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Cable and Wire Harness Assembly

Cable and Wire Harness Assembly

Cable and wire harness assembly comprises a set of wires, cables, as well as subassemblies, which are designed to supply power in industrial applications. A cable assembly usually features two ends, while the wire assembly may feature multiple ends, which run in multiple directions. At Suntronic, we specialize in the manufacturing of complex cable harness assemblies and wire harness assemblies. Our cable and wire harness assemblies are widely used in various industrial applications such as automotive and military. All manufacturing is performed in-house at our well-equipped facility by leading industry experts. This helps us assure quality, repeatability, and performance.

Cable and Wire Harness Assembly Capabilities

We use advanced assembly techniques and design software like CAD to convert layout ideas into performance-centric product drawings. We believe the following wire and cable harness assembly capabilities that we have built over the years have helped us serve our clients better.

  • Types of cables and harnesses: We regularly manufacture the following types of cable and wire harnesses.
    • Flat Ribbon Cable Assemblies: Flat ribbon cables, also known as planar cables, offer a versatile and convenient way to connect electronic components and devices. Flat cable assemblies are made up of rows of flat wires that are parallel to each other making them easy to route, providing a high degree of flexibility. Flat ribbon cables are thin and flexible, makin them ideal for use in a wide range of applications such as computer and telecommunications equipment, office machinery, and consumer electronics.

      Flexible flat ribbon cables have a variety of applications in technology and offer several advantages over other types of cabling. Here are the top features of these types of cable assemblies:

      • They are easy to work with and ideal to install because they are lightweight and flexible due to having a larger bending amplitude.

      • They offer a high degree of conductivity, making them ideal for applications where signals need to be transmitted with minimal loss.

      • Flat ribbon cables have a smaller footprint than other types of cables, which saves valuable space in your equipment racks.

      • They are available in various configurations and can be customized to meet specific needs. Some of the main customization options for flat ribbon cables include the number of conductors, the pitch of the conductors, the type of insulation, and the overall length of the cable. You can also choose to have your custom ribbon cable assemblies printed with your company logo or other markings.
      • They have fast heat dissipation which helps to minimize operating temperatures.
      • Flat ribbon cable assemblies are designed to have a uniform stress distribution across the length of the cable. This ensures that the risk of conductor breakage is minimized, and that the cable will perform reliably in its intended application.
    • RF Cable Assemblies: RF cable assemblies are used in various applications where it is necessary to transfer radio frequency (RF) signals from one point to another with minimal loss. RF cable assemblies typically consist of a coaxial cable with connectors on each end. The connectors allow the RF cable assembly to be connected to RF equipment, such as radios and antennas. RF cable assemblies are key components in various electronic devices and systems. They are used in everything from computer networks and cell phone towers to satellite dishes and medical equipment. RF cable assemblies are also used in many military and aerospace applications.

      Some of the top features of RF cable assemblies include:

      • RF cable assemblies have a very low loss, which means that they allow signals to travel through them with very little interference.
      • These cable assemblies can support high frequencies, which means that they can be used in various applications.
      • They can help protect against electromagnetic interference (EMI), which can cause interference in electronic systems.
      • They are designed to be durable and withstand harsh environments.
      • These cable assemblies are available in various sizes and configurations to meet the needs of any application. Being one of the leading RF cable assembly manufacturers, we at Suntronic offer custom RF cable assemblies in various connectors, lengths, and colors.
    • Shielded Cable Assemblies: Shielded cable assemblies are designed to offer superior protection from electromagnetic interference (EMI) that can interfere with the proper functioning of electronic equipment. EMI can cause data loss, signal degradation, and other problems. Shielded cable assemblies are manufactured with a metal shielding that surrounds the inner conductors. This shielding helps to deflect or absorb the electromagnetic waves that can cause EMI. As a result, shielded cables are able to provide better protection from EMI than non-shielded cable assemblies. Shielded cable assemblies are used in various electrical and electronic applications where noise prevention or interference is a concern. Common examples include; computers and other digital devices, audio and video equipment, telecommunications systems, control systems and instrumentation.

      Here are the top features of our custom shielded cable assemblies that make them the best choice for your cable assembly needs:

      • Shielded cable assemblies can help protect your equipment from electromagnetic interference (EMI), which can cause data loss and equipment damage.
      • They can also help to reduce crosstalk between wiring, which can improve the quality of your communications.
      • Shielding helps to reduce interference from electromagnetic and radio frequency signals, which can result in better signal quality.
      • The extra layer of protection provided by the shield can help improve the overall strength and durability of the cable.
      • Shielded cables are often more flexible than unshielded cables, making them easier to work with in tight spaces.
      • Shielding can help to improve the temperature performance of a cable, making it less susceptible to degradation in high heat environments.

In addition to the above, we also design and manufacture the following types of cable and harnesses

    • Coaxial cables
    • Fiber optic cable assemblies
    • Synthetic and stainless steel cables
    • Electromechanical assemblies
    • FEP, ETFE, and PFA – wires and cables
    • Halogen-free cables
    • Custom cable harnesses
    • Passive component-to-wire
  • Components: We manufacture complex cable harness assemblies with the following components:
    • Wires
    • Shrink Tubing
    • Wire Ties
    • Wires
    • Shielding
    • Connectors
    • Strain Reliefs
    • Molding
    • Clamps
    • Clips
    • Terminals
  • Materials We Work: Our advanced manufacturing capabilities enable us to work with a wide range of materials that meet your specific application requirements.
    • Thermoplastic elastomer (TPE)
    • Polyvinylchloride (PVC)
    • Thermoplastic polyester elastomer (TPEE)
    • Polyurethane (PU)
    • Silicone
    • Polytetrafluoroethylene (Teflon)
    • Thermoplastic vulcanizate (TPV)
  • Conductor Insulation: The choice of the right insulation material is important for protecting your cable and wire harness assembly from environmental factors. Our experts choose these conductor materials based on factors such as abrasion resistance required, flexibility, protection from environmental factors, and so on. Silicone, PTFE, TPE, and PU are some common materials that we regularly work with.
  • Ends: We can provide cables and wires with the following ends:
    • Cut
    • Lug
    • Tinned and Stripped
  • Conductor Sizes: We can easily extrude conductors as large as 12 gauge and 34 gauge. The following are a few common conductor sizes we work with:
    • 12 awg
    • 14 awg
    • 16 awg
    • 18 awg
    • 20 awg
    • 22 awg
    • 24 awg
    • 28 awg
    • 30 awg
    • 32 awg
    • 34 awg
  • Assembly and Processing Capabilities: The following assembly and processing capabilities allow us to serve our clients better.
    • Crimping
    • Cutting
    • Stripping
    • IDC and Modular Crimping
    • Wire Bundling
    • Wire Twisting
    • Labels
    • Form Board Layouts

Wire and Cable Harness Assembly Testing Procedures

Wire and cable harness assemblies are manufactured for use in various complex applications. Thus, the wires within these assemblies undergo functional testing to ensure their performance, safety, and reliability when used in an application. The wire and cable harness assemblies are subjected to the following tests to ensure their excellent performance.

  • Visual Testing: This is the most basic level of testing performed by our experts. Under this, they examine the wires and cables for signs of damage, which may occur during any phase of manufacturing. In addition to this, they also inspect connectors and sockets, examine enclosures to ensure they are secured safely, and check if the assemblies comply with the specifications of applications, and so on.
  • Electrical Testing: The cables are tested for shorting, incorrect wiring, and open wires. All these tests are performed at once by linking the connector assembly and an electrical fixture using a mating connector.
  • Signal Integrity Testing: In this type of testing, the cables and wires are tested for their signal integrity. It means, they are tested for their efficiency to maintain signals in an application. Crosstalk, error testing, and signal strength testing are a few common types of tests conducted here.
  • Environmental Testing: Cable and wire harness assemblies are used in various applications, indoors and outdoors. These cables and harnesses may be exposed to a wide range of environmental conditions such as high temperatures, salt fog, saltwater spray, condensation, and so on. Thus, cable and wire harnesses used in these conditions must withstand these conditions, else, they may be subjected to degradation, premature aging, as well as accelerated corrosion. We perform various environmental testing on regular and complex wire and cable harness assemblies.
  • Mechanical Testing: The cables are tested for their mechanical properties to ensure they meet the requirements of an application. In this testing, our experts test cables for their tensile strength, elongation, impact and crush resistance, and so on.

Benefits of Choosing a Wire and Cable Harness Assembly from Suntronic

Owing to their utility in all regular and high-end electronic applications, today, it is quite easy to find several manufacturers specializing in them. However, the following benefits offered by our assemblies make them popular with our OEM clients.

  • We assure the highest level of customizability to support specific functions required by different applications.
  • These cable and wire harness assemblies can be availed in unlimited combinations to meet complex requirements.
  • They are designed with multiple interconnects, which assure speedy installation time.
  • These wire and cable harness assemblies assure safety by consolidating the dangerous electrical wiring.
  • Made of high-quality materials, these harnesses enable customers to protect their cables from bending or tangling, and also from harmful exposure to environmental elements.
  • Being a leading cable assembly manufacturer, we can provide sleek cable and wire harness assemblies that allow customers to save space inside the electronic applications.
  • Our high-quality interconnect systems meet IPCA620 standards.
  • We have invested in advanced systems that can perform automatic stripping, termination, as well as testing that allows us to assure efficiency and quality in all products that we ship.

At Suntronic, we treat each project equally. We regularly process repeated orders for standard cable and harness assemblies, as well as the ones with complex designs. For us, there are no standard or complex requirements. All requirements are equally important. We specialize in the pcb assembly and layout of various types. Feel free to get in touch with our experts today to discuss your requirement for complex cable harness assembly. They will work closely with you to develop cable and harness assemblies that meet your requirements and assure you the best value for investment.