comprise highly durable materials that stand up to heavy use and massive power loads.

Better Fuel Efficiency

You can use an automobile wire harness to enhance the fuel efficiency of your vehicle.

Enhanced Performance of Hybrid Cars

Automobile wire harnesses enhance the performances of hybrid cars, even under extreme weather conditions, making hybrid cars more reliable.

They have excellent capacities to withstand heavy power loads, extreme thermal conditions, and lousy electromagnetic noise.

However, there are no guarantees that every automobile wire harness you’ll be acquiring will deliver all these benefits. It all depends on the quality of the harness, and that leads us to the issue of automobile wire harness manufacturing.

 CHAPTER 6: Automobile Wire Harness Manufacturers

 The design and composition of an automobile wire harness depend on its intended function. The design and composition also depend on the type of vehicle that the harness will be used in. Manufacturers, therefore, produce wire harnesses based on customized specifications.

There’s, therefore, the need for excellent communication between the manufacturers and customers to minimize the possibilities of errors. You also need to keep close tabs on the manufacturer to ensure that they’re using only the best materials.

These materials must have excellent pliability and thermal capacities.

An excellent wire harness manufacturer tests harness at various phases of the production process. You need to check to ensure that the harness proves to comply with the latest industry standards in various tests.

Tips for Choosing the Best Automobile Wire Harness Manufacturer

Since there are numerous aspects to the fabrication of wire harnesses, you need to pay attention to many details. To help you avoid getting your wires crossed while choosing a manufacturer, here are some essential tips you should consider:

Emphasize on Excellent Communication

You can insist on frequent one-on-one meetings with the representatives of the company to avoid any misunderstanding. A company’s capacity to meet with your requirements goes beyond its engineering and manufacturing prowess, encompassing communication skills.

Seek Out Testimonials and Reviews

You need to be sure that the company has sufficient experience in fabricating harnesses similar to yours. Moreover, the best way to determine that is to investigate their track records and previous projects.

Create Sketches

With a detailed sketch at hand, it’ll be easier for you to communicate the specifications of your harness to a manufacturer. It can also help to provide the manufacturer with any relevant paperwork.

It is also advisable to put down as much as you can concerning the purpose of your harness in a paper.

Check for the company’s credentials: Certifications are imperatives when it comes to the fabrication of electrical and electronic devices. It is due to the relatively higher safety and performance requirements in electronics.

Some certifications that you should look out for when choosing a wire harness manufacturer include the CSA International, the UL Registration, and so on.

Consider the Environment Which Your Harness Will be Operating In

Environmental factors should be one of the main determinants of the appropriate material and designs for your automobile wire harness. These factors include sunlight, vibration, water, and so on.

It’s crucial for the company to take the presence of these factors into account during the fabrication processes.

Inspect the Fabrication Plant

It’s essential for you to ensure that the company has all the essential facilities. If the company outsources some parts of the fabrication processes, look into the arrangements and the parties involved.

 Conclusion

 A faulty automobile harness can wreak havoc in numerous ways. Safety and reliance are, therefore, two vital considerations that you must have in mind when looking to acquire an automobile wire harness.

We understand that there are many things to look out for when sourcing for a wire harness. Our production processes are designed to put you at ease, regardless of the unique requirements of your automobile harness.

We’re here to provide you with our automobile wire harness expertise whenever you’re ready for it.

Coaxial Cable-The Ultimate Guide to Choosing the Right One for You

Exclusive Bonus: Need Custom Coaxial Cable? Contact our support team today to get started  Quick click>>

We need to use coaxial cables in our homes or office for various video and audio installations. 

It also has widespread commercial use in the telecommunication, cable TV, and internet industry. 

Whether you are looking to use a coaxial cable for your home or want to make commercial installations, it is a good thing to know what you are dealing with. 

Click here to learn about our coaxial cable customization service.

If you want to dig into the coaxial cable, I think you can keep reading this guide. Let’s start.

Chapter 1: What Is A Coaxial Cable?

 Coaxial cables are used to transmit video, audio and voice signals by telecommunication, internet, and cable TV providers use coaxial cables to transmit video, audio and voice signals. It is also widely used in homes to connect DVD players, speakers, digital cable set-top boxes and similar applications.

The specialty of the coax cable is that it can ward off external interferences and transmit a strong signal without loss of quality. The wires have a central metal core, generally made from copper and an outer insulating layer.Over it, a layer of conductive shielding made of foil or copper mesh is applied, and then another external insulation is provided.

Generally, coaxial cables have a female connector at one end and a male connector on the other side for making a connection. That is how it looks like:

The internal view of a coaxial cable

Now let’s explore the different types of coaxial cables and their application.

 Chapter 2: The Types of Coaxial Cables

 

2.1 Digital Coaxial Cable

The digital coaxial cable is similar to RCA connector in looks, but it carries digital signals instead of analog ones. The thickness of the digital coaxial cable is higher than ordinary connecting wires because it comes with shielded foil or mesh to shield the interference of signals.The cables also have a higher bandwidth so that it can carry the digital signals efficiently.

You may not be able to tell the difference between a standard cable and the digital coaxial cable just by looking so better enquire what you are buying.

2.2 Coaxial Digital Audio Cable

Coaxial digital audio cable is necessary to connect two audio sources. You can connect your laptop or computer to the amplifier and transmit digital audio signals between the two devices. There is a male RC jack fitted at both ends of the cable.

You can connect the cable to the sources on either side. Unlike analog audio cables, only one wire is needed to carry the audio signal in coaxial cables. Generally, coaxial digital audio cables come with a rating of 75 ohms so that it can transfer the signals efficiently.

The end of the cable might be color-coded in orange or black for convenience.

You should use a digital coaxial cable for your audio needs as RCA cables suffer from loss of quality as the length increases and absence of shielding. That being said, coaxial digital audio cables are a bit more expensive than RCA cables but worth it!

Coaxial digital audio cable

2.3 75 Ohm Coaxial Cable

75-ohm coaxial cables have an impedance of 75 ohms.

Ohm is used to measuring resistance which is generated by the flow of electrical signals inside a circuit.When we are transferring DC through the circuit ohm is used to measure the strength. However, in the case of AC, ohm represents the impedance.

75 ohm and 50-ohm coaxial cables are used for standard applications and are used as industry standards. 75-ohm coaxial wires are ideal for sending signals through the cable effectively without losing the signal strength during the process.The cable is commonly used to connect cable TV receiver boxes, satellite TV, FM/AM radio receivers, high definition TVs and police scanners.

You can also find the 75 ohm cable in case of coaxial digital audio cables.The capacitance and low attenuation also makes it ideal for any kind of digital video, digital audio and data signals.

2.4 White Coaxial Cable

The white coaxial cables come under the purview of RG6 category. It is equipped with a thick conductor and comes with a larger dielectric. You can also find better quality of braid and foil in the cable for effective transmission of signals.

White coaxial cables are used as the industry standard for internet, satellite and cable TV. You can also achieve a better result in appearance as white color of the wire easily blends in with your interior décor or wall colors. It also produces less remarkable results when wired around trims or ceilings.

2.5 TV Coaxial Cable

You can use the TV coaxial cables to connect TVs, satellite dishes and VCRs and current RF aerials. The coax cables come either as male to male connectors or male to female connectors.You should check out the type of connections your TV and cable boxes have to decide which one you need.

Generally, the TV coaxial cables will have an impedance of 75-ohm for better signal transmission. The connectors are gold plated or silver plated in a bid to improve the quality of transmission.The length of the cables is usually short and you the regular TV coaxial cables are 10 meters long.

TV coaxial cable

2.6 Coaxial Audio Cable

Coaxial audio cables are used to establish audio connections between two sources such as DVD or CD players, media players or turntables and speakers and amplifiers. Coaxial audio wires transmit digital signals from one source to another.

The cables are generally hardwired and use copper wire with a shield around it. They are quite durable, and both ends are fitted with RCA jacks for connection. Usually, the audio coaxial cables are short in length to maximize the signal strength and start to lose signal as the distance increases.

2.7 RG6 Coaxial Cable

The RG6 coaxial cable is required for a wide range of commercial and residential purposes.The term RG6 is applied to different types of coaxial cables which differ in the composition of the internal conductor, shielding material, and kind of dielectric.

This kind of cable is derived from military use which refers to Radio Guide. The six is used for covering to the sixth page of the guide where the information was located.The term RG is obsolete and used to refer to coaxial cables with 75-ohm impedance and 18 AWG center.

You can find the most common use of the wire for cable TV installations. The wire can be used to route and distribute cable signals to home and within it. And it has been chosen as an industry standard for cable TV connections taking the place of RG59 cables in the recent past.

Generally, the cable has a steel center conductor coated with copper and features aluminum braids or foil with around 60% coverage.

The cable is also used for professional video applications. The conductor is generally made of solid copper and features a heavy shielding of up to 95% with aluminum foil or copper braids.The cables can transmit a serial digital interface (SDI) signals or baseband analog video signals.

The tolerance of the cables is heavily controlled to enhance the stability of impedance.The wires have a different type of connectors fitted at both ends, and you need to choose them based on your purpose. They can have BNC connectors, F connector and also RCA plugs.

It is also suitable for CCTV connections and have heavy shielding.

2.8 100 ft Coaxial Cable

You may need a 100 ft coaxial cable for commercial use or at home depending upon your purpose.can be used for a wide range of audio and video applications are come with different connectors for greater versatility.

The cables are made durable with strong shielding so that they can resist wear and tear. You can use them to connect yours over the air satellite dish with your TV or for distributing cable TV connection between different rooms in your home. The conductor is also made of copper so that signal is carried on effectively without significant loss.

1oo ft coaxial cable

2.9 Flat Coaxial Cables

You can use a flat coaxial cable instead of the round shaped one for specific purposes around your home or office.The different types of coaxial cables may come in flat shape whether they are RG6 cables or digital audio cables.

You can use the flat cables if you don’t want to drill holes in the wall. They are also convenient when you place them under your window sash or the door jamb. You can find different connectors fitted at the ends for various applications.

Flat coaxial cable

Coaxial Cables used for Cable TV

Today the cable TV industry uses two types of coaxial wires in most installations.The most popular choice is the RG6 coaxial cables which are used commonly in homes to connect cable TV receiver boxes with televisions and the main line. 
You can also use the 75-ohm coaxial cables for cable TV installations as it is the industry standard. The two types of coaxial cables are also ideal for connecting satellite dishes with television sets. You can use any of the wires for video installations.

Now that you have got to know about the different types of coaxial cables let’s take a look at how to set them up in the next chapter.

 Chapter 3: How To Splice Coaxial Cables?

 Splicing a coaxial cable is an easy job if you have got the right tools. You can also do it without tools but the process it a bit more taxing. Let’s find out how to splice coaxial cables using tools available at your local hardware store. You need to arrange the following tools for the job-
  • A coaxial cable stripper (compatible with your coax cable)
  • Compression connectors (matching the input of the device you will be using)
  • Splice adapter or barrel connector
  • Compression tool
  • Extra coaxial wires (if you are extending the length)

It looks like you have gathered the required tools. Now let’s take a look how to go about splicing your coax cable.

1. Strip the coaxial cable with the coaxial cable stripper

Insert the terminated end into the coax cable stripper. Ensure that the end of your wire aligns with the guide on the stripper tool. If you don’t align it with the guide, then the lengths of coaxial cables being spliced will not be uniform.
Now rotate the cable stripper around the cable for few times and check to see if it is done.Remove the stripper tool and slowly pull off the end of the cable from the cut. You will be able to see the inner conductor in the center of the wire.

Fold the wire mesh or foil around the edge so that they don’t interfere with the core. Make sure to hold all the wires or mesh as any left dangling will interrupt the signal transmission and quality.

Repeat the process with the other end of the coaxial cable too.

Coax cable stripper

2. Insert the compression connectors

Insert the compression connectors over the insulated edge and ensure the metal core is not damaged.The metal core should be sticking out of the connector once it is placed.

Insert the other compression connector carefully in the same way on the other end of the coaxial cable.

3. Use the compression tool to compress the connectors

Keep the compression connector in place and put it inside the compression tool. Now apply enough pressure to crimp the ends of the connectors.

Do the same thing with the other connector at the other end of the cable.

Compression tool

4. Use the splice adapter or barrel connector

Insert both ends of the coaxial cable in the barrel connector so that the metal core enters the female jacks on both ends. Push the collar of your cable connector tightly in the barrel connector to get over with your job.

Coaxial Cable Signal Booster

You can install coaxial cable signal boosters which enhance the quality of the signal transmitted by the cables. The amplifiers can be used for your TV to antenna connection, satellite dish connection and for improving cable TV distribution in your home.
There are different types of amplifiers available, so you should check whether it is compatible with your installation before purchasing.

Coaxial Cable Splitter

Coaxial cable splitters are small connecting devices that have a single input and several outputs.For example, you can connect the cable line into the splitter and connect multiple television sets using the outputs.
Generally, you can buy two-way cable splitters and four-way cable splitters from your electrical store.

Coaxial cable splitter

Coaxial Cable to HDMI

Coaxial cables may not be compatible with modern high definition TV sets equipped with an HDMI port. You have to use a six-sided plug to fit in the input. However, you can convert coaxial cable to HDMI by using a powered adapter available in electronic stores. 
You have to connect the coaxial cable carrying the signal in one port and the HDMI cable to the other port.

Wireless Coaxial Cable Transmitter

You can get a wireless transmitter for your coax cable for distributing TV signals. Generally, it comes with a receiver and wireless transmitter along with a power adapter.

We have to connect the cable TV into the receiver box while the TV will be plugged into the receiver. This way you can transmit the TV signals wirelessly.

Now that you have a good idea about how to splice your coax cable and use different tools, so let’s increase your knowledge on the subject a bit!

Wireless, coaxial cable transmitter

 Chapter 4: Extending Knowledge of Coaxial Cable

 

4.1 Best Coaxial Cable

RG6 coaxial cables are the best and industry standard for home and commercial use. They have a high dielectric with a thick conductor and come with improved mesh and foil.

You can also go for the quad-shielded RG6 coax cables which have extra coatings of foil and mesh to prevent any outside interference. These are suitable for homes located near police stations, fire departments, TV stations, and airports.

RG6 is also the best choice for cable internet as it has enough protection for active transmission of signals.

4.2 Coaxial Cable Adapter

Coaxial cables are not suitable for bending around corners or sharp angles as it may damage the wire. You can use coaxial cable adapters to prevent such damage. 
Various adapters are available in the market such as 90-degree adapter which has a male jack at one end and a female connector on the other end.

You can insert the coaxial cable ends matching the jack of the adapter and lay your cable without any worries.

90-degree coaxial cable adapter

4.3 Target Coaxial Cable

You can purchase a wide range of coaxial cables from the Target store. The wires are ideal for use at home for internet or cable TV or for connecting other devices. You can also find commercial coaxial cables at Target.

4.4 Outdoor Coaxial Cable

Satellite dishes, cable TV or internet installations might need the outdoor use of coaxial cables.Sometimes you will also need to bury the wires underground to make connections.

Outdoor coaxial cables are weather resistant, and you can expose them to rain or sun. They are also ideal for underground connections and won’t let moisture in. The cables also feature heavy shielding to prevent any outside interference with the signal transmission.

4.5 Coaxial Cable Amplifier

Coaxial cable amplifiers are small devices which boost the signal transmission of your cable TV or internet. You have to put the source cable in one end of the device while the other terms connected to the devices. It can be found in general electronic stores.

We have given you a thorough understanding of coaxial cables and how to work with them.Now let’s see where you can buy them along with a few buying tips!

Coaxial cable amplifier

 Chapter 5: Where To Buy Coaxial Cable

 We will start off with a few tips on how to buy coaxial cables.
  • High-quality coaxial cables don’t necessarily mean they have to be expensive
  • Search for wires that have a screw-on connector than push on connectors
  • Cables with compression connectors last long and don’t cause RF leaking
  • RG6 cables are one of the best options to buy
  • Quad-shielded cables are best for stronger signals
  • Here’s how it should look:

RG6 coaxial cableYou can also order custom coaxial cables from us, and we will customize it to meet your needs. We can produce coaxial wires with customizable connectors, shielding, connecting core and other elements.

Conclusion

 Coaxial cables are standard around the household and also used for commercial purposes. Whatever be your installation type- cable TV, internet, CCTV, other audio video applications- you know which coaxial cable you will need for the purpose.

We manufacture high-quality coaxial cables and customize it accurately according to your specifications. Get your coaxial cable from the industry leader.

Wiring Harness: The Ultimate Custom Guide

Exclusive Bonus:Need a custom harness? Contact our support team today to get started  Quick click>>

Has it been quite hard for you to make a custom wiring harness for your wiring project?

Do you want the expert’s knowledge on making a good custom wiring harness?

Just one read of this article will make you a professional wire harness designer.

We’ve covered extensively in this article all you need to know about wiring harness, the components required for a successful cable harness design and a step-by-step guide on how to make a custom wiring harness for your trailer, car stereo, and engine.

Get ready to become a professional custom cable harness designer.

CHAPTER 1: Everything you should know about a Wiring Harness

 A wiring harness is a systematic bound of electric wires, which send signal and power to different points in an electrical system. The bounding of these electric cables is done using straps, electronic tapes, wire lacing and so on.

A wiring harness is always designed according to the application or the specifications of the electric system in which it’s needed. Over the years, there have been several developments and uses of cable harness.

The following industry uses a lot of wire harnesses for their solutions, this includes:

  • Automotive,
  • Medical,
  • Telecommunications,
  • Acoustic,
  • Military and Electronics.

All these industries have specific needs, based on the designs, environment, electrical load and so on, therefore, there is a need to make custom cable harness designs for every application.

Instead of connecting different cables through different points in an electric system, a cable harness can only be designed for the system.

The advantages of using a wire harness over loose cables are numerous;

  • reduced installation time;
  • optimum space management;
  • easy maintenance;
  • prevention of short circuit, and security from effects like vibrations, moisture, and abrasions.

With all these in mind, let’s start our journey of helping you make your custom wiring harness.

What are the things you need??

CHAPTER 2: Things you need to make your custom Wiring Harness

 Before making your custom wiring harness, the first and most important thing to have is a design or wiring diagram.

This diagram is what will lead you to measure wires, cutting and stripping wires, bounding the cables, etc. In the next chapter, we’d look much more into using the wiring harness diagrams.

Asides the diagram, the following tools are needed in making a wiring harness.

  1. Wire Cutter: used to cut the wires;
  2. Wire Stripper: used to strip off some part of the insulation of a cable;
  3. Crimping Plier/Ratcheting Crimpers: used to tighten the terminals to the stripped wires;
  4. Heat Gun: uses high temperature to shrink the covering plastic tubes to the body of the cable;
  5. Multimeter: used to test for continuity and other parameters within the wiring connection;
  6. Heat shrink: a soft plastic used as a covering for connection joints;
  7. Wires: connecting wires for the flow of signal/power from the source to the needed terminal;
  8. Terminals: a plastic body with a conducting head that makes contact with the bare/stripped wire;
  9. Zip Ties: used to bundle the wire harnesses neatly.

This equipment varies on a large scale production of wiring harnesses.

There are now fully automated machines that take care of the whole process from the wire cutting, stripping, crimping and joining terminals, etc.

These machines have correct and efficient outputs, ensuring there are no loose ends or short circuit.

That’s why we at Cloom use the fully automated machines for all our custom wiring harness.

Like I said earlier, to make your custom wiring harness, you must first have a circuit diagram.

Let’s look in details, why and how to use one.

CHAPTER 3: How to use a wiring harness diagram?

 The circuit design/diagram is very foundational to make a custom wiring harness successfully.

Everything you have to customize in your cable harness comes from a well-designed wiring diagram.

Please note, the wiring diagram is entirely different from a schematic diagram.

A wiring diagram gives a physical layout of the connection, unlike the schematic diagram.

However, it also makes use of abstract symbols to represent some components.

You can tell from the wiring harness diagram how complicated or how pure your custom wire harness would be.

Ideally, every cable harness circuit diagram will have the following;

  • Symbolized components,
  • Optimum positioning,
  • Splice positions, and Wire colours.

Whatever you see on the wiring harness diagram is a representation of what and how the wire bundling will look.

If you don’t have a wiring diagram, you would need to consult an expert to design the perfect wiring diagram for your application.

This video would be a helpful link:

Once you’ve got the wiring diagram and components ready, these are the possible types of harnesses you might be making, so take note to identify it.

CHAPTER 4: Types of Wiring Harness

 Two major factors determine the type of wire harness to make.

Firstly, the application, secondly, the environment. Based on these two factors, there are 3 types of cable harness that you can make.

They include:

Open Bundle:

in this type of wiring harness, the cables are attached to the connectors and lugs and are coupled in bundles with various breakouts using plastic tie wraps or waxed lacing twine.

Closed Bundle:

Wires are bundled with a covering, such as pulled-on braided tubing, braided-on Nomex or nylon, or in some cases, metal braid.

Waterproof harnesses:

Legs are covered with tubing, such as neoprene. The junctions between the legs and backshells of the connectors are molded with a material such as urethane or rubber compounds.

In some cases, PVC tubing and molding are used.

Curled from CONNECTOR SPECIFIER magazine.

Enough of theory, let’s get our hands on, you can follow the instructions below and the shared links to customize your trailer, car stereo, and engine harness.

CHAPTER 5: How to custom Trailer Wiring Harness?

 

Step 1:

To make a custom trailer wiring harness, you first have to come up with an intended design based on the geometric and electrical requirements of a trailer. This design should be represented on paper so you can easily refer to it.

Step 2:

After putting down the design, you cut the wires into desired lengths using a wire-cutting machine/cutter.

Step 3:

When making the design of a custom trailer wiring harness which would usually be fixed on a towing vehicle, you have to consider the requirements of the trailer; This includes powering the operating lights on the container which are the turn, tail, stop, park and brake lights and other electrical parts of the trailer depending on the trailer. Take note of this process mentioned to ensure the towing vehicle is in total control of the electrical elements of the container.

Step 4:

When purchasing wires to use for a custom trailer wiring harness, you have to ensure your cables can withstand fire, abrasion, vibrations, corrosion and extreme temperatures. One way to ensure this is by getting heat-shrink collars galvanized wire clips to make the wires firm and straps to pack the cables together.

Step 5:

After knowing the electrical requirements of the trailer and getting suitable wires, the next thing is to make the connections to the guiding lights ensuring you work on one view (circuit) at a time. Connect connectors on one end of the wiring harness to the part designed for it on the towing vehicle and the other purpose to the trailer lights accordingly.

Step 6:

After making all the necessary connections, you then tidy up the wires using the clips, collars and straps talked about earlier so that the cables don’t just dangle around when driving. The most advisable is to tape the wires together using the straps to hold it in one place.

Step 7:

Put your wiring harness to test. If you encounter any problems, you can refer to this video to troubleshoot it.

Let’s move on to car stereos.

CHAPTER 6: How to make custom Stereo Wiring Harness?

 The function of a stereo wiring harness is to transmit audio signals.

Step 1

To make a custom wiring harness for a stereo, you have to consider the stereo port and pins in it. Check the pins in it and find out the function of each of the nails; This varies from stereo to stereo, so it’s best if you search for your particular radio on the internet to know each pin’s functions.

Step 2

After getting this, then you get wires suitable for audio transmission. The quantity of cable you will get depends on the number of pins in the port and the distance over which the wiring harness is meant to connect.

Step 3

Then you get a connector which has pins that match the stereo’s port. Solder the wires accordingly to these pins ensuring that the pins don’t touch each other in the process; This can be achieved by insulating each connection with a piece of heat shrink.

Step 4

After soldering wires to all the pins required successfully, the next thing is to get female A/V jacks. These can be obtained from electrical stores. Solder the wires to the female A/V cords accordingly taking note that the outside metal of the A/V jack is harmful while the inside is positive.

Step 5

After this, use a multimeter to ensure that all the connections are right and connected.

Step 6

After ensuring the connections are correct and working, make the relationships strong and durable by melting the plastic on each link using a glue gun. After this, recheck the connections to see if they are working with the multimeter.

Step 7

Lastly, bind the wire together using wire straps to make it firm and neat. Your custom stereo wiring harness is ready.

Step 8

Put your wiring harness to test. If you encounter any problems, you can refer to  this video to troubleshoot it.

To the last DIY project, the engine wiring harness; This can be quite tasking though, but we believe in you.

CHAPTER 7: How to make custom Engine Wiring Harness?

 Making a custom engine wiring harness depends on the engine in question and the function it’s to perform;This would determine the structure of the wiring harness.

Step 1

Highlight the function of the wiring harness in the engine. It’s essential to draw out a plan then and list out the parts and materials needed.

The wire specifications would also depend on the engine and the function the wiring harness is to perform.

Step 2

Basically, for engine wiring, relays are always used. You start by attaching the wires to the relay accordingly. After wiring the relays, you mount the relays and then create a switch and route the switch harness from the relay to the switch location accordingly.

Step 3

After making the switch connections, route the wiring towards the engine part and also make the connections there accordingly.

Step 4

After all the connections have been made, ensure the connections working using a continuity checker.

Step 5

After this, tape the wiring together to make it firm and stable; This can be achieved via various means like using wire straps or electrical straps. After taping them together, secure the wiring harness away from moving engine parts.

Step 6

Put your wiring harness to test, and if you encounter any problems, you can refer to this video to troubleshoot it.

Clear, right?

If you bother to know, this is how our experts at Cloom make the customwiring harness solutions to companies all over the world.

CHAPTER 8: How we Custom Wiring Harness in Cloom?

 To customize a wiring harness to suit your applications, our design experts follow the following steps meticulously.
  1. We understand the specifics of your system and applications of the wiring harness to be made; This will help us determine the type of wires, kind of insulation, connectors to use, and so on.
  2. We get your detailed circuit drawing for the electric system to be wired. Our design experts can also make a professional wiring circuit drawing for you.
  3. Using state of the art equipment and technical expertise, we design a prototype set of wire harnesses for your desired system, to suit the applications, resistance, and all other specifics.
  4. We test the accuracy, efficiency, and functions of the cable harness with the aid of a state-of-the-art test board.
    This way, only A+ solutions are produced for any application you might need.

Cloom, your most reliable wire harness and cable assemblies manufacturer, has professional expertise and latest technologies for offering excellent custom wiring harness.

We have more than adequate experience in Electronics wiring harnesses, Power cables, Signal wiring harness, and Automobile wiring harnesses.

Conclusion 

 Worth the read, right? We hope you can now boldly say I’m a wiring harness professional.

You can send us an inquiry for the custom wiring harness you need and we’d reach you promptly.