Technical Cable Applications Blog

Wire Harness vs Cable Assembly

To those of us who work as cable assembly manufacturers every day here at Technical Cable Applications, as soon as we learn about the application a client is needing, we will typically know whether a wire harness will do the job, and when a more robust cable assembly is required. However for just about anyone else who doesn’t work with cables every day, it’s likely that the terms “wire” and “cable” will seem somewhat interchangeable. It’s also even more likely that your average consumer wouldn’t know the difference between a harness and an assembly as those also sound very similar, and again wire versus cable sounds like you’re comparing the same thing. This will be a quick refresher on the difference between a wire harness and a cable assembly, and when one or the other is most likely to be used.

Wire Harness

Wire harnesses are the most basic way to configure any product or project that needs a couple or more wires strung together to connect one item to another. As long as the wires are in a safe place without extreme temperatures, pressure, or other physical danger, oftentimes this simple configuration of attaching a few wires together to ensure that everything will get the power or data transfer needed is more than sufficient. Wire harnesses are extremely cost efficient and will more than suffice for many indoor applications, or applications where the wires will be protected by a product’s pre-existing external shell or casing, i.e. computer servers or refrigerators.

Cable Assembly

The primary difference between a wire harness and a cable assembly is that a cable assembly will not have single exposed wires, and will always have multiple wires braided together and covered in some sort of protective sheath or coat. Cable assemblies are most important to use when there is no additional protection for the wires from the elements or when the connection has to hang rather than being precisely placed and mounted. This is because the protective sheath will ensure that the cables are protected from damage even if they are visible outside the product or machinery they are powering. Cable assemblies can be encased in all sorts of different types of protective materials for many different applications, so whether your cables need to continue working in harsh outdoor environments, or extremely hot factory/industrial conditions, there is a method and a material for your needs that will protect your cables and keep them working. Some industries use cable assemblies more frequently as well due to their general durability and the fact that protective sheaths can also prevent data loss, which is excellent for the military and medical fields who need both high durability and fast data transfer in emergency scenarios.

Hopefully this guide is helpful for anyone who is not familiar with the nuances between cables and wires. If you’d like to learn more, WHMA.org has an excellent guide they’ve published as well that is more in-depth than what we wrote here. Meanwhile if you are in need of a manufacturer for your bulk cable assembly or wire harness needs, please give us a call or send your cable drawing to us via our contact form so we can get started.

Custom M12 Cables: Tailored Solutions for Automation and More!

In the increasingly fast-paced world we live in today, automation is becoming not just a plus to have for many businesses, but a necessity for improving operational efficiency to meet budget and time restrictions. When not just a few, but all of the biggest players in any industry have begun implementing automation into much of their production, manufacturing, and processes, automation is no longer a luxury, but a necessity. This is the case for leaders in all kinds of industries including robotics, aerospace, logistics & shipping, military, medical and so many more. It’s simply not an option to avoid using automation for companies providing services across the nation or the world, because you will fall behind the competition in terms of efficiency. This includes software applications like artificial intelligence which are now becoming more prevalent, or the types of automation we’ve specialized in providing cables for since our founding in 2002.

One of the most frequently used and important types of connectors that power this automation is the ever reliable, compact and powerful M12 connector and the specialized cables we build that utilize said connectors. There are many variations on the standard M12 connector including the older M5, M8 and RJ45 styles that are all still extremely popular, and even within these types there are hundreds of different styles with the numbers of pins used, materials utilized, type of signal to be carried, and all sorts of other variables. We are experts in all of the possible variations, and even if you can imagine an M12 cable assembly with an exceedingly unusual configuration, we’ve probably manufactured something similar before due to our many years of experience and the plethora of businesses we’ve done orders for.

As a custom M12 cable and cable assembly manufacturer, here at Technical Cable Applications we specialize in crafting custom and off-the-shelf solutions tailored to meet the precise needs of our clients. We are ISO 9001:2015 and UL certified for cable assembly and are extremely experienced with M12 cables and assemblies and all the intricacies of the different kinds of M12 connectors, how they work with other types of connectors that we can also provide, and ensuring that they will be protected and durable for all your needs. You can trust us to manufacture your M12 custom cables order perfectly no matter how complex the specifications are.

Don’t miss out on the opportunity to enhance your automation systems with our custom M12 cables that will provide exactly what you need and be built to last. Call us today or submit your cable drawing on our contact page to discuss your specific industry requirements!

The First Article Process

The First Article Process is a crucial part of production requirements at Technical Cable Applications.  The process confirms that an assembly has been designed as intended and that documentation is complete and interpreted correctly.  It verifies that proper assembly techniques and tooling are used and assures that later builds of product are produced without variation.

Quotation

At TCA the first article process starts before an order is ever placed.  During the quote process the customer drawings or specifications are carefully reviewed.   This assures that all the elements for successful production are included.

The bill of materials is evaluated to make certain all the components shown on the drawing are called out and in the correct quantities.   They are looking for any obvious material conflicts such as wire size /terminal compatibility.  A mismatch like this could be because the insulation diameter or wire AWG is too large or too small for a terminal. Discrepancies like this could affect the integrity of the product or damage tooling.

The drawing is checked for clear dimensional criteria and for tolerances that are achievable for cable assemblies.   It is also reviewed for references to any documents or quality standards other than IPC.  If other quality documents are referenced Technical Cable Applications quotations specialists assure those documents are on file.

Tooling and Test Fixtures

During the quote process tooling requirements are checked for all the components.  At Technical Cable Applications the component manufacturers recommendations are checked to assure that the right tools are on hand.   It is verified that mating test fixtures are available for all connectors.  If either of the tooling or test fixtures are not on hand, they will need to be ordered for the build.

Work instructions

Work instructions are created by Technical Cable Applications production engineers.  These seasoned professionals have broad knowledge and training in cable assembly production and quality standards. For cable assemblies this would be to the IPC/WHMA -620B standard.  If there are other production or quality standards called out in the customer documentation the production engineers will obtain a copy and make sure they are part of the process.

The work instruction lists all the machines, tools, fixtures, and materials used.  It contains set up and programming instructions for any equipment used.

A Detailed Accounting

As the production engineers build the first article, they keep a detailed step by step accounting for every process used to build the assembly and in the order it is to be completed.    Special instructions and cautionary notes are often part of the instructions with detailed pictures for each step included.  The completed work instructions are controlled on a central server and every workstation has a computer terminal with to access the information.

In the event the production engineer finds any issue, conflict or has any concerns during the first article build the Sales Specialist is notified, the customer is contacted, and the concern and any resolution are documented.

Test and Inspection

Test and inspection steps are included in the work instruction including inspections where a process might be hidden by a subsequent step.

The finished first articles are sent to the Technical Cable Applications quality department where the assembly undergoes a series of dimensional and quality checks to assure that the assembly meets or exceeds the customer specifications.  The first article assemblies are tested and sent to packaging to be shipped with first article documentation to the customer.

Validation

Once the first article is inspected, tested, and approved by the customer the work instructions are validated by Technical Cable Applications quality personnel.  Production can then be scheduled for the assemblies.

Contact

Technical Cable Applications is an ISO9001:20015 registered company.  Please contact the Technical Cable Applications sales team for help with all of you cable assembly needs.