Custom Designed Audio Cable Assembly for Telecommunication Client

Consolidated Electronic Wire & Cable collaborated with a customer’s engineering team to design and develop a product that fulfilled their requirements for a high-definition audio/video pullout cable assembly.

TelecommunicationClientPortfolio-retouchedFeaturing HD-XLR, RCA and custom-molded DB connectors Consolidated designed a stronger, better designed, and less expensive assembly than our competitor.

To meet the client’s performance requirements, Consolidated Electronic Wire & Cable engineered strength mechanisms into the complex cable assembly so that it could be pulled by the cord without losing a connector. Given the demands that would be placed on the product, we used an extra durable, high-quality jacket insulation suitable for high-end telecommunications.

homethumb-molded-cablesThe customized cable wire assembly, which has an outside diameter of .333”, has 7 unshielded coaxial conductors and 19 shielded coaxial conductors. It meets tolerances of +/-10%, withstands temperatures of -40oC to 80oC and has a 300-volt rating.

We performed cable performance and conductivity tests and worked within an 8 week lead time to deliver 2,000 units a month to our customer.

To learn more about this project, or for more information on our other products and services, please contact Consolidated Electronic Wire and Cable.

Custom Cable Assembly Project Details

Product Description

High Definition Audio/Video Pull-out Cable.

Capabilities Applied/Processes

Cable Fabrication Services

Equipment Used to Manufacture Part

MODEL 30-150 Cable Extrusion Machine
Videojet Ink Jet Printer
Artos Stripmatic

Overall Part Dimensions

Wire Diameter: .Nom. O.D.333"

Conductors: 19 Shielded conductors
7 unshielded conductors
26 AWG (19 x 38) Tinned Copper Wire
Annealed Bare Copper Wire
Insulation: .009" Wall Thickness
Polyester / Aluminum Foil Shield over 7 unshielded conductor core
Overall Polyester / Aluminum foil shield
PVC (Polyvinyl chloride) Jacket

Tightest Tolerances

±10%

Material Used

26 AWG 19 Shielded Coaxial Conductors + 7 Unshielded Coaxial Conductor PVC Jackated Cable
Jacketed Cable
One (1) 44 position D-Sub Connector
One (1) 9 position D-Sub Connector
Twenty (20) BNC Female Connectors
One (1) Ferrite Core
One (1) Custom Label

In process testing performed

Cable and conductivity testing

Features

Withstands Temperatures from -40ᵒC to 80ᵒC
300 Volt Rating
Consolidated Electronic Wire & Cable engineered strength mechanisms into the complex cable assembly so that it could be pulled by the cord without incurring the loss of the connectors. Extra durable, high jacket insulation for high performance telecommunications.

Industry for Use

Audio / video telecommunications

Lead Time

8 Weeks

Quantity

2000 Units per month

Delivery Location

Canada

Standards Met

UL
CSA
RoHS

Product Name

Custom Communication Distribution Cable Assembly