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Cable assemblies are critical to manufacturing, ensuring the performance and reliability of electrical systems. It describes a series of steps, from material preparation to quality control, using specific terminology.
1. Cable Preprocessing Stage
- Wire Cutting: Cables are automatically cut to precise lengths by machines to ensure consistency across all manufactured products.
- Cable Treatment: Clean the cable surface to prevent damage and ensure a neat harness.
- Laser Removal of Aluminum Foil Mylar: Laser ablation of aluminum foil Mylar is performed with a laser, enabling subsequent processing.
- Braid: An EMC braid is applied to reduce electromagnetic interference.
- Stripping and Tin Plating: Wires are stripped of their insulating layers and then tin-plated to improve conductivity.
- Untangle the Strands: The wires are untwisted, making them easier to solder and crimp.
- Twisted: The wires are twisted according to the application’s requirements to reduce signal interference.
2. Terminal and Connector Processing
- Crimping: Terminals are crimped onto wires to make a gas-tight connection.
- Terminal Check: Covers crimping practices to ensure durability.
- Soldering: Wires are soldered to connectors to ensure an electrical connection.
- 360° Soldered Shielded: The entire shield layer provides better resistance to interference.
- High-Frequency Soldering: High-speed signal transmission is applied.
- Solder Joint Inspection: This covers the quality inspection of solder joints to verify their integrity.
- Auto Laser Double-sided Soldering: This process simultaneously soldered both sides of the cable, improving efficiency.
- Auto Gluing: Automated gluing would enhance connection strength.
3. Assembly and Protection Layer Processing
- Premold: First part of the injection molding process; used to support over-molding.
- Overmold: A layer of plastic on the outer surface of the cable and connectors (enhances the cable’s and joint’s mechanical strength).
- Assemble Iron Shield: An overmetal layer for enhanced protection from interference.
- Shear Braid: Trimming of superfluous braid for a neat finish.
- Assembly Tube: Inclusion of cable within the protective tube—increased mechanical strength.
- Heat-Shrinkable Tube: Heat-shrinkable tube and connector technology for sealing.
- Thermal Contraction Machine: This machine applies heat to the shrinking tubing to achieve a tight fit.
- Metal Can Crimping: Crimping of the metal can at the cable assembly to make it mechanically robust.
- Auto Laser Metal Can Soldering: This method employs laser technology to solder the metal housing, making the connection mechanically robust.
In specific applications, cable assemblies may be installed within housings or mounting structures that incorporate neodymium magnets for positioning and stability.
4. Quality Control and Testing
- Electrical Test: It tests the assembly for electrical performance.
- Finished Product Inspection: Ensures the finished product meets quality standards.
- Computer Test: These tests check cable performance by transmitting data.
- Microphone Test: This test evaluates the audio signal quality of audio cables.
- Check Line Sequence: Checks whether the signal is flowing through the wires in the correct sequence.
- Wire Color Ordering Test: Confirms the wire color sequences.
- Final Quality Control: A comprehensive quality audit confirms compliance with specifications.
5. Packaging and Shipping
- Packing: Cable assemblies are packed as specified for transportation and identification.
- Labeling: Every product shall be labeled with traceability information and batch numbers.
- Acetate Cloth: This material provides enhanced environmental insulation and protection, providing added strength.
Summary
The cable assembly process encompasses key steps from preprocessing to final packaging, each featuring specialized terminology. Romtronic, a manufacturer of wire harnesses and cable assemblies, is dedicated to delivering high-quality products for a range of applications. For any questions or additional information, please get in touch with us.
Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.
