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The Care and Feeding of Your Custom Cable Assembly

Custom cable assemblies require a certain amount of special care, to ensure their reliability and efficiency in the long term. Just as with any working part, it should be installed and maintained properly, because safety and reputation are on the line. Neglected parts can fail, adding to increased assembly line costs. Periodic quality checks can help keep the overall production in check, but by being proactive in the treatment of the assemblies, the problems can be eliminated before they are even put into the product.

While handling the assembly unit and installing it, remember that various conductor wires can handle different stress levels. Some don’t bend as easily, so great care should be taken when manipulating the wires through a housing. If the wire or assembly is handled too roughly, the product could break or end up with a safety flaw. Covering the wire and connectors with a shrink wrap covering where they join can also help add stability. Especially during the assembly stage, the pulling and manipulating typically done during assembly could seriously damage the product. The consumer should also have clear instructions for how to properly use and install the end assembly or product.

It is also important to select the proper components in the beginning, when the custom cable assemblies are ordered. By using the right gage of wire with the right insulation, the unit can hold up the integrity of the product. Pay attention to how flexible the wire needs to be, the amount of current it can safely handle, and the type of environmental stresses it needs to withstand. Utilizing accessories, such as clamps and adapters that keep the cable from rotating or bending within the connector, or reduce mechanical stress at the adapter is a good idea for parts that could be subjected to movement.

Choosing the proper connector for custom cable assemblies is key. Electrical connectors are an integral part of assemblies. Often, a good deal of stress is put on the device at that area, due to the transition between wire conductors and the handling that the joint is subjected to. When ordering connectors, it is important to explain the intended purpose of the harness to the supplier. They will be able to help make an educated decision about which one is appropriate and will stand the test of time. The installation of the harness should be done with care, to make sure there is a solid connection between it and the conducting wire. There should also be great care taken when connecting and disconnecting electrical connectors. The assembly should be held firmly by the connectors, not the wires.

Taking care of custom cable assemblies doesn’t have to require a higher degree, or a full time trained staff to handle. Much of the attention to proper handling and maintenance is done during the assembly process. In order to help staff be as successful as possible, take the time to create a step by step procedure for installing, testing, and troubleshooting assemblies. They might not be at the top of your mind when running a company, but through the added level of attention, a reliable product can be created for the end customer, building loyalty and increased sales.

If you would like to learn more about custom cable assemblies, visit LoDan Electronics, Inc.

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