Overview of Electronic Cable Assemblies

In simple terms, electronic cable assemblies are designed as different types of interconnect solutions for a wide range of applications and industries. These assemblies are often referred by several different things to include a wiring assembly, cable harness, wire harness, and more but overall, this consists of a grouping of wires or cables used to transmit electrical power and signals.

When cables are properly bound together, the full assembly prevents the signal from being disrupted because of fire, abrasion, vibration, moisture, or electrical shorts. Depending on the work, an electronic cable assembly is made using various types of casings such as sleeves, conduit, cable lacing, straps, braiding, cable ties, weaved extruded string.

In some instances, a combination of more than one method is acceptable. However, no matter the option, the ultimate goal is to increase product efficiency. Electro-mechanical assemblies are designed following very strict electrical and geometric mandates, which are translated in the form of a diagram that engineers used to prepare and assemble the harness.

Wires are first cut to the needed length using an automated or manual marking process which helps with identification. Following this, wires are stripped whereby the metal cores are exposed. Next, the wires are assembled using the proper connector housings or extra terminals. This new bundle of wire is then clamped onto an assembly fixture or form board where a conduit, extruded yarn, or protective sleeves fit over the finished mass.

In most cases, the process of preparing electrical cable assemblies is something done by hand since every phase of production is so intricate. For example, the wires have to be carefully routed through taping or sleeves, they are often inserted as one sleeve into another sleeve, crimped terminals go onto wires, and strands are fastened with cable ties, tape, or clamps. Because this type of work is so detailed, the work requires special expertise.

After everything has been completed, the final electrical cable assembly has to be tested using special equipment. Usually, a pre-programmed circuit tester is used to check functionality of the electrical component. If at any time during the testing the assembly does not perform as intended, based on the problem is it either fixed or completely reconstructed.

Most often, electrical cable assemblies are used in consumer products to include headphone cables, power cables, and so on but today, there are some that are customized for more sophisticated uses. Using various discrete wires and cables, the electrical cable assembly is built.