Electrical systems are very complex, even though they are a vital part of daily life. People who design electrical systems and appliances must complete further education in addition to years of expertise and training before they can use the equipment.

Certain regulations must be in place to keep people safe, and the systems are functioning at their peak because electricity is equally dangerous. Electrical cable assembly is among the most significant components of this safety. Many individuals are unaware of how these straightforward tools keep systems safe and orderly.

This article focuses on an electric cable assembly, how it differs from a wire harness, and what to remember while selecting a cable assembly.

What is an Electric Cable Assembly?

An electric cable assembly is a particular kind of cable harness assembly that contains electrical wires and cables.

It is a collection of wires or cables bundled into a single object, like a woven braid or an insulated tube, for organization and protection against mechanical and other damaging impacts.

The range of cable assemblies’ interior and outdoor applications is fairly broad, including medical settings, the military, and high-speed data connections. Suppose you need extra protection for your wiring or want to make better use of your available space. In that case, you might employ a cable assembly at some time.

Why Are They Important?

Electrical wiring is a very difficult procedure requiring much training and cautious, organized effort. Maintaining regulated and secure wiring is critical because electricity is essential to contemporary life and dangerous. 

Electrical cable assembly allows electricians to maintain their cables neatly organized for themselves and any upcoming electrical professionals who may need to understand the electrical system.

Cable Assembly vs. Wire Harness:

Cable assemblies and wire harnesses are not the same products, even though the terms are sometimes used interchangeably. Furthermore, electric cable assembly and wires are not the same things.

Thin strands of conductive material, like copper, make up wires, including hook-up wires. Cables are typically made of two or more wires braided or linked together, such as a twisted pair cable, and are thicker. For this reason, cables often seem like a jumble of wires.

Wire harnesses are typically little more than a thermoplastic or thermoset material covering the wires’ exteriors. The wires are also protected by their jackets, but they are grouped together in the wire harness for better organization.

Wire harnesses are inexpensive to keep cables secure, but they aren’t the best option for harsh environments. Shrink-wrapped thermoplastic, vinyl, or thermoplastic rubber is frequently used to make heavier-duty cable assemblies. They come in a variety of sizes and forms. They protect cables from hazards like friction, heat, moisture, corrosion, and more.

Things to keep in mind while selecting electric cable assembly:

You should be aware of the electric cable assembly‘s purpose and the kind of assembly required for the specific application when making your choice. To make the best choice, speak with the assembly’s maker. There are, however, several other factors to keep in mind.

Copper or copper-alloy conductors: Although copper wires are used for cable assemblies more frequently than any other material, copper alloys may have advantages due to their greater strength and flexibility. They are also useful, particularly for tiny assembly sizes.

Stranded or solid wire: Once again, flexibility is an issue, and stranded wire provides more in this regard.

Plating: For situations with high humidity, tin is probably the best option because it is the most widely accessible material. Silver is a strong choice for high-frequency applications in a more expensive assembly. Still, nickel, with a temperature rating of 250 C, is excellent for high-temperature environments.

Insulation: PVC, PE, PP, and different types of Teflon are frequent choices for electric cable assembly. The main criteria to keep in mind are the cost, dielectric constant, flexibility, temperature rating, and flame-retardancy when selecting the insulation for a cable assembly. Teflon is the best material for high temperatures and flammability. In contrast, PVC, PE, and PP are the best materials if flexibility is your top need.

Shielding: Foil, braid, and foil braid are all acceptable shielding materials to avoid electromagnetic interference. Overall, the latter is the greatest choice for EMI protection.

Jacket: PVC, polyurethane, and Teflon are common materials for an outer jacket. It is important to consider the jacket’s flame retardancy, durability, maximum operating temperature, low-smoke zero-halogen status, and level of durability.

Connectors: Since there are numerous possibilities for each assembly, the electric cable assembly maker is the ideal person to ask for advice when selecting the type of connector.

One-stop shop for electric cable assembly

Let’s connect with the Prismecs team and get all services related to electric cable assembly at market-competitive prices. We are a one-stop shop for all your industrial product needs. So, call us today at 18887747632 for a more detailed review of our industrial products range!

You can also write us an email at sales@prismecs.com for more information!

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