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Category Archive: Cable Assembly

The Return of Willy the Wire

Our customer favorite Willy the Wire has returned in this exciting video to provide more insight into the inner workings of Consolidated Electronic Wire & Cable. In this adventure, Willy takes us on an enlightening tour through our facility, where he provides fascinating insights into our custom capabilities. He also walks viewers through each step of our project process for a fascinating overview of our internal operations and project processes.

Our Custom Capabilities

Welcome to Consolidated Electronic Wire & Cable, where our teams of seasoned experts provide an extensive range of wire and cable products. We are pleased to offer services ranging from simple wire cutting and stripping to total custom solutions. Our dedicated personnel work hard to produce everything from complicated custom wire harnesses to simple custom cables for customers in a range of industries. We are also pleased to offer custom power cords for a variety of applications. 

While our team makes it look easy, these complicated custom arrays require a great deal of attention to detail. We can create wire assemblies in an array of lengths and thicknesses to ensure your wiring works as intended while still fitting into a variety of housings. Custom color coatings are available so your employees and repair technicians can identify wires within the assembly for faster, safer repairs. In fact, to make your product assembly as easy as possible, we are pleased to design and manufacture custom assemblies with special features to streamline assembly. 

At Consolidated Electronic Wire & Cable, we pride ourselves on offering custom wire and cable solutions that meet our customers’ most critical needs. We take the time to thoroughly understand the needs of your product, so you can rest assured that your custom cable and wiring assembly will provide optimal product performance.

The Project Process

Willy takes the time to walk our customers through the project process at Consolidated Electronic Wire & Cable. The process is designed to be as easy as possible for our customers from beginning to end:

  1. First, our sales team will discuss your project with you. They will gather the details and specifications and send them to our production team. 
  2. Our production team reviews your project specifications in full and creates a detailed quote for your custom wire or cable solution. 
  3. Once your quote is complete, our production team sends it back to the sales team, who sends it back to you for review. 
  4. You have the opportunity to review the quote, ask questions, and make any changes. Once you have approved the quote, you simply advise our sales representative and fill out a New Customer Form with your contact and business information. 
  5. The Consolidated Electronic team takes it from there! We work to create a custom wire or cable array to meet your project specifications. 
  6. Once production is complete, we conduct a thorough quality assurance check before packaging and shipping your completed array directly to you.

Our goal is to ensure that your entire customer experience is smooth and streamlined, with simplified processes and open communication throughout your project.

Partner With Consolidated Electronic Wire & Cable for Your Next Custom Project!

Whether you need complex custom wire harnesses or a simple cable array, Consolidated Electronic Wire & Cable has the right solution for you. With more than a century of experience, our custom capabilities are second to none in the industry. To learn more about our wiring solutions and project processes, contact our experts today or request a quote.

Cables for Cryptocurrency Applications

Cryptocurrency refers to digital money that is based on blockchain technology, such as Bitcoin and Ethereum. It is secured by cryptography and issued by decentralized networks, which make it hard to counterfeit and immune to government manipulation. Over the years, this type of currency has significantly risen in popularity, leading to more and more people getting involved in its mining. 

Given the increasingly high number of computer calculations needed to mine cryptocurrency, the mining process generally necessitates the use of high-speed data processing centers. Cables and wires play an essential role in the operations of these facilities.

The Role of Cables in Data Processing Centers

A key component of data processing centers is cable systems. These systems make up and connect the networks that allow transmissions, such as cryptocurrency transactions, to be made. 

The rise in cryptocurrency mining has created many new challenges for data processing centers. Since miners often need to go through millions of combinations to discover cryptocurrency, they require high-speed systems that have the power to perform the necessary calculations. As a result, data processing centers must develop and adopt new technologies, such as better cabling systems, to meet these increasing demands. 

Types of Cables in Use 

cryptocurrency equipment mining

The design of cable systems can be structured or unstructured depending on the needs of the data processing center. Structured cabling designs are based on predefined standards that dictate the connection points and pathways, while unstructured cabling designs have connection points and pathways that are not based on predefined standards. 

The cabling itself can also vary. Two of the most commonly used are copper cables and fiberoptic cables. The former is used for its low cost and power usage and high transfer rate and reliability, while the latter is used for its smaller footprint and greater transmission coverage. 

Data processing centers used for cryptocurrency mining require cable systems that are reliable and flexible. The cables must be able to transmit data at high rates consistently. Otherwise, the entire network can go down, potentially costing the facility a significant amount of time and money. Other features that may be critical to a data processing center include portability, grounding ability, and stability. 

Types of cable systems used in data processing centers include: 

  • Cable assemblies. Cable assemblies are collections of wires or cables that are enclosed within durable outer sheaths. The sheath protects the wires and cables from extreme environmental conditions that could damage them. 
  • Wire harnesses. Wire harnesses are wires or cables or a collection of wires and cables that are enclosed within lightweight sheaths. While the sheath provides some protection to the wires and cables, it is primarily used to keep them organized. As such, these cable systems are best used in indoor environments where exposure to harsh conditions is not likely.
  • Power cords. Power cords are designed to transmit power from the source to connected equipment. 

Custom Cable Solutions From Consolidated Electronic Wire & Cable

Need cables and wires for your cryptocurrency mining operations? Consolidated Electronic Wire & Cable is here to help. We’ve provided high-quality custom cable and wire solutions for over a century, which gives us the knowledge and skills to meet virtually any wire and cable need. To learn more about our custom cable and wire solutions, browse our Custom Cable Guide or contact us today.

Overmolded Cable Assemblies & Customization

Overmolded Cable Assemblies - Consolidated Electronic

Cable assemblies enclose vulnerable wiring in protective sheaths and incorporate a nearly unlimited variety of connectors based on the intended use. Overmolded cable assemblies go a step beyond a simple sheath by enclosing the cable or wire and connector with overmolded material.

Cable or wire assemblies are placed within a mold, which is then injected with a pressurized molten plastic. Once the material hardens, it turns into a protective layer that seals the junction between the wires/cable and connectors to reduce the risk of damage.

Why Customize?

Customizing your overmolded cable assemblies is the best option for ensuring your electronics are protected. They are ultimately more rugged and cost-effective because the assemblies are seamless and essentially turned into just one comprehensive piece. The overmolding process allows customization of the following:

  • Overmold materials. Different materials imbue the assembly with different degrees of chemical or moisture resistance, heat resistance, and more. There are a variety of common plastics available for overmolding. Polyvinyl chloride (PVC) is an inexpensive general solution, but only offers minimal protection against strong acidic chemicals. Conversely, polyethylene (PE) and thermoplastic elastomer (TPE) can withstand strong acids. Polyurethane (PU) and thermoplastic polyurethane (TPU feature good resistance to weather, aging, and other harsh environmental conditions, making them ideal for outdoor applications. Material selection is based on degrees of protection desired and compatibility with wire insulation or jacket materials.
  • Color. During custom projects, manufacturers can add distinct colors and resins to the molten plastic. These colors can be used to match a company’s branding, color code the assembly according to instructions or regulations, or make the equipment more aesthetically pleasing. Custom colors can improve safety and organization, as well as increase the marketability of a product.
  • Environmental suitability. Overmolded assemblies can be built with unique features and molded layers to protect the wires against any extreme levels of wear, stress, and abrasion that may be expected in the intended operating environment.
  • Regulatory compliance. Some industries maintain specific regulations regarding required levels of protection for wiring and cable assemblies. Custom overmolding processes can be customized for compliance with a variety of quality standards including IPC/WHMA-A-620 and RoHS.

Customized Overmolded Cable Assembly Applications

Custom overmolded assemblies offer enhanced strain relief and suitability for a wide range of environments. They can outlast units with multiple separate parts or thin layers of protective sheathing. Custom colors also make them ideal for complex installations or environments where visibility is poor. We’re proud to serve the following industries:

  • Automotive. Automotive assemblies must withstand the harsh heated environments inside vehicles, exposure to dust, and contact with chemicals.
    Communications. Communication wiring needs to be able to withstand harsh environmental conditions to ensure stable performance.
  • Home electronics. Wiring for consumers needs to be able to withstand a lot of flexing and adjustment and organizational coloring strategies make DIY installations and assemblies more appealing.
  • Medical equipment. Wiring for medical equipment and tools need to be able to withstand constant flexing and wear. They also need to be able to withstand continuous sanitation efforts to make them compliant with hygienic standards in hospitals.
  • Military and defense. Custom overmolded assemblies can withstand harsh conditions and extreme weather, use in a variety of different environments, and constant flexing. They offer an ideal solution for equipment which must operate reliably in harsh and dangerous environments in a variety of situations.
  • Oil and gas. Oil and gas industrial facilities, both in the processing plant and on the oil field, rely on cable assemblies for machinery and equipment that operate effectively near chemicals and constant wear and tear from harsh environmental factors.
  • Wind and solar energy. Alternative energy systems need robust wiring systems that remain durable in interior and exterior environments.
  • Industrial and OEM. Overmolded wire and cable assemblies are ideal for the harsh conditions found in industrial environments.

Consolidated Electronic Wire & Cable Solutions

When you choose custom overmolded cable assemblies, you get more than custom designs and colors. This process ensures you have a cable assembly that’s the right fit for the electronics, the environment, and the relevant regulatory standards of your operation. At Consolidated Electronic Wire & Cable Solutions, our team uses high-performance materials and expertly designed systems to create assemblies that outperform and outlast other assemblies.

Contact us today for more information about our overmolding capabilities.

Cable & Wire for a Vast Array of Medical Applications

Consolidated Electronic Wire & Cable is a leading medical cable manufacturer that provides custom engineered and manufactured wires and cables for an extensive range of medical applications. With more than 100 years of experience, we have established a thorough understanding of the particularly rigorous standards and regulations that apply to the medical industry. Our experts can provide quality wiring solutions tailored to meet your particular needs, and our facility is designed to create cable and wiring products that meet and exceed even the most stringent industry standards.

Medical Cable & Wire Applications

At Consolidated Electronic Wire & Cable, we offer the highest quality wiring and cable on the market. Our medical cable products can be found in a variety of medical applications, from diagnostic equipment to laboratories and lighting systems.

Medical Imaging and Diagnostics

man in front of illuminated MRI scansMedical diagnostic and imaging equipment requires high-performance, reliable wiring and connections to transfer information accurately and securely. Common diagnostic and imaging systems include MRIs, PET and CT scans, ultrasounds, and X-rays. This type of equipment is critical for the diagnosis and treatment of patient injuries and illness.

Laboratory Equipment

Medical laboratory equipment requires medical cables and wires to ensure the accurate measurement, analysis, and monitoring of patient health. It is used to help medical professionals examine bodily fluids for signs of disease or infection. Lab equipment also includes life support equipment such as dialysis machines, cardiopulmonary bypass (CPB), ventilators, and anesthetic dispensers. It can further be used to measure and track patient vitals using EEG and ECG measurements.

Treatment Units and Operation Tables

Medical cable and wire is critical for use in treatment equipment such as surgical lasers, LASIK equipment, and medical infusion pumps. Operation tables must be equipped with reliable wire and cable arrays to ensure appropriate positioning of the patient during sensitive procedures. 

Surgical Lights

hospital surgical lamp lightIn addition to accurate table orientation, surgeons must have extremely bright lighting to operate safely. This requires extremely reliable and durable wire and cable assemblies that can withstand high power levels and extreme temperature fluctuations.

Surgical Robots

As automation becomes more common in medical practice, robot-assisted surgery is helping medical care practitioners provide quick, efficient, and accurate surgical procedures. Surgical robots are highly complex and require the ability to move smoothly and quickly with a high degree of precision. A surgical robotics system will require data cables to receive and transmit instructions, as well as sensor cables to transmit critical information to the operating system in real time. These cables must be highly flexible and able to withstand bending and turning motions common in surgical robotics functions.

Electronically Adjustable Hospital Beds

Adjustable hospital beds with electronic controls make it easier for patients to enter and exit the bed comfortably and safely, and provide an easy means of adjustment for comfort. Not only does this allow patients more freedom of movement, it helps healthcare practitioners move patients with a significantly lower risk of injury due to falls. Cables in electronically adjustable hospital beds must be flexible and able to operate when bent by the bed’s movement.

Hospital Lighting Units

Hospitals require highly adjustable and specialized lighting for different applications. Lights over workstations must be bright enough for healthcare professionals to read charts, while room lighting must be adjustable. Bright light is necessary for nurses and doctors to read patient charts, insert IVs and deliver injections, but the lights should be able to dim for the comfort of the patient. Medical cables are available with a broad range of designs and fixtures to ensure optimal operation for all healthcare applications.

PA and Communication Systems for Staff

Reliable communication is crucial in a healthcare environment. From requesting emergency care to communicating patient needs, healthcare professionals must be in contact almost constantly over the course of the workday. Medical cables and wiring arrays help hospitals and other medical facilities establish clear overhead PA systems for code calls, emergency requests, and paging, as well as small communication devices that can be used for direct interpersonal contact. 

Contact Us for Medical Cables & Wires

For more than 100 years, Consolidated Electronic Wire & Cable has been a proud provider of quality custom solutions for wire and cable arrays for the medical industry. We offer an extensive selection of conductive wire materials of varying lengths in both shielded and unshielded designs, with coatings and color options to suit the specific requirements of your medical applications. 

Contact our experts to learn more about our medical cables and discuss your customization options. 

 

How to Source Cable Assemblies With Fewer Purchase Orders

Custom-designed cable assemblies serve as critical components in many different applications, including commercial and home electronics, appliances, medical equipment, aerospace and military projects, telecommunications, automotive products, and industrial equipment.

Designing cable assemblies to ensure optimal performance is a tough enough job on its own. Having to make multiple purchase orders throughout the process only adds to the headache, wasting both time and labor. But there’s a way around this …

Beyond the Products

Consolidated Electronic Wire & Cable doesn’t just produce quality products; we also ensure that our clients’ business processes are as streamlined and efficient as possible.

One of the ways we achieve this is by processing just one invoice against multiple purchase orders (POs).

The Consolidated Advantage

Consolidated is a customer-driven, employee-owned company. All of our skilled workers are dedicated to client satisfaction and are deeply committed to constantly improving and innovating our manufacturing processes, customer support services, and product offerings. As a smaller business, we’re able to provide personalized, one-on-one service, ensuring that our customers receive ideal solutions for their exact needs.

So what does this mean for your company?

  • Reduced Total Cost of Procurement

Relying on Consolidated for your cable and wire needs will save you both time and money while increasing overall efficiency, as our Just-In-Time (JIT) stock program ensures fast turnarounds for every order.

  • One-Stop Shopping Experience

We offer a huge range of products, including electronic wire and cable, power cords and retractile cords, molded cable assemblies, and cable and wiring harnesses. Consolidated has the resources to meet all of your specific needs, whether you require bulk wire and cable or finished “box-build” units.

  • Quick, Convenient Distribution

Our expansive, modern distribution center is just minutes away from Chicago’s O’Hare International Airport, allowing for fast, easy deliveries to anywhere in the world.

  • Unrivaled Quality Assurance

Our Total Quality Management (TQM) system is utilized throughout the entire manufacturing process to ensure products meet our customers’ unique specifications and all relevant standards.

  • Extensive Custom Capabilities

Throughout our nearly 100 years in business, we’ve served virtually every market in the world, fulfilling unique cable requirements for companies of all kinds. Whether your order is for 5,000 feet or 1,000 pieces, we can design and manufacture a custom product to meet your exact needs.

Learn More

To learn more about Consolidated’s single-invoice PO solutions for cable assemblies and discuss how we can help with your next project, reach out to the team today.

Start Your Custom Project With Us Today
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