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After so many years of development, YDX had become a professional and reliable cable assembly manufacturer. We can design and manufactures all kinds of cable assembly, even the custom for your specific applications and demand.

Please feel free to tell us what you need for the cable assembly, with the professional experience and strong production line(design, soldering, termination, wrapping, testing, production), we definitely can supply the best cable assembly for you or your customer!

Cable assembly is an electronic component commonly used in the wires and cables; the main function of a cable assembly can connect different parts together to form parts of electric devices, such as computer hardware components or industrial electronic control equipment. The term “computer” refers to a broad category of electronic products that include many subsystems, such as computer towers, monitors, and computers.

Cable Assembly Manufacture and Design

Cable assemblies are produced mainly by the following methods: braiding wire rope; extrusion-bending-covering; welding of wires or wire winding process; sealing technology. The choice of manufacturing method depends on the operating conditions (temperature, voltage, etc.) and the cable assembly design.

Because of its high-temperature resistance and good flexibility characteristics, plastic is an ideal material for wire insulation. Depending on operating conditions and other requirements (high or low heat, flame retardant), cables are made with different materials to meet customer needs. For example, PVC insulated cables; silicone rubber insulated cable; silicone-impregnated glass fiber reinforced plastic (GRP) insulation cable; flame-retardant polyvinyl chloride (FRP or CRP); fire-resistant polyvinyl chloride (FR).

Cable assembly generally refers to the entire wire and cable structure, including inorganic material, such as PVC sheath, steel wire, and core wire; organic material, such as conductor, insulator, adhesive, and winding protection layer.

The cable assembly conducting wires have different cross-sectional structures: solid conductor (round wire or flat ribbon) or stranded conductor (multi-core), twisted to form a sheath of multi-core cables. Insulation is placed on the conductor and sheathed to form a multi-core cable.

Wires are made by drawing, extrusion, rolling, or other processes; plastic-coated wires are formed by coating or laminating two or more layers of different materials. Compared with bare wires, cables have some advantages:

  • Increase the strength of the wire (twisted core and many-core cable).
  • Increase the flexibility of wires, control joint stress, and enhance the stability of operation.
  • Reduce wiring errors.

In general, a cable assembly is designed by engineers according to user needs. The specification includes the specifications of cables (such as wire diameter, outer diameter, or width), insulation materials for different operating requirements (such as flame retardant or heat resistance), wire insulation, and joint requirements. The cable assembly design mainly aims to meet the user’s needs for protection, insulation, flexibility, and other aspects.

Cable Assembly Manufacture

Cable Assembly Types and Applications

The following describes different types of cable assemblies in accordance with the position of the conductor wires relative to the wire insulation. This is partially based on the wire assembly classification of IEC 60502, which describes cable assemblies through seven types of cable assemblies: 1-wire-insulation cable; 2-single shielded cable; 3-double shielded cable; 4-magnetic separation shield with shell and core-sheath; 5-twisted pair cables/parallel twisted pair cables; 6-circular cross-section cable with shrouding/sheathing; 7-flat ribbon cables.

1-wire insulation cable

This type of cable assembly is generally composed of two parts: conductor and sheath, which form the core wire and the insulating layer to provide protection for the conductor.

The core wire may be solid or stranded, and the insulating layer is generally formed by extrusion or injection molding.

The cross-section of a 1-wire insulation cable may be round or rectangular, but the most common shape is circular. This type of assembly has been used for many years and is widely used in areas with high-temperature requirements such as electrical appliances, telecommunication devices, industrial robots, and so on.

The cable assembly is widely used in the fields of energy, petrochemical engineering, machinery manufacturing, and metallurgy industries.

2-single shielded cable

This type of cable assembly includes a single host conductor surrounded by a metal shield surrounding the insulating layer. In addition, there is tape on the surface of the assembly to prevent contact with water or oil.

The shield is usually made of braid wire, and the sheath may be made of steel or plastic material. The conductor is coated with insulation material (such as PVC) which has good heat resistance and insulating properties for high-temperature applications.

The cable assembly is widely used in low voltage power cables for the transport and distribution of electrical energy, telephone and Internet communications, control equipment (such as PLC), direct current (DC) motors, electric tools, and so on.

3-double shielded cable

This type of cable assembly includes a multiple host conductor surrounded by two metal shields, which surround the insulating layer. In addition, there is tape on the surface of the assembly to prevent contact with water or oil.

The shield is usually made of braid wire, and the sheath may be made of steel or plastic material. The conductor is coated with insulation material (such as PVC) which has good heat resistance and insulating properties for high-temperature applications.

The cable assembly is widely used in low voltage power cables, control and transmission cables, electric tools, and so on.

4-magnetic separation shield with shell and core-sheath

This type of cable assembly includes a multiple host conductor surrounded by two metal shields, a metal shell, and a plastic core-sheath. The insulating layer is in the middle of the assembly.

The shield is usually made of braid wire, and the sheath may be made of steel or plastic material. The conductor is coated with insulation material (such as PVC) which has a good heat resistance and insulating properties for high-temperature applications.

The most common winding is parallel cable assembly, which can be wound on the reel in a roll form to save space and reduce the time for installation of electrical appliances and equipment. The inner conductor may also be stranded or solid, but it must have good flexibility and bending properties; insulation material with excellent heat resistance and dielectric properties should be used.

The cable assembly is widely used in the fields of energy, petrochemical engineering, machinery manufacturing, and metallurgy industries, where high-temperature applications are required. It is also suitable for areas with water or oil splash.

5-twisted pair cables

This type of cable assembly includes four twisted pairs of wires in the center, with an insulating layer surrounding it. Two wires in each twisted pair are surrounded by a metal shield, which is then surrounded by another layer of insulation or sheath. The cross-section can be round, square, triangular, and rectangular; commonly used sections include 2.5 mmx0.8(mm), three mmx1 mm, 3.5 mmx1.2(mm), and four mmx1.6(mm).

The cable assembly is widely used in data transmission of electrical energy or telephone communications, computer networks, and high-temperature wiring of light industry and machinery manufacturing to prevent short circuits caused by the interface between wires. The cross-section of a cable assembly is usually determined by the shielding material, conductor size, and insulation thickness.