Custom Cable Assemblies – Construction and Uses

The mess of wires behind our TVs or desktops has probably overwhelmed some of us once or twice. In many industries, it’s crucial that these cables be better organized. This is where cable assemblies come into play.

Custom cable assemblies can also be known as wire harnesses, wiring assemblies, or wire looms. Regardless of what they are called, they are basically a grouping or wires or cables that transmits electrical power or signals. By binding these cables together, the assembly prevents disruptions in the signal that could be caused by moisture, fire, vibration, abrasions, or electrical malfunctions or shorts.

How They’re Made
Custom cable assemblies can made using a variety of different casings – after all, they are custom. These casings include sleeves, electrical tape, braiding, straps, cable ties, a weave of extruded string, or a combination of any of these materials. The purpose is always to increase the efficiency of the products. The assemblies are designed according to very specific electrical and geometric requirements, which are translated into a diagram used during production. After the wires are cut and labeled, they are stripped to reveal their metal cores, put together using terminals or connector housings, and then fitted with protect sleeves.

The process is typically done by hand because of how intricate it is. After construction, technicians use electrical test equipment to test the assemblies. They check for electrical functionality with a pre-programmed circuit tester. If the assembly doesn’t perform well, it will have to be remade.

Common Uses
Cable assemblies are commonly used in LED lighting systems, solar inverter systems, oil refinery safety equipment and more. It’s also used quite commonly throughout the automotive industry. Examples include brake lights, power windows, power door locks, ignition systems, air conditions, and battery cables.

Safety Features
As previously mentioned, assemblies prevent cables from moving around and being exposed to the dangers of the world. This is incredibly important in applications like cars, because protecting the cables from moisture, heat, abrasions, and more decreases the likelihood of electrical malfunctions, which could be deadly to whoever is operating the vehicle and other people on the road.

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