Posted by Megan Siwa on | Comments Off on How Are Cable Assemblies Overmolded?
Overmolding adds strength and resilience to a cable assembly so that it can withstand more extreme environments than it otherwise could. The cable overmolding process combines and seals a cable with a connector, resulting in a unified part that adds protection to its internal components.
Learn more about how cables are overmolded, the materials used during the manufacturing process, and the benefits of overmolded cable assemblies.
Cable Overmolding Materials
Common overmolding materials used in cable overmolding include:
PVC: Polyvinyl chloride or PVC is one of the most widely used thermoplastics for cable overmolding. PVC has a soft, rubber-like texture and high flexibility.
TPU: Thermoplastic polyurethane or TPU has a softer texture than PVC and comes in a wider array of colors. TPU is also more pliable and has a greater low-temperature flexibility, making it more stable amidst temperature changes.
Cable Overmolding Process
Overmolded assemblies are manufactured through injection molding, a manufacturing process that forces material into a mold cavity under pressure. The process starts when a storage area or hopper is filled with plastic resin, and an injection ram delivers the material into a barrel, where the plastic is heated to a liquid state.
Through a variety of methods, such as color compounding or master-batching, color is added to the resin. Inside the cavity, the material will cool and conform to the shape and design features of the mold, that may include logos, part numbers, and trade names.
Tamper-Proof Construction: Overmolding makes cable assemblies tamper-proof by encapsulating components. Unlike standard cables, overmolded cables have an extra layer of insulation that makes it harder for unauthorized personnel to interfere with or cut the cables.
Long Service Life: Overmolded cable assemblies are highly durable and long-lasting. They are protected from outside elements like extreme temperatures, abrasion, dust, water, dirt, debris, chemicals, and moisture, improving performance and enhancing cable assembly life.
Enhanced Cable Assembly Processes: Overmolding makes the assembly process more efficient and secure. This efficiency allows production costs to be reduced.
Shock and Vibration Resistance: With a robust housing and stable connections, overmolded cables can withstand shock and vibration without damage.
Flex and Strain Relief: By overmolding your cable assemblies, you can improve resistance to strain at the cable exit, where most of the stress between a cable and connector occurs. Cable overmolding also provides 360° strain relief and increased pull strength. The outer casing acts as a buffer between the inner wires of the cable and the external elements, protecting connector terminations and wires from damage over time.
Cable Management: Overmolded cable assemblies can have a soft, tactile feel when handled manually and make it possible for the cables to be easily managed.
Overmolded cable assemblies are no longer the rigid plastic they were decades ago. Overmolding materials are soft, tactile surfaces that are easy to handle and organize. They provide flexibility, strain resistance, durability, customizability, and strength to meet the most demanding cable applications. Overmolded cable assemblies are ideal for your custom design projects to enhance the protection of the assembly.
At Consolidated Electronic Wire & Cable, we provide custom overmolded cable assemblies for nearly any application. As an ISO 9001:2015 certified company, we are industry leaders in Total Quality Management (TQM) and are RoHS compliant. This ensures that our production process and customer service meet the highest quality standards. Contact us online or call us at 1-800-621-4278 for more information about our overmolding capabilities. To start your project, request a quote.
Posted by Consolidated Electronic Team on | Comments Off on Where are Wiring Harnesses and Cable Assemblies Used?
Wherever there is a complex electrical system, there is likely also a wire harness or cable assembly. Sometimes called cable harnesses or wiring assemblies, these units serve to organize, consolidate, and protect electrical conductors. Since wire harnesses are custom designed for their application, they can dramatically improve a system’s efficiency.
What is a Wiring Harness?
Simply, a wire harness is a bundle of cables and wires, plus the components used to sheathe, support, and organize them. These elements include tapes, sleeves, and ties, which keep cables in the optimum position for transmission. Wire harnesses are designed based on the electrical and geometrical requirements of the application and are used to simplify the connection to larger components.
What are Wiring Harnesses and Cable Assemblies Used For?
Wiring harnesses solve many challenges associated with electrical systems. By combining many individual wiring elements, they make it easier to connect and assemble complex systems. At the same time, they provide additional protection to wires and cables, preventing unwanted flexion and insulating bundles against the environment.
This combination of benefits means that wiring harnesses and cable assemblies are used across diverse applications. Most manufacturers find that combining electrical elements in a harness is a cost-effective way to improve performance while also simplifying installation. Uses can be found in industries ranging from aerospace to residential wiring.
Aerospace equipment often includes dense bundles of electrical and communication cables. Wire harnesses enable power transmission in aircraft engines, data transmission from satellites, and similar aerospace applications.
The automotive industry makes extensive use of wiring harnesses and cable assemblies, including in both gasoline and electrical vehicles. In these contexts, harnesses are indispensable for saving space and ensuring wires fit around mechanical components. Organizing conductors is also essential for keeping distinct systems separate under the hood, enabling both efficient operation and easy maintenance. Automotive systems using harnesses include lights, turn signals, displays, and more.
In the hospital, clinicians must be able to quickly establish reliable connections. In many cases, this is a matter of life and death, such as when setting up critical care equipment. Harnesses enable these rapid links, keeping patients safe. Other medical applications include more permanent installations such as imaging equipment and dental chairs.
Telecommunications systems may include anywhere from tens to thousands of cables, all of which must be organized to save space and facilitate identification. Assemblies serve this role, bundling cables for modems, routers, and similar communication equipment.
Within IT, harnesses are used at every scale. Wire harnesses and cable assemblies save space within small laptops and organize the thousands of cables within a networking facility.
Safe and efficient wiring powers residential and commercial buildings alike. Construction personnel rely on harnesses to insulate and organize electrical wiring in compliance with all relevant codes.
In a manufacturing environment, stray wires represent a significant safety hazard. At the same time, many machines include extensive wiring, including CNC units, 3D printers, and conventional workstations. Harnesses keep facilities safe by containing wiring and ensuring connections are reliable.
Robotics and Automation
Robots of all sizes require organized and durable wiring to function properly. Often, space is limited, so harnesses are needed to route and contain circuits.
Benefits of Wiring Harnesses and Cable Assemblies
The advantages of wiring harnesses and cable assemblies have made them nearly ubiquitous. Key benefits include:
Decreased Installation Time: Assemblies group cables sensibly, speeding installation for large or complex systems. This organization makes it easier to identify and locate the appropriate components.
Safety: Harnesses can incorporate structural supports, insulation, and shielding to protect against dangerous shorts. Harnesses also keep wires contained to avoid accidents in the workplace.
When working with wires and cables, it is nearly impossible to achieve the same efficiency without a well-designed harness or assembly.
Choose Conwire for Wiring Harnesses and Cable Assemblies
Conwire has offered cost-effective, streamlined wire and cable solutions for over 100 years. We have crafted harnesses for virtually every industry, tackling unique requirements and challenges with each project. As an ISO 9001:2015-certified manufacturer, we work with the highest-quality materials and adhere to the most rigorous quality standards. Whatever the application, you can trust our solutions will maintain excellent performance across their long working lives.
Posted by Consolidated Electronic Team on | Comments Off on 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:
First, our sales team will discuss your project with you. They will gather the details and specifications and send them to our production team.
Our production team reviews your project specifications in full and creates a detailed quote for your custom wire or cable solution.
Once your quote is complete, our production team sends it back to the sales team, who sends it back to you for review.
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.
The Consolidated Electronic team takes it from there! We work to create a custom wire or cable array to meet your project specifications.
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.
Posted by Consolidated Electronic Team on | Comments Off on 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
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.
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.
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.
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
Medical 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.
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.
In 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.
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.
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.
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.
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.