Cable assembly
The cable assembly (including cable assembly called) is the production of ready- cables , cable bundles and complete harnesses with connectors , contacts or ferrules .
Various connector solutions can be used in processing . Both the crimping technique and the soldering technique are very widespread. Many requirements arise in the area of application of corresponding cable harnesses or connection cables.
development
The cable harnesses or connection cables are designed as ready-to-connect segments according to the application parameters and, if necessary, constructed three-dimensionally with CAD . This is increasingly used in aircraft construction , automobile construction and mechanical engineering , for example to check laying routes. The data that are important for processing, such as cable lengths, bending radii of cables , fasteners and mounting points can be determined. The dimensioning of cables and protective hoses is particularly critical in the development phase, since cable harnesses are often installed in hollow profiles or behind cladding elements (e.g. doors, walls, etc.). If the wiring harness is incorrectly dimensioned, there could be space problems or problems with the assembly, which could lead to problems at this stage. & Could mean very expensive change. For this reason, the CAD data must be checked for plausibility and approved by an experienced technician.
The following points must be taken into account during development:
- Bending radii
- Mountability
- Weight
- Dimensioning of the lines
- Isolations
- Strain relief for moving elements
- Documentation for assembly and, if necessary, for troubleshooting
- Heating of the different components
- Wear from dynamic movements
- Media resistance (e.g. to oils and greases in the engine compartment)
- Temperature differences
Connection cable for underwater applications
In the course of the construction of cable harnesses and connection cables, it is often necessary to provide the plug connectors or connection points with a potting compound . Either this is intended for use in a damp environment or even under water. A pressurized water test is usually carried out in an autoclave for the use of a cable harness or connection cable under water . This means that the water tightness can be simulated to the depth of use, depending on the facility and application, to over 10,000 meters.
Manufacturing
In mass production, cable harnesses and connection cables are often created with the support of machines, and in small to medium-sized series production for cable harnesses, they are manufactured by hand using the classic method .
The processing of cable harnesses and connection cables requires a high level of concentration on the part of those performing the work and the highest level of precision in planning and execution. The wire cross-sections can be less than 0.04 mm² / AWG 31 during processing .
Well-known German manufacturers in cable assembly are Telegärtner, Leoni AG, Coop Systems, Nexans and HIK.
optical fiber
Optical fibers are often used for the transmission of digital data . Cable harnesses for several cameras in one housing in a drone are also manufactured here. The processing of fiber optic cables is a demanding requirement for the assembler.
Hybrid cable assembly
In hybrid cable assembly, several cable types such as fiber optic cables , copper cables and / or hoses are provided with connectors, contacts or hose couplings.
See also
- Litze (electrical engineering)
- Electrical line
- Three-phase line
- Telephone cord
- Structured cabling
- Type codes of cables
- Abbreviations in cable technology
Web links
- What is cable assembly? Background knowledge of cable assembly
Individual evidence
- ↑ Cable assembly in the competence center. Retrieved January 8, 2019 (German).