Whether marine or automotive, it’s best to store wires, cables, and hoses neatly and out of the way. That’s where clips come in. They help organize your wire harness and electrical system. Read on to learn about automotive wire harness clips, including how to use them.
What Are Cable Clips?
Cable clips feature a loop or cradle and hook, which holds it neatly in place after you fold the wiring. Then, depending on the type, cable clips will have or not have holes, which will determine how you use them.
For clips with holes, you need nails, pins, or screws to fasten them to the surface. Just ensure the nail or screw size is correct.
But if the clips don’t have holes, they’ll have an adhesive strip instead. All you need to do is peel off the backing and stick the clip to the surface.
What’s the Difference Between a Cable Clamp and a Cable Clip
Cable clips are tools used to mount wires or cables. Many refer to them as cable mounts or wire mounts.
On the other hand, cable clamps assist with clearly defining how cable and wire installations get mounted. In addition to holding the wires or cables in place, they restrict movement and clearly define a cable path from where it starts to its destination.
Types of Cable Clips and Their Uses
Below is an outline of different cable clip types and their uses:
Self-Adhesive Cable Clips
These clips have an adhesive strip (sticky surface) covered with a backing layer. Simply peel off the backing and affix the clip. Note, though, that the strength of the adhesive strip varies depending on the gauge wire it’s meant to secure.
Normally, self-adhesive cable clips are best for securing cables or harnesses where drilling holes is not an option.
Metal Cable Clips
Usually, manufacturers use steel, stainless steel, and brass to make cable clips. That’s primarily because the clips are highly wear-resistant and not susceptible to damage from chemicals, heat, humidity, or water.
Some examples of metal cable clips include routing clips and wire loom clips.
Nail Cable Clips
These are the most commonly used professional and DIY clips. Usually, they have a hole with a nail or pin for fixing onto a surface.
Image of a nail cable clip
Nail cable clips are round or rectangular and come in several sizes and materials. And this diversity contributes to their popularity.
In addition to their use in cars, people use these clips for running wires for lighting or power, keeping TV and ethernet cables neatly, and motors and machinery.
Image of running cable tucked neatly using a nail cable clip
Screw-in Cable Clips
Coaxial cable clips make mounting wiring and cable easy. And when it’s necessary to make any changes, these clips are easy to remove and replace.
The two primary coaxial cable clips are nail and rounded push-puns, both plastic and available in black or white.
Mostly, people use coaxial clips for stereo wiring.
Image of white coaxial cable clips
P Clips
As the name suggests, P clips, when closed, appear like the letter P in shape. What’s interesting about these clips is that they wrap around the wiring or cable bundle, and then you can fix the bundle into position using a screw.
Further, P clips come in varying materials to suit different environments. And they’re also available in various sizes depending on bundle diameter.
Usually, people use P clips where chafing and damage to car components are likely.
Saddle Cable Clips
Saddle cable clips enable securing wiring and cable slightly away from the surface onto which you’re affixing them. That way, there’s less chafing or strain. Additionally, these clips have snap-in bases that make installing them easy and tops that lock so you can add or reduce wires as desired.
Further, saddle clips consist of molded plastics ànd metals. Usually, people use these clips for various automotive, industrial, and home applications.
Adjustable Cable Clips
Like the saddle cable clips, these clips allow adding or removing wire to suit your rerouting changes. What’s great about the adjustable cable clip is that it won’t open until you release the tab.
Metal Cable Clips Vs. Plastic Cable Clips
Metal cable clips in electrical wiring are stainless steel, steel, aluminum, or copper. And in case you’re wondering, the metal clips are all corrosion-resistant. As you know, aluminum, stainless steel, and copper are corrosion-free, and the steel clips are zinc-plated.
Some examples of steel clips are P clips. These have a rubber ring that absorbs vibration and provides electrical insulation.
However, rapid corrosion occurs when metals like copper or brass come into contact with galvanized steel. Therefore, you’re better off choosing another material like plastic. Nylon cable clips, for example, are a great option that’s pocket friendly.
Additionally, you must consider where you’re using the clips when choosing between metal and plastic. For example, metal is suitable when exposed to extreme heat as it won’t melt. But for most other applications, it’s safe to go with plastic.
Conclusion
There are several types of cable clips. Your choice depends on the wires or cables you want to mount and where you’ll install them. At Cloom Tech, we pride ourselves on superior cable assembly capability and expertise. If you need help, please don’t hesitate to contact us.
In every industry, electricity is important to keep up the good work. For that, you need to use an electric wire harness. Now, you can get it ready-made in the store, but it might not be able to fulfill your intended use. In that scenarios, you might want to customize the wire harnesses for your task. Also, you may want to improve its appearance by adding tags and colors. Either way, we suggest a cost-effective and better way; building a wire harness yourself.
Components Making up a Wire Harness
It would help if you had various components to build a wire harness.
Wires
Individual wires are the most basic components. And when choosing the single wire, you should consider the following.
Wire size
According to the American wire gauge, the bigger the gauge number, the smaller the diameter of the wire. Hence, you will determine the wire gauge by two factors: the accessory’s required current and the distance the wire must travel to reach the power source. You will need a bigger gauge wire to power an accessory with a higher current draw effectively.
Wire material and construction
Aluminum or copper is common for conducting current in wires. Stranded copper wire is a top pick for automotive applications due to its malleability and electrical conductivity. And Solid one is ideal for outdoor use where more durability and higher currents are required.
Wire color
It’s simple to overlook the significance of wire color unless you’re trying to track down a defective circuit. In the wire harness manufacturing process, you can easily track each cable that goes where if you label it.
Standard colors and functionality include:
Black wires typically designate a hot or positive current.
White wires will typically be for negative currents.
Green wires are typically for ground wires, especially in residential wiring applications.
Red wires can be a secondary line for hot and positive currents.
Blue wires are good for designating a point of connection.
Wire insulation plays a key role in safeguarding the wires within a wire harness assembly, yet it often goes unnoticed. When constructing a wire harness, a cable engineer must consider the system’s expected exposure to moisture, temperature extremes, acidic compounds, and other external conditions.
Insulation materials typically used in wire harness assemblies are:
Polyvinylchloride (PVC) is a cheap but durable material used for low- to medium-voltage cables.
Polyurethane (PU) is typical insulation to shield wires from moisture and abrasion; it can be either thermoplastic or thermosetting.
Thermoplastic elastomer (TPE) is a versatile material since it is both elastic and resistant to cracking under stress.
Thermoplastic vulcanizate (TPV) is a subset of thermoplastic elastomers (TPEs) that vulcanizes at elevated temperatures, lending it a superior compression set and thermal stability.
Polytetrafluoroethylene, or PTFE, is a strong chemical that is an inert form of epoxy resins. Mostly, electric systems use it because of its versatility and great performance in extreme temperatures and wet environments.
Silicon insulation provides better heat resistance because of its wide thermal range. When dealing with wide temperature changes, silicone is the best insulation material.
Caption: Components of wiring harness
Connectors and terminations
To properly insert a cable into the connecting point of a panel, equipment, wall outlet, or another device, you must select the right connector with the proper terminal. There is an almost infinite variety of terminations that you can use in your desired field.
Soldered and solderless (crimp connectors) are the two most common forms. Oversized wiring or splicing calls for the use of soldered connectors. All additional wiring can be crimp connectors, which is what we advocate utilizing wherever possible.
You can rely on a solid connection from a solderless connector; they’re a breeze. The insulators of most solderless connections have color codes to indicate the wire gauge to show the specific functioning. There is a wide range of solderless connector types available, including:
Butt Connectors
Cylindrical butt connectors connect two separate wire ends. You will place both ends of the wire into the connector and crimp them down.
Spade Connectors
For frequently repaired or replaced parts, spade connectors are the way to go. Here, you will make a connection when a male connector on one end of the wire inserts into a corresponding female connector on the other. However, you can always pull the plugs in opposite directions to detach them.
Ring Connectors
Ring connectors are essential to prevent the wire from slipping out of screw-type terminals.
Sleeves have several advantages, including protection from the sun and abrasion, better cable management, and more. It’s common practice to utilize a variety of sleeves in wire harnesses, some of which are:
It’s customary to use Velcro sleeves because they’re simple to fasten.
Spiral polypropylene wraps are available in a wide range of diameters. Incorporating UV protection in addition to enhanced durability. Superb for controlling your color palette.
Braided sleeves are not only aesthetically pleasing but can also be heat shrunk to fit a particular set of cables and connectors.
Polyethylene spiral wrap provides adequate protection for wires against heat and normal wear and tear at a low cost.
Shrink tubing is useful for protecting connections when soldering or using solderless methods. In addition to protecting against electrical shorts and the elements, shrink tubing can be quickly and easily installed.
Caption: Wire harness connector with terminals
Overload protection
Overload protection is essential for safeguarding expensive electrical equipment. The following are the primary methods of overload protection.
Fuses
The fuse blows when the circuit gets more current than the fuse threshold. The most common fuses are 3, 4, 5, 6, 7.5, 10, 12,5, 15, 20, 25, and 30 amps, with other sizes also available. Hence, its best practice to use a fuse with a slightly greater rating than the accessories. For safety, use a 25 amp fuse for an electric fan with a 19.5 amp rating.
Fusible links
You can also use fusible linkages. These are not typical copper wires; they are alloyed with a lower melting point. The connection is made directly to the accessory’s power cord. The link will melt in the instance of an electrical overload.
Circuit breakers
If an overload occurs, a breaker will cut power to the appliance. Once the cause of the overload is eliminated, you can reset the breaker. Circuit breakers are available in manual and automatic reset varieties in the same widely used amperage ratings as fuses.
Relays
When wiring, if your electric devices have higher current consumption than a regular power switch can handle, you should also install relays. Most switches can only handle low currents. Therefore wiring in an aftermarket electrical accessory almost always necessitates a relay. Large electric fans, fuel tanks, and high-intensity discharge (HID) headlights are just a few examples of high-amperage electrical accessories that benefit greatly from the employment of relays. An electric coil switches them on and off. A closed relay prevents electricity from reaching the disconnected device. When an electrical accessory is activated, power is transmitted via an electric coil through a relay.
Caption: Rubber damaged surface due to overheating
Mapping the strategy before starting DIY Wire harness manufacturing projects
Make sure you have a plan before you start wiring anything. Make sure you have enough wire to finish the job by laying out the wiring or wiring harness. Also, you should install the required fusible links, relays, or breakers at the power supply and electrical device connections.
Each cable and harness should be clearly labeled with the components they connect to if they aren’t already. Grommet the hole in the firewall where the wiring or harnesses will pass to prevent the wires from severed by the metal. When the wires have passed through the wall, only then should you tighten the connectors.
Here, you need to locate the negative-side chassis ground at one position. Moreover, your common grounding point for the harness should be near the firewall. This strategy can easily reach the vehicle’s negative side with ease. Additionally, when connecting the common ground to the chassis, use a 10 gauge or larger wire. Take your time, keep everything neat, and you’ll soon be a wiring pro!
Caption: Designing and Testing cable harness
Steps to Build a Wire Harness
The fundamental criteria and procedures for creating a wire harness are as below.
Construct a Wiring Diagram
It would help if you first created a wiring diagram for your system before you can start cutting any wires. Utilizing a computer program like CAD will allow you to complete this. A wiring diagram typically consists of two components: a schematic and a harness. The pieces, their locations, and their connections will all be shown on the schematic.
You can use the harness diagram to make a precise plan for connecting each component. And color the diagram to represent the many components. Circles of various colors, for instance, can represent connectors.
Gather Your Resources
You’ll need these proper tools:
Wires
Snap ties
Heating gun
Connectors
Terminals
Multimeter
Wire Cutters
Crimping Pliers
Heat-shrinkable tube
Wire Strippers (manual or automatic)
The size of the terminals will determine the diameter of the heat-shrinking tubing used. For that, choosing GXL cable with PVC is wise because wire harnesses are frequently used for demanding applications. This wire can withstand high temperatures, making it perfect for severe settings. Moreover, it will provide heat, flame, moisture, and chemical resistance to the wire.
Strip the Wire
Take a tiny section of the insulation off one end of the wire using the wire stripper. You must ensure that the cut length corresponds to the size of the terminals. It is because you will attach the wires using terminals.
Building a Wire Harness:Cut the Heat-Shrink Tube
Heat shrink tubing should be cut so that it is slightly longer than the length of the bare wire. Over a wire segment that hasn’t been stripped, place the heat shrink.
Building a Wire Harness:Connect the Terminal
Take a terminal, insert its joint into the crimping pliers, and slightly press it to attach it. Using the pliers, squeeze the terminal and wires together after inserting the terminal into the wire. Use enough pressure to crimp the two pieces together without damaging the wire.
Building a Wire Harness:Cover the Connection
After finishing the previous step, place the heat shrink tube over the crimp edge and seam to cover the wire. Make sure the tube fits the two sections securely.
Shrink the Tube
Use a heat gun to shrink the tube at this point. Activate the gun, adjust the temperature, and give it a moment to warm up. Heat shrink tubing by directing the hot air from the gun over it.
Caption: Cable harness in a car
The Safety Brief When Building a Wire Harness
Automotive wiring is the surest way to get a few scrapes and bruises on your knuckles. Cuts are inevitable whenever you work with sharp objects, even if you’re merely installing a new radio. Moreover, dust and dirt can get into your eyes if you’re dangling behind the dashboard. Even though wearing safety goggles and gloves can sometimes be painful, they are essential in this work area. So, you need to wear them at all times.
In addition, electrical shocks are quite dangerous. Accidents happen, and if you’re not careful, they might lead to a fire, so stock up on fire extinguishers. Due to the possibility of electric shock, you should never connect the wiring harness to electricity while working on it. Also, keep in mind the location of the wire as you work. Avoid all moving parts, including those with smooth or rounded edges. The constant rubbing will eventually wear away the protective coating, leaving you in a precarious situation.
Conclusion
Building your wire harness, you need to be careful while making the strategy and choosing your tools. But if you need more professional cable assemblies and wiring harness solutions, contact us now.
Today, features like Light sensors, Powerful stereo systems, Internet access, advanced driver assistance systems, and voice control systems are common in every vehicle, which means the ever-increasing diversity of the connection systems. According to SourceToday, there were 240 connectors in an average vehicle five years ago. We will understand automotive wire harness connectors in detail.
Automotive Wire Harness Connector Basics
The automotive wire harness is an assembly of the connectors, cables, and terminals spread throughout the vehicle.
And connectors are responsible for transmitting electric power and information to different components within your car. There are different types and varieties of connectors used by automakers; for example, printed circuit boards, circular, rectangular, charging connectors, etc.
These connectors connect or disconnect the electrical lines and consist of male and female terminals. Male and Female terminals are collectively combined with linking you to the electrical connection, which results in fulfilling your desired action (e.g., automatic window or stereo system).
Wire harness in Motor Vehicle
What are the main functions of the Automotive Wire Harness Connector?
These connectors fulfill three purposes.
Internal connectivity
These connectors connect the components inside the car. For example, stereo systems, sensors, etc.
External connectivity
You can use the connectors during the car repair process. Mechanics try to detect the real situation of the car by connecting the vehicle with external equipment via an external connector.
Replacement
You can also use the connectors to replace other connected devices. Although for a temporary period, these connectors play a crucial role. By then, you are free to use your vehicle.
Electric cabling in car
Characteristics of Automotive Wire Harness Connector
It is no secret that automotive connection systems have high standards due to the different environmental factors involved in the vehicle’s functionality. And the OEMs (Original Equipment Manufacturers) keep the technical reliability sharp in light of the environmental conditions such as vibrations, braking oil, engine oil, high temperature, etc.
Here, it is super important that the different connections within the vehicles are connectable or disconnectable in rough working conditions. Therefore, producers focus on inventing a powerful connection system to ensure your car’s best performance.
Automotive-colored connectors
Automotive Wire Harness Connector components and their functionality
Consider the following different components to make things easier for your understanding of the connector.
Connector Housing
You can use the connector housing to carry the terminals and pins while securing the connection with the mating part. You can also call it plastic insulation, whereas its design differentiates between male, female, sealed, and unsealed connectors.
However, it is crucial to know that the sealed connection system contains a radial seal that guards your electrical system against dust and water. Furthermore, this component has different coding in various notches. Also, manufacturers mark it with various colors to help new people understand its works.
Terminal Position Assurance
As the name implies, you will mobilize the terminal positions together in the housing through your hands. You insert the crimps into the housing and create a technical link. For assurance, the automaker/mechanic hears a sound of a certain click.
Electricians introduced this clicking property of the terminal to reduce mistakes in mass production. Once you make the perfect technical link, you will set the secondary lock to keep the connector in its location.
Connector Position Assurance
All the connectors are assembled connection systems via hands. Of course, if connectors lack proper assembly, you may be able to achieve the electrical connection. However, the connector will not protect the connection against water and wind.
Single Wire Seal
Most people use it to protect the cavity against environmental conditions. Automakers ensure to crimp the seals into the terminal and cable in one step and push it into each cavity. These Single wire seals comprise an important fluid known as silicon oil that supports the assembly process.
Block seals
Block seals also play a role similar to a single wire seal and protect the cavity from external factors while offering openings to retain cables. It means that a block seal guards several cavities altogether.
Cavity Plug
A cavity plug protects unused cavities from external environmental factors by blocking them. You can insert and remove them using your hands or a screwdriver.
Wire harness with plastic housing
Types of Automotive Wire Harness Connectors based on connection systems
You can connect three types of connection systems as per desire.
Wire-to-wire Connection
This type of connection comprises male and female connectors. Mostly, it connects and disconnects small applications and creates a link with the main wire harness.
Board-to-wire connection
The connection is fixed to a conductor board using this type of connection system. Here, the conductor board is linked to the male connector known as the “PCB Header.” On the other hand, the female terminal links to the wiring harness. This connection connects the engine control unit with the main power source.
Device Connections
This type of connection system is used mainly in sensor systems. And similar to the board-to-wire connection, it is composed of female mating parts already assembled for the given application.
Cable assemblies
Types of Automotive Wire Harness Connectors based on the electrical system
According to ISO standard 10487, there are about four types of connectors.
A-Group connectors
These connectors, also known as Power Connectors, join the vehicle’s head unit to the power supply unit.
B-Group connectors
These types of connectors are used to connect the speaker around the vehicle.
C-Group connectors
These types of connectors are optional and used to connect peripherals.
D-Group connectors
These types of connectors are optional similar to C-Group and are used to connect the navigation system.
Wiring harnesses under the dashboard
Standards of the automotive connectors
Automotive electrical connections are prepared, tested, and installed in the vehicles per global standards and specifications. It includes ISO:
10487 for passenger car radio connections.
7736 for Road vehicle front radio installation.
9458 for Passenger car motor connections.
Challenges faced in the automotive connector industry
With technological advancements in heavy-duty vehicles, many connectors are used to overcome excessive stress and strain experience. However, manufacturers tend to rely heavily on connector equivalents or component availability. Therefore, it creates multiple problems since this connector equivalent is less durable than the real connectors.
Another challenge faced in the automotive connection industry is sourcing wire harnesses in today’s market. Several distributors either do not deliver the connectors and wire harnesses on time or don’t have the desired quantity.
Wiring harnesses
Conclusion
There is a rising need for more durable wiring and connectors as modern automobiles become increasingly networked and microprocessor-controlled. Do you need help with them? Here at Cloom, we offer wiring harness and cable assembly solutions so that you do not have to worry about perfection.
It would help if you had wires and cables for all types of electrical systems as they make the system function. Also, they have a considerable role in maintaining safety in wiring. Thus, you must pick the correct type of wire for a particular application. Wire diameter or gauge is the most crucial among so many different features. How? Let’s learn how the gauge affects the different technical specifications of the wire and have the AWG Wire Size Chart in detail.
What is the American wire Gauge?
In North America, AWG is the standardized wire gauge system denoting the wire sizes. In this system, as the AWG number increases, the wire diameter and thickness become smaller. The smallest standard size in AWG is 40 AWG, and the largest is 0000. You can also call it the Brown & Sharpe wire gauge or just the wire gauge. They are for solid, round, conductive, and single-stranded electrical wires.
The AWG system came into existence in the year 1857. Before this standard, manufacturers used different methods to measure very confusing wire. The AWG system is similar to the Standard Wire Gauge system used in Britain. Several other countries use international metric standards where wire cross-section is represented in square millimeters, as mentioned in International Electrotechnical Commission 60228. The AWG system does not include the insulation size in the diameter dimensions.
Caption: cross-sectional wire area
Importance of American Wire Gauge
As the wire’s cross-section area increases, the wire’s resistance decreases. At the same time, the amount of current that a wire can carry safely also increases with the increase in the cross-sectional area. Also, a small gauge or larger diameter wire can have more power than the wire with a larger gauge.
AWG holds importance for wires which carry electrical current like home or business wiring, high power wires in automobiles, extension cords, etc. Using too small a wire, i.e., a very high AWG, can melt, overheat, and catch fire. Thus, to ensure safe electrical wiring, you must consider the wire’s current carrying capacity.
As larger wires use more metal, they are more expensive than smaller wires.
For wires that carry signals, such as video interconnect or audio hookup wires, the AWG is not as essential as it is for power wires. It is because the electrical signals in these wires have low power, and thus you do not need smaller AWG wires. Cable pair twisting and efficient shielding are more critical in these wires to maintain the integrity of the signals.
Caption: Gauge Wire
Relationship between the AWG thickness and other technical specs
The gauge affects the wire’s different technical specifications, which is why we say it has a considerable role in maintaining safety in wiring.
AWG to diameter
In this system, 0000 AWG indicates a wire diameter of 0.46 inches, and 36 AWG indicates a wire size of 0.005 inches. There are 39-gauge sizes between these two sizes which you can get through logarithmic calculations. The ratio of different sizes is 1 to 92 in diameter. So, you can say that each AWG step is around the 39th root of 92, which is approx. 1.12293 times changes in diameter.
You can calculate the wire diameter with this formula:
D(AWG)=.005·92((36-AWG)/39) inch
For gauge numbers 00,000, and 0000, you can use -1, -2, and -3 as gauges as they make more sense mathematically.
In the AWG system, the wire diameter doubles with every 6 gauge reduction, and the cross-section area doubles with every three gauge reduction.
AWG to Cross-sectional area
Commonly, when you refer to the size of a conductor, you talk about its cross-sectional area, which is expressed in mm2. To calculate the cross-section of solid round wires, you can use this formula:
Area = πr2, where r is the radius (1/2 of the diameter)
The gauge is ten times higher than the diameter in millimeters in the metric gauge scale, meaning a 50-gauge metric wire is 5mm in diameter. You must know that in the AWG system, the diameter increases with the decrease in gauge, but this does not apply to the metric gauge scale. Metric size wires are mentioned in millimeters instead of metric gauges to avoid confusion.
AWG to load current carrying capacity
The ampacity of the wire refers to its maximum current carrying capability of the wire. The table below mentions the copper wire current capacity. However, these are just rules of thumb. In reality, insulation, voltage drop, temperature limit, thermal conductivity, thickness, and air convection should also be considered.
Based on the AWG system, a smaller gauge or larger diameter wire conducts more electricity than a wire with a larger gauge or smaller diameter. As you decrease the AWG size of the wire by six, its cross-sectional area and the electric current amount increase doubles when AWG reduces by three. When you change the AWG size by ten, the cross-sectional area also changes tenfold.
As aluminum is not as good as copper in its conductivity, we consider aluminum as two gauges larger than copper when we compare the conductivity of both.
AWG to Maximum frequency for 100% skin depth chart
You can use this data for high-frequency AC applications. When alternating current flows through the wire, the current tends to flow along the sides of the wire. As a result, the effective resistance increases. The table below mentions the frequency at which skin depth equals the wire radius, which means above this frequency, you have to consider the skin effect while calculating the resistance of the wire.
Breaking force for copper wire
The table also shows the breaking force for copper wire. Here the estimation is based on the nickel-free soft annealed copper wire with a tensile strength of 37000 pounds/sq inch.
Caption: AWG Wire Size Chart
What is the American wire Gauge for Multiple Conductors Stranded Wires?
The AWG system primarily describes the size of single-stranded solid wires. However, when there are multiple conductors stranded wires, you can use AWG to get the cross-section of all the strands and then add them together.
In stranded wires, you usually use three numbers to define their measurements, representing the AWG size of the wire, the strand number, and the American Wire Gauge size of each strand.
For example, 23 AWG 5/30 means a stranded wire of 5 strands of 30 AWG or 0.0509 mm2 which is equal to the 23 AWG or 0.258mm2.
twisting two electrical wires
Applications for Different AWG Diameters
Wires have different physical and electrical properties, making them suitable for various applications. The wires with thin gauges are ideal for lightweight applications, and the thicker wires are suitable for heavy-duty applications.
Here are some uses of wires with different gauges.
Gauge 4 wire: suitable for large heaters and furnaces.
Gauge 6 wire: ideal for heaters, large air conditioning units, and the clothes dryers
Gauge 12: small air conditioning units and outlets in residential areas
Gauge 14 wire: suitable for electrical circuits, devices, and lighting fixtures
Gauge 16 wire: ideal for light-duty extension cords
Gauge 18 wire: suitable for low-voltage lighting and cords
AWG wires
Conclusion
Hopefully, with this information, you will choose the correct wire size for your applications. If you need more help regarding high-quality cable assemblies and harnesses, contact Cloom. We are a leading manufacturer of superior quality.
When you connect bare wires to equipment, they become loose and curly and rust over time. Electrical equipment needs safe and secure connections to keep the equipment functional. Banana plugs are an easy solution to form a solid connection. How do they work? This article will discuss the banana plug cable assembly in detail.
What are banana plugs?
Banana plugs are cylindrical connectors that you use for electrical wiring. It got its name from the fruit banana because of a protruding prong that bulges out from the center. This protrusion has a spring-mounted fin which can expand once you insert it into the equipment socket. Thus, it results in a firm and almost permanent hold. You can also call them 4mm connectors; the 4mm refers to its standard diameter.
Uses of banana plugs
With banana plugs, you can safely, easily, and quickly connect or disconnect electrical wiring to equipment through matching banana sockets. If you do not use a banana plug, you may need to attach and reattach the bare wires on equipment, resulting in short circuits and equipment overload.
You can use banana plugs in a wide range of audio equipment, such as:
The screw type is the standard banana plugs, and there are different designs to hold wiring.
Open screw banana plugs
In open screw banana plugs, there is a lug connector or a protruding bolt where you can attach the length of insulated equipment wire. You can do this through crimping, soldering, or an easy-to-use built-in screw.
In these types, you can hold the wire in place through a metallic cylinder into which you insert the wire from the rear end. Following this, you can screw an upper cylinder with a prong on its top.
Open screw banana plugs vs. Closed screw banana plugs.
The similarity lies in the cable termination in both types. There is a rear section that you can remove to allow the cable entry and then clamp it internally.
The main difference is that in the closed screw types, there is an enclosed chamber; on the other hand, in the open screw, there is a side entry point providing a versatile solution along with an enclosed chamber.
Open screw banana plugs
Closed screw banana plug
Additional Features of Banana Plug Connector
The banana plug comes in different varieties.
Locking banana plugs
In these plugs, there is a mechanism through which you can expand the prong more than the typical spring-mounted fin once it inserts into the socket. As a result, it forms a stronger bond.
Gold banana plugs
These plugs provide a high electrical conductivity level and are very attractive. It has a gold plating that combines with other conductive metals like brass.
Banana Plug Cable Assembly: Banana plugs with covers
You can also call them shrouds. These covers are tube-like structures that surround the prong to protect them. These covers automatically retract once the prong inserts into the socket. Some sockets also have been shrouded. Generally, these plug covers are more used in high voltage equipment such as test laboratories.
Banana Plug Cable Assembly: Double banana plugs
As the name clears, these plugs have two in one housing, which may feature a different cable connector on another side. As a result, it helps form a sturdy connection between two other audio cables.
Banana Plug Cable Assembly: Angled banana plugs
These special banana plugs have a pin at a 90-degree angle to the cable. With this, you can insert the cable in the top-down position, giving a more robust and more secure connection than the side insertion. The side connections often become loose due to wire stress or accidental tugs. Typically, you will find them with a multimeter or other electrical test equipment.
Different types of banana plugs
Banana Plugs Genders
You will find electrical connectors in female (i.e., enclosing) or male (inserting) designs. The banana plugs are male connector types that you can insert into their female counterparts, i.e., banana sockets or jacks.
The presence of insulation affects the compatibility between banana plugs and banana sockets. When insulation is there, the sheathed male plugs will not fit appropriately into unsheathed female banana sockets. Unsheathed banana plugs may fit into both sheathed or unsheathed sockets. The speaker plugs have uninsulated endings.
Angled banana plugs
Banana plugs sizes
Banana plugs can have pins that vary in size and diameter. However, you will commonly find metal pins 4mm in diameter or 5/32 inch as the standard size. Other than this, there are miniature plugs of 2mm in diameter. Also, there is a 3mm plug which you can refer to as a mini banana plug or small banana plug.
The standard length of the banana plugs is 20mm or 3/4inch; however, some shorter sizes are also prevalent. Especially in the US, banana plugs of length 15mm or 5/8inch are more common. Sometimes, people refer to them as short banana plugs, and you get a discreet connection with these plugs. Other than these, there are 25mm or 11mm plugs. However, they are less frequently seen.
Banana cables for the electrical laboratory
Do I need Banana Plugs for my Speakers?
Banana plugs offer several benefits, but connecting the amplifier to your speakers is not essential. However, with plugs, you can benefit a lot.
Using banana plugs will keep your speaker wires tidy and prevent them from damaging.
The two ends of the speaker do not mix when you use banana plugs.
Also, with banana plugs, you can easily connect or disconnect your speaker wires. It is tough when you use the bare wire of the speaker to connect with the amplifier. Ensure the wires are exposed, and you must place them in a grip to ensure their contact with the metal surface. However, when you use banana plugs, you only need to connect the plug to the corresponding port.
An additional advantage, though not very prominent, is that they improve the sound quality.
Speaker wiring without plugs
How to Install Banana Plugs on a Speaker Cable?
Follow the steps for a successful banana plug cable assembly.
Banana Plug Cable Assembly: Preparation
Most of the audio systems are inside any entertainment unit. Thus, you cannot expect too much light in that area. Therefore, please carry a compact torch with you before the installation begins.
Besides this, you need to take a stripper to strip off the insulation from the wire to insert inside the connector. You can also use a blade or a scissor if a stripper is unavailable. However, make sure that you do not cut the inner strands.
Don’t forget a screwdriver (according to the banana connectors type) so that you can tighten the fasteners that lock the screw to make a secure connection.
Next, you need not follow any rules for the tracer wire. However, we suggest you maintain consistency with the color to which the tracer wire goes through your installation, which will help you wire your speakers correctly.
Banana Plug Cable Assembly: Select the correct banana plugs
It would help if you chose the plugs with the right size, quality, angle, and so on.
Banana plugs come with different measurements based on the thickness of the speaker cable. You can find speaker wires in different gauges. However, the common gauges of wires that you use for connecting speakers to a receiver or an amplifier are between 12-16 gauges, and that’s what you pick with banana plugs too.
The angle of approach of the speaker cable to the speaker terminals is also critical. In general, you can use a banana plug having a rear entry point; however, you may also need to pick a side entry point.
Banana plugs are available in different metals and alloy options. Some of them come with 24K gold plating, which ensures that the connection will be more durable and will not rust over time.
Other than these main factors, you may also look for manufacturing materials and general artistry.
Closed and open screw banana plugs have rear entry points, so both installation processes are the same. However, the open screw banana plug also has an entry point from the sides, and the installation differs slightly.
Installing closed and open screw types through the back entry point:
Banana Plug Cable Assembly: Method 1:
First, strip the required length of the speaker wire from every conductor.
Second, fold the cable over the halfway point so that strands double to fix onto the plug.
Now, unscrew the banana plug’s top section from the lower side.
Next, insert the speaker’s cable into the bottommost section on the rear side until all stripped cable protrudes.
Now, form a tiny ball shaped from all exposed strands so that the plug clamp effectively.
Now, screw back the top part, so it stands for the speaker’s cable you made in the last step.
Finally, insert plugs into the connectors on the amplifier or the speaker.
Banana Plug Cable Assembly: Method 2:
First, strip the required length of wire (approx. 30mm)
Now, remove the upper section of the plug from the lower side.
Now, insert the speaker’s cable from the rear bottom until you notice the cable of the speaker cable protruding out up to 3-5mm.
Next, expand the wire and fold it around the bottom piece’s circumference.
Put back the screw piece of the top so that it works as a stand for the speaker’s cable.
Finally, insert the banana plug into the connectors of the amplifier or the speaker.
Note: for cables under 12 American Wire Gauge, you must use method 1 to terminate securely.
Banana Plug Cable Assembly: The side entry point is for open screw type only.
First, strip the required length of the wire (approx. 12mm)
Now, twist the wire strand of the cable to make them tight.
Now, make an L-shaped from the twisted wire at around ⅓ of the bare wire.
Now, remove the top part about half of the way.
Next, insert the cable into the entry point towards the sides. Make sure that the L-shape points toward the bottommost section.
Put the top piece back to work as a clamp for the cable prepared in the last step.
Finally, put banana plugs into the binding posts on the amplifiers or the speaker.
Note: if you use this entry point, you can also use the back entry point to connect other banana plugs for bi-wiring.
First, strip the required amount of wire (approx. 12mm) from each conductor.
Remove the banana plug’s outer section to reveal the inner chamber.
Now, make the screw locking fasteners on each plug loose.
Next, insert the speaker’s cable into the plug while applying minimal force until the wire touches the chamber’s end.
Now, tighten the fasteners.
Conceal the inner chamber by placing the outer section again
Finally, insert the plugs into the binding posts.
Speaker wires
Conclusion
Although banana plugs are not necessary for your audio system, they have a wide application. Before you pick a plug for your use, make sure that you choose the right size and type. You can get professionals to help from Cloom. We are a leading manufacturer of wiring harnesses and cable assemblies.
Automobile batteries frequently die in the bitter winter, but the problem may not lie with the battery. The battery cable assembly could be at fault. Today, we will have a clear picture of the ideal cable.
What are Battery Cables?
They are a pair of thick cables connecting the battery to the electrical system. The positive charging cable is the red-sheathed wire that runs from your car’s battery to its onboard computer. Additionally, you will connect the battery’s negative terminal to the vehicle’s chassis through a black-sheathed wire known as the negative dc cable (sometimes called the ground strap or ground cable). They form an autonomous circuit that allows for constant energy transmission.
Red and black battery cables with 6mm hole connectors
Where Are Battery Cables Used?
The most effective method for connecting the batteries to a starter is with a battery cable. Boats, trucks, buses, vehicles, RVs, and tractors use battery cables. Boats, trucks, buses, vehicles, RVs, and tractors use battery cables. The battery cable’s strength and longevity shine through straight lines with minimal battery cable 90-degree bends.
Compared to other types of wire, like welding cable, battery cable is a simple and inexpensive way to connect batteries. Hence, there are numerous cable types to choose from, and the one you use will depend on your unique requirements. In general, the voltage rating of this cable is 60V DC, and the gauge sizes available are somewhat varied. In general, the voltage rating of this cable is 60V DC, and the gauge sizes available are somewhat varied.
Copper battery cable
How do Battery Cables Work?
The wires connecting your car’s battery to the electrical system are in plain sight. Additionally, the starter solenoid is often the immediate target of the positive cable. Then the route proceeds to the starter’s positive lead. Also, the negative battery wire of the vehicle is connected to the vehicle’s chassis, so electrical components like the starter can operate when the relevant switches are engaged.
Jumper cables
Symptoms of Bad Battery Cables
The illumination inside your car gets dimmer.
Your engine cranks slowly.
Your engine won’t turn on.
When you press the key, you hear a clicking sound, but the engine won’t start.
Your car’s electrical system is down.
Without moving the car, the engine stalls.
How to Check Your Battery Cables
For a deep examination of your battery, follow these simple steps.
Check the terminal and battery electrical connection; they should be in perfect condition, and the work environment can expose the wire’s conductor.
Clean the corrosion on the terminals, if any
Check the negative battery cable for any grime on it.
Look for any wear and tear that loosens the cables or expose the conductor.
When to Replace Battery Cables
Unlike oil changes, there is no standard for how frequently damaged you should replace battery cables. Moreover, you should regularly inspect the battery cable sheathing for cracks since a crack could expose bare wires to corrosion and other factors.
Pay attention to the signs of a bad battery cable described below, such as difficulty starting the vehicle, dimmer interior or exterior lighting, or stalling while the vehicle is running.
The lithium battery pack in electric car
Things to Double-Check When Choosing Battery Cables
Let’s analyze their functionality, inspect their condition, and determine the following characteristics of battery cables.
Wire Gauge
Electricians can meet power requirements with the help of the many different wire gauges available in battery cables. Also, power capacity increases with cable size. Hence, its intended use, location, and surrounding temperature determine the maximum current that can safely flow through a cable.
10 gauge is for low-power alternators, accessory leads, and trigger wires
8 Gauge is best in Low-power alternators and accessory leads
6 Gauge is for most stock alternators and accessory leads. It also works for battery cables on small engines.
4 Gauge is mostly for battery cables. Also, it works well for wiring the alternator and other accessories.
2 Gauge wire is best for four small 6-cylinder engines, power converters, and other things.
1 Gauge is best for big 6-cylinder engines, small V8 motors, and high-output alternators with a current rating of 200A or more.
1/0 Gauge is for simple V8 motors and 6-cylinder engines
2/0 Gauge is for engines that are hard to turn, battery banks, electric cars, and large power converters.
3/0 and 4/0 Gauge is best for the high-power energy banks and big diesel or marine engines
Stranding
Battery cable assemblies’ adaptability is significantly affected by the wire’s stranding. So, when a wire’s current is more likely to travel along its outer surface, a greater strand count will have slightly better conductivity and power distribution than a lower one.
Connectors
Standard battery terminals, which fit over lead posts, and ring lug terminals are two of the most popular connectors used for battery hookups. They are available in straight and right-angle shapes to accommodate a wide range of wire diameters. These can be found in both plated and unplated copper forms.
Insulation
It is common for the oil and toxins present beneath the hood to increase the temperature of a car’s battery cable assembly. Battery cables of SAE type SGT and SGX are designed for usage in cars and other vehicles. A standard SGT battery cable will suffice for most uses, but it lacks the advanced capabilities of the SGX battery cable.
SGT： A common battery cable with several uses is the SGT variety. Because of its resistance to moisture, oils, acids, and cracking, SGT is great for electrical work like replacing batteries and other similar operations.
With its thick PVC insulation, your connection will remain intact and trustworthy. According to a general opinion, this cable is the most cost-effective choice for many common tasks. The SGT battery cable is rated for temperatures up to 80 C (176 F) and complies with SAE (Society of Automotive Engineers) standards J-1127.
SGX： SGX distinguishes itself from its rival by using XLPE insulation as its insulation. As a result, there is resistance to coolant, ethanol, diesel fluid, fires, gas, ozone, acid, alkalis, abrasion, acid rain, power steering fluid, transmission fluid, and oils. In addition, as they can endure up to 125°C/257°F, it offers more heat protection than SGT.
Engine compartments are the best for SGX battery cables because of the enhanced protection. Boats, buses, trucks, RVs, tractors, and other large vehicles can all be supported by SGX cable. This cable typically costs more than the SGT power cable since it is more dependable and long-lasting.
Length
The voltage drop, or the voltage lost across the length of the automobile wire or cable, must be considered while deciding on the length. Also, electrical resistance increases with wire length, reducing the voltage to an unsafe level if the wires aren’t short enough.
As the resistance of a wire depends on its cross-sectional area over distance, thinner wires with a larger gauge will have a greater drop rate than thicker wires with a smaller gauge.
Conductor material
The conductor material of the wires is also a significant influence.
OFC (Oxygen Free Copper): To connect speakers or a high-powered amplifier, stereo shops frequently sell OFC (Oxygen Free Copper) wire. As for the benefit, OFC has a purity level of 99.5% or higher, which is 0.05% more copper than a simple one. However, it costs twice the standard cable, making it an expensive option.
CCA (Copper-Clad Aluminum): Copper clad is just aluminum that has been coated in copper. With only 60% of copper’s conductivity, a CCA wire would need to be around 2 times larger to match the performance of a standard copper wire. As an alternative, a CCA wire of 2 gauge would be required to replace a 6 gauge copper one. Hence it’s better to stick to the plain old copper battery cable.
The battery in an electric car
Custom Battery Cable Assemblies according to your needs
Cloom continues to be a cable assembly manufacturer that leads the way in conventional and custom battery cable assembly.
Marine rating Battery Cable
Many different kinds of wire go by the name “Marine.” The “wet” or marine environment is where it shines. Another requirement is to be a “self-extinguisher” in the event of a fire. That is why all products intended for use at sea must have a special marine rating, as required by the manufacturers.
Fuse Link or Fusible Link Battery Cable
The high-temperature shielding of the fuse link will keep the cable secure if it overheats and fuses open. The most typical use is in automobile alternator wires. Common applications include harsh environments, relay wires for heating systems, and diesel engine plugs.
Tapered Post-Battery Cable
The terminals of the tapered post cables might be made of lead, brass, or forged bronze. Furthermore, it can be with various coating options and features lead cast heads made from 8-gauge wire. Additionally, it offers numerous choices for covering connections, such as heat shrink tubing, to ensure their safety.
Ring to Ring Battery Cable
Ring-to-ring battery cables enable you to crimp many wires onto a single lug. In addition, you can dip it in tin, which increases its corrosion resistance and gives it a powerful pull.
Booster Cables
Finally, the booster cables are useful when you have limited space yet still need to charge the car’s battery. In addition, it is built with purpose-built components for certain applications.
Ground/Flat Straps
Connecting to the ground with a flat strap takes up very little room. Additionally, it offers various crimp alternatives, such as lugs, open-barrel, and lead cast battery terminal connectors.
Battery Cable Repair Splices
Batteries with built-in cable repair splices allow for speedy and easy replacement of worn or broken connectors. Moreover, fixing a damaged battery terminal is easier than changing the entire battery cable harness.
Just unplug it, strip back the insulation, splice in the new terminal, and reconnect the connection to the battery. Since you can replace the terminal end of a battery cable independently, battery cable repair splices are more convenient and cost-effective than replacing the entire cable.
Booster battery cable assemblies
How to Change Battery Cables
Reinstalling battery cables is easy if you know the basic phenomenon.
Materials Needed
Terminal Cleaning Tool
Battery Cleaner
Extra Battery Cables for Replacing
Diagonal Cutters
A basic set of Hand Tools
Procedure
Carefully look into the battery cables and see where they connect inside the engine compartment
First, remove the negative battery cable from the car. That way, you will disconnect the ground connection from the vehicle’s electrical system, avoiding accidents.
Next, remove the positive wire from the car.
Once you have removed all the cables, remove the battery from the chassis. Remove the battery cables from the battery as well,
Check whether the new cables are the same length as the previous one. If so, connect these new wires to the car.
Reinstall the battery inside the vehicle and clean its terminals. Then connect the cables while installing the positive one first and then the negative one.
Test the vehicle by starting it. In case of any issue, talk to professionals around you.
Conclusion
It would help if you replaced the battery cables before any further problems. Hopefully, with this information, you will choose the correct one for your lasting battery connection. Also, here at Cloom, we offer wiring harnesses and cable assemblies to make your connection reliable and safe.
If you pride yourself on exploring your car’s mechanism, you’re probably aware of the vehicle’s wiring. However, if you’re new, this could be a challenging experience and you are supposed to begin with the term, automotive wiring harness wire.
What Is Automotive Wire?
Put it in simple terms; an automotive wire is simply a wire that’s best suited for automotive wire harness purposes.
Different types of automotive wires or cables are designed to serve specific purposes. The most common wires you’re likely to come across are the brake, speaker, primary, and battery cable.
If you pick the wrong type of wire for a specific application, it will lead to system failures in your car. Furthermore, improper Wiring could result in an engine fire.
Also, as a side note, a wire thicker than gauge 8 is referred to as a cable.
Engine fire
Different Types of Automotive Wires and Cables
The following are different wires used in vehicles.
GPT or Primary Wire or Main Wire
This wire is probably the most common one you’ll come across in any vehicle’s wiring system. The primary wire (GPT) has a multi-strand core with flexible insulation to allow it to fit through tight spaces. They’re mainly used for interior wiring purposes. They’re used primarily for internal wiring purposes. GPT wires should not be exposed to the outdoors for prolonged periods.
Primary wires can endure temperatures of up to 176 Fahrenheit. They can also withstand chemicals, acids, and oils without complications.
Motor Wire
The motor and main wires differ because the motor wire’s insulation has more delicate strands of copper. They usually can withstand up to 600 volts and temperatures as high as 2210F. Also, it can withstand higher voltages without any complications.
TXL, GXL, SXL Wire
Wires made of single-stranded conductor type of copper are usually TXL. These wires have cross-linked polythene to insulate them. GXL wire is a single-conductor primary wire with XLPE insulation. SXL wire, on the other hand, has a bare copper conductor and is protected with XLPE.
The jacket made of cross-linked polyethylene means the wires have better aging, abrasion, and heat resistance.
Further, depending on the application area, the insulation thickness differs. The TXL wire differs from the other two types because it has thinner insulation. And GXL wires are a cross between SXL and TXL wires in terms of thickness.
Due to its extra durability, the SXL wire is preferred for more intense conditions such as industrial or racing vehicles. However, TXL wires are also used in racing vehicles because they are lighter, helping save on weight.
Battery Cable
The battery harness cable connects the battery to the ground and the electrical system. Often it’s thicker in size than most wires.
Speaker Wire
You’ll need speaker wires to transmit audio signals from the stereo receiver to the speakers. Typically, speaker wires serve low voltage purposes. To ensure the speaker sounds right, properly connect the negative and positive terminals of the wire.
Trailer Wire
It refers to the primary wire that’s been tailored and colored to serve as a trailer wire. Often trailer wires utilize a color code of brown, green, white, and yellow.
Colorful wires
Difference Between a House Wire and Automotive Wire
Automotive wires are often used in harsh environments of your vehicle. For instance, they’re used in the engine where if house wires were in the application, they could easily get damaged upon coming into contact with battery acid.
In contrast, automotive wires can withstand high temperatures and chemical corrosion. Also, automotive Wiring is a more robust and secure jacket while maintaining more flexibility than house wires.
A common mistake many people make is opting for house wires to serve automotive purposes simply because they’re cheaper. Even if the housing wire you picked fits the ideal current carrying capacity, several other factors remain to consider.
Wire conduits
Common Vehicle Wire Damages
Due to some reasons, your automotive Wiring suffers a lot from:
Short Circuit
If the Wiring to the ground or electrical power source is short, it will cause some components in the circuit to malfunction or perform partially. However, it depends on where the Wiring is lacking and how fast it is.
Open Circuit
If any wire in your system is cut, no current can move from one end of the circuit to the other. Such instances result in an open course.
High Resistance
High resistance can block the current flow, resulting in some of the circuit’s electrical components malfunctioning. The High resistance is often caused by improperly connected Wiring or rusted wires and components.
Interior wiring
What Are the Signs Your Car Has Damaged Wiring?
Wires have conduits that allow the safe passage of electricity along various circuit parts. In case of a wire malfunction, your vehicle will display some signs in correspondence to the connected electrical device.
Automotive Wiring Harness Wire: Malfunctioning of Vehicle Electrical Components
Faulty Wiring could result in several electrical issues, such as a broken radio or lights.
A fuse is designed to blow if excess volts of electricity pass through a given circuit. If your vehicle has a shorted wire, it could result in excess electricity flowing through a course, which will trigger the fuse to blow.
Automotive Wiring Harness Wire: Car Won’t Start
It’s common for your vehicle to exhibit some issues starting if there are any wiring issues. The problems range from PCM ground wire corroded to a damaged wire in the starting circuit.
When picking a wire for your project, some factors should help you make the best decision.
Wire Size
Wires are measured according to their gauge size. However, the gauge scale is inverted, with the thicker wires having a smaller gauge size. For instance, a 10-gauge wire is more comprehensive than a 20-gauge one.
The amount of current drawn from the circuit and wire length between the electric power source and the course will guide you in picking the correct gauge size to serve your needs better and ensure complete Wiring.
However, if your intended use is doing repairs, ensure you have the technical manuals for vehicles to avoid making costly mistakes. The manual will help guide you as it will likely always have the exact gauge size required for specific automotive components.
Wire Amperage
Amps determine the total amount of electricity a wire can allow to flow through.
Before purchasing any electrical wires, carefully check the label to determine the current rating. Overloading a wire is dangerous and could lead to shorting out, damage to essential systems, stalling equipment, or in some extreme cases, it could spark a fire. It’s advisable always to ensure you have the right amp rating before buying any wires.
Ensure you know the relays, circuits, breakers, fuses, and any other form of overload protection your wiring project needs. In addition, have suitable automotive wiring connectors for the job. Excess amps will likely short out your connectors.
Wire Materials: Copper or Aluminum
Electrical cables and automotive wire materials are mainly available in two forms; aluminum and copper. Copper wires are often the right choice for automotive wire harness applications. Copper wires are more flexible and conductive compared to aluminum. Also, copper wires are less likely to corrode.
Aluminum wires, on the other hand, are considered lighter and cheaper. However, they are less durable and more susceptible to corrosion. Also, over time, aluminum wires are likely to develop electrical resistance.
Wire Core: Stranded or Solid
Solid wire is mainly suitable for the wiring harness industry and home use. It’s best to avoid using reliable cables in your car’s Wiring unless you plan on using them to bail wires. With automotive Wiring, you should opt for flexible Wiring. Stranded wire is more flexible since solid core wires can’t bend over and over.
To create PVC insulation, first, heat the PVC. Then there’s a die on the stranding through which the PVC is extruded. The insulation is then added via melting through a heat source, which could change the form. There are three main categories of PVC automotive wires:
GPT: Rated 80 °C and suitable for common types of circuit wiring.
HDT: Also rated 80 °C and used as automotive wire for heavy walls.
TWP: Rated 105 °C and used primarily as a thin wall automotive wire. It’s also considered lead-free.
To create cross-linked insulation, first, you’ll use a tube to extrude the polyethylene while keeping it under high pressure and heat. This will cross-link the molecules to another state. Compared to PVC automotive wires, automotive cross-link wires can withstand far higher temperatures, better serving the wiring harness industry. The three most widely used cross-linked automotive cables include:
GXL: Rated 125 °C, considered thin wall, and suitable to work with typical automotive types of connectors.
SXL: Rated 125 °C and considered a standard wall.
TXL: Also rated 125 °C, considered fragile wall and best suited for application on wire harnesses requiring small size and minimal weight.
Wire Coloring, Striping, and Printing
Automotive wires are available in a variety of colors. A more straightforward way to organize the necessary cables to accomplish a task or repair is to assign colors to the wires according to the intended use.
You can use colors to identify and track wires back to their circuit. Today, various market sectors have their standard wire color system. Furthermore, you can expand the color scheme by adding a color stripe.
You could purchase wires with printed wording indicating their exact use for further clarity. Quickly sorting your wires allows you to conduct repairs and efficient constructions efficiently. You’ll develop a color code for future custom wire stripping tasks, saving time.
Connections
Generally, Wiring uses two types of automotive wire connections; solderless and soldered.
Often, solderless connections are considered the quickest and easiest way to terminate wires. Solderless bonds involve readily available automotive wiring connections such as ring terminals, spade terminals, and quick disconnects.
To properly use the following equipment, it’s advisable to learn how to make a proper crimp. Unfortunately, solderless connections aren’t always as long-lasting as the ones you’d wish. However, you could use additional strain relief equipment, such as auto wiring harness tape or heat shrink tubing, to increase the lifespan of solderless connections.
On the other hand, soldered connections are more susceptible to error and difficult to install. With the wide variety of solderless links to pick from, it’s rare to find people using soldered connections. Many professionals today discourage soldered associations because it makes it harder to control quality during the process.
Wire Length
Wire length chart by amps and wire gauge.
Conclusion
There are different types of automotive wiring harness wires, each with other properties. Cloom Tech is one of the leading wiring harness wire manufacturers, serving automotive companies. Any signs of wiring damage? Look to us for help.
Wire harness assembly is a manual and time-sensitive process that frequently ends in high costs and a lack of product quality consistency. Also, the project production time could take weeks, depending on cable types and quantities. However, more and more manufacturers are lately using automated cable assembly processes. These have proven to reduce project time spans significantly and be cost-effective.
Wire Harness Manufacturing
Granted, we are unable to transform to complete automation for specific processes. But we can still automate many of the crucial functions.
Processes That Can’t Be Automated
Wire Harness Assembly: This is a step-by-step process that must be done manually.
Terminal wire installation
Removing wires and cables via sleeves and conduits
Multiple crimping of individual wires where you’ll pass more than one wire through a single terminal
Taping harnesses at the branch after using fabric
Binding or harnessing components with loose clamps or cable ties
Processes That Can Be Automated
Cutting and stripping wires during the wire harness assembly
Crimping terminals on the sides of wires
Plugging of wires that have terminals into connector housings
Soldering wire ends
Testing for electrical functionality
Caption: Heat shrinking tubing
Cable Assembly Equipment and Automatic Wire Harness Machine
Below are some automatic wire harness machines:
AutoStrip 7400
The AutoStrip 7400 wire processing machine is for any strip length. It has a maximum strip length of 1200 and can cut and strip wires at a rate of 500 pieces per hour. If your project requires shorter strip lengths, the AutoStrip 7400 can do the task at a faster speed of 8200 pieces per hour.
This device can handle gauges of up to 8.66mm. Furthermore, it can take a multi-conductor and flat cable gauge of around 8mm.
AMP-O-ELECTRIC G II+ Terminating Machine
The G II+ is a vital machine the production department uses to process gauges of increased diameter (16mm). It offers precision variable speeds, allowing technicians the flexibility to handle any custom wire harness application.
Additional features include split cycle operation, a toolless applicator, and manual crimp height adjustment.
Branson 2000 Xt Ultrasonic Welder
The Branson 2000 Xt Ultrasonic Welder can handle any welding process requiring precision. The device features advanced digital amplitude control to ensure consistency. It also features a comprehensive range splicing system that takes diameters between 0.35 to 32mm.
In addition, the designs are stacked vertically to prevent side slicing, a common issue in the industry.
Branson 2032S Wire Splicer
The Brabson 2032S wire splicer can handle any custom harness design process requiring an ultrasonic splicing system. The machine allows the automation of welding operations via ground detection, peak power, or time.
In addition, the device features programmable starting ramp time, digital autotune, and precise digital amplitude control with proofing to enable complete automation of wire harness production.
Additional Production Tools and Equipment
A wide variety of hand tools are necessary for semi-automation.
Caption: Open wire
Benefits of Automated Cable Assembly
Some benefits of automated cable assembly include:
Make Up for Downsides of Manual Processing
While machines can malfunction, there’s always a margin of error accompanied by manual production. Often these errors are related to incorrect wiring systems and damaged pins and connections.
In contrast, once programmed, machines are less prone to errors and don’t get tired, bored, or distracted from repetitive tasks.
Also, their levels of output and efficiency are much higher. For example, instead of employing traditional visualization, you can save up to 70 percent of the time with automated wire assembly.
Make Sure Product Uniformity
Wire harness manufacturing processes like balanced terminal pressure and precise stripping ensure continual quality and product uniformity, which means consistency and shorter production time.
Control Quality
Optimizing quality control in manufacturing components with automated cutting, stripping, and crimping machines are more accessible. These processes also follow exact specifications.
For example, automated systems enable monitoring of sealing, crimp force, wire end, and knots in components, as well as separating the good from the bad. Also, when fully automated, crimping machines can provide processing options and twist and turn wires to varied lengths and cross sections.
Increase Production Run Capacity
Both high-mix, low volume requiring quick changeover capability or high-volume production of wire harnesses requires automating the cutting, stripping, and crimping machines.
Automating these machines also helps maintain consistency, efficiency, and quality. The result is optimized quality control, higher output and efficiency, and reliable wire and cable components.
Embrace the 4.0 manufacturing philosophy
New-generation wire harness design software employs advanced tools. Such tools are not only automated for today’s options. They’re built for compatibility with future manufacturing solutions.
Automated Wire Harness Assembly Processing at Cloom Tech
Below are some of our capabilities in automated wire harness assembly processing, showcasing our expertise and precision in delivering high-quality solutions.
Equipment
At Cloom Tech, to satisfy customer needs, we have incorporated the use of state-of-the-art designs in the cable and wire processing industry, such as:
Crimping/Presses/Applicators
Circuit Analyzers
Heat Shrink Applications
Terminators/Automated Termination Equipment
Overmolding Equipment
Ultrasonic Welding
Automated Testing
Wire Stripping Equipment
Laser Marking and Kitting
Services
We can provide you with:
Machine Precision Wire Preparation
We utilize automated machines and benchtop equipment to cut, strip, and terminate coax, ribbon, and jacketed cables. We are capable of processing wires between 30 AWG and 40 AWG. With the help of our automated machines, we can work at rates of up to 10,000 wires per hour.
Crimping
Seeing that terminal crimping of wires is a core production process at Cloom Tech, we assure you that we have the experience and proper equipment to handle the job. We use hand tools, benchtop presses, automatic processing machines, and pneumatic and hydraulic presses to manage any tasks.
Wire Marking
For all your wire marking needs, we provide the following services:
Heat shrink labels
Hand-placed vinyl labels
Direct inkjet printing
Machine-wrapped vinyl labels
Wire Bundling
To securely bundle wires, we utilize tie wraps manually or via semi-automated machines.
In addition, we are fully stocked with a wide array of shrink tubing sizes, styles, and colors. We can shrink the tubing using a heat gun or a calibrated oven.
Also, we use cutting-edge equipment to perform precise and uniform wire twisting. In addition, wires are retained in the twister by softly gripping the cables inside the pressurized surgical tubing.
Automated Cable Assembly: Soldering/Tinning
At Cloom Tech, you can rest assured because we can handle all your soldering tasks, from PC boards to through-hole devices.
Automated Cable Assembly: Beading
Beading is the wrapping of wires on a component or device. For most jobs, ferrite beads are used.
Automated Cable Assembly: Custom Harnessing
We fully utilize our cable and wire harnessing techniques from crimping to bundling to design any complex wiring harness.
Automated Cable Assembly: Testing
Before any project, we always ensure to perform a complete electrical continuity test. The test helps ensure there are no opens, shorts, or incorrect wiring.
Conclusion
Automation of wire harness processes enables manufacturers to increase productivity, maintain quality, and improve efficiency, satisfying all your needs. At Cloom Tech, we pride ourselves on the wiring harness and cable assembly industry. We are constantly upgrading our computerized systems to enable the real-time cable assembly process.
Vehicles have numerous systems, all of which rely on proper wiring. The wiring regulates power, receives signals from the ECU to control components, and stores data that ensures the car runs smoothly. And the more systems the vehicle has, the more wiring is required.
Engines are designed to run continuously at very high temperatures of over 2000F, to which the wires are constantly exposed. A lack of proper wire insulation would damage the wiring, which could potentially cause a short circuit igniting an electrical fire. However, overheating is just the beginning of automotive wire harnesses’ problems. The wiring needs noise reduction, thermal protection, electromagnetic shielding, radiant heat protection, abrasion, and mechanical protection. All in all, automotive wire harness protection is necessary.
What Are Wire Harness Protections/Coverings?
Harness protection is the sleeve, wrapping, conduit, tape, or tubing that securely covers and bundles the harness, protecting it from high temperatures and environmental conditions. However, different harnesses require specific characteristics and properties, such as:
Braided Cable Sleeve
Braided cable sleeves are made of mesh to protect your wires. You can singe the sleeve with a hot knife to prevent unraveling at the edges.
You could opt for expandable sleeves made of polyester that provide an open-end weave construction, allowing for easy installation and reducing installation costs. It protects the wires by allowing moisture and heat to dissipate. Plus, it maintains flexibility even if you bundle a couple of wires together. Expandable also comes in polyphlyne that best suits high-temperature assemblies. Also, polyline has low moisture stability, low wear, and high chemical resistance.
You can also opt for self-closing braided sleeves that are abrasion resistant and made of polyester. These provide a 25% overturn, hence easy access to the bundle inside. Plus, it can be assembled over already laid wires.
Another sleeve option is the thermal sleeve protection made of Nomex fiber. The fiber is ideal for high-temperature conditions and provides abrasion resistance and thermal protection.
Cable sleeve
Cable Wrap
Spiral cable wraps provide cost-effective protection for wires and hoses. They’re flexible, crush resistant, and easy to install. These cables can be branched to provide a simple cable management solution.
Most wraps are made from polyethylene or nylon. Nylon wraps are more heat-resistant because they contain stabilizers that slow down the loss of physical properties as temperatures increase.
Polythene wraps, on the other hand, provide a more durable cable wrap solution. Plus, polythene wraps maintain their integrity and strength even after being flexed and bent a couple of times.
You could choose between nylon and polythene with hook and loop braided cable wrap. They offer the simplest cable assembly management solution. These cables better serve nonindustrial purposes such as lighting and photography. Also, they can be reused, which could save you a lot. Similarly to spiral wraps, breakouts could happen.
The Cable wrap
Cable Conduit
Cable conduits route and protect wires in machines and structures. The lines have grounding and bonding abilities, helping minimize electromagnetic interference. Pipes also prevent emissions from the power cables they house.
Some conduits are plastic, offering more flexibility and higher fatigue life. Plastic pipes are vital, enabling them to recover quickly after being crushed. They also provide UV resistance, allowing for use in exterior areas. Some of the plastics include:
HDPE – Durable, flexible, and chemical resistant. Ideal for telecommunication, power utilities, and trenching.
Polypropylene – Offers high flexibility and compression strength. Mainly used in cable assemblies, embedding into walls, and under-floor wiring.
Nylon – Protects against abrasion and impact damage. Ideal for vehicle harness protection and hydraulic hose protection
PVC coated metal – It’s corrosion resistant and liquid tight. Most used in factory wiring and machine connections.
Caption: Conduit image
Heat Shrink Tubing
Heat shrink tubing involves enclosing cables and wires in plastic tubes. To provide a close tight fitting for the wires and a rope,e you’ll need to shrink the lines using a heat gun or blow torch.
Polyolefin is mainly used to make heat shrinking tubing because of the following reasons:
Flexibility
Durability
Chemical resistance
UV resistance
Ideal electrical properties
The tubes not only act as cable sleeves but also provide strain relief. Cables and wires often serve a shorter lifespan because of the strain caused by working in limited spaces or being fast. Heat shrinking tuning reduces the stress on your wires and cables enabling them to work effectively.
With heat-shrinking tubing, you can opt for colors or clear tubing. Colored tubing is ideally used in automotive, cable TV, wireless and telecoms, and electronics, while clear tubing is used primarily for electronics, automotive, and appliances. You could opt for the clear tubing, especially when heat retardancy is a priority, but mechanical performance and electrical insulation are vital.
Heat shrink tubing
Tape
Taping is a tiresome task. Although tape might not be the best solution due to its high cost, it takes up little space and is easy to install. The tape is wound around the wires in a spiral form to cover the areas between sleeves and other solutions.
Taping
How to Select Cable Protection for Automotive Applications
When choosing protection for your automotive’s wire harness, there are several factors to consider, including:
Sealed or Open System
When choosing cable protection for automotive purposes, the main factor is whether the cables can operate efficiently and reliably with zero to minimal protection.
Automotive split walls are highly flexible and light. Therefore, they tend to peel open when exposed to frequent vibration or excess flexing.
When that happens, it lets in water and debris, which make their way to the harness, causing wear and, over time, damage. Hence the need to cover automotive looms with tape to seal off the conduit and help avoid such problems.
However, taping the automotive looms demands extra work. A lot of labor goes into the building process, consequently increasing the overall costs and reducing the functionality of the harness. And since automotive looms are made of lightweight materials, they don’t offer adequate protection on expensive vehicle harnesses.
Cable protection systems like the IP66 and IP68/69K protect the cable from splashing and high-pressure washdowns, keeping the harness clean and safe from quick wearing off and failure.
Sealed polyamide protection systems are more robust and serve longer than taped automotive looms. Polyamide also offers a wide selection of materials with numerous features and different flammability ratings, allowing you to make the best choice according to the intended use.
Automotive Wire Harness Protection: Location of Harness
When the harness is close to the transmission, engine, or catalytic converter, it requires high-temperature polyamide protection.
There’s a wide variety of products with temperature ratings ranging between -400C to 1150C and products that can handle temperatures of up to 3000C.
You don’t have to use solid materials if the harness is inside the vehicle. However, a retrofittable and divisible conduit system could prove beneficial, enhancing the ease of adding wires for add-on features like lighting and WiFi.
Material Selection
Light and medium wall products are sufficient if the components are not exposed to harsh conditions or rough handling. But if they will be exposed to extreme conditions, it’s better to go with the heavy wall polyamide cable protection made of material with the following qualities:
High impact and can resist high temperatures
Increased flexibility to continuous motion, such as in the robotics field
Low toxicity performance in passenger areas that complies with the Bombardier and ASTM standards
UL94 V-0 compliance for low smoke
Robust polyamide cable protection systems also offer increased flexibility and high impact resistance, vital in applications involving jumper cables linking automation, such as subway cars.
The protection system should also have an increased diameter to protect large bundles of cables. In addition, the capability to be retrofitted and divided to allow adding or removing of wires during the vehicle’s service life or while building the prototype.
Automotive Wire Harness Protection: Cable Protection System Accessories
The best cable protection system supports the conduit, ensuring efficient and effective installation. There are several accessories to enhance performance, including:
Y and T junction fittings
Divisible lock nuts
Fittings with inbuilt strain relief
End sleeves
Clamps
Abrasion rings
Divisible fittings for retrofit applications
Image of Clamps
For heat shrink tubes
Whether to opt for a single wall or dual wall heat shrink. Although the single fence is widely used, the double wall (adhesive lined tubing) has a better connection and more robust seal, among other advantages. The following are factors to consider when choosing heat shrink tubes:
The tube’s shrink ratio. The heat shrink ratio differs from the initial heat shrink tube size to its skeletal form. The difference is a ratio of 2:1 to 4:1. Typically, the heat shrink tube decreases the size by 50% to 75% once some heat is introduced.
Lastly, it’s essential to consider the heat-shrinking tube size.
6 Types of Cable Wrap for Automotive Wiring Harnesses
Below are six cable wrap options, depending on the auto wire harness’s physical properties and electrical performance.
Automotive Wire Harness Protection: Corrugated Flexible Conduit From PE, PA, or PP
While the car is running, the engine gets exposed to high temperatures. Therefore, the PP plastic wrap for the engine is a unique material with a high flame redundancy and light-off to prevent sparking a fire.
PP wrap has a high melting point, making it the perfect wrapping material. Even when the engine is under extreme temperatures, it’s less likely to result in a fire.
In addition, PP corrugated tubes have a low thermal conductivity. Therefore, even if the engine temperatures are high, it won’t affect the expected operations of the neighboring components.
Self-Closing Non-expandable Sleeving From Polyester Monofilament and Multifilament
This open-type design is easier to install and remove. Also, it has high wear resistance, providing excellent protection for the harness during bending activity.
Automotive Wire Harness Protection: Braided Self-Closed Wrap From PET Monofilament
This wrap has a self-rolling coincidence of around 25% and combines flame redundancy and wear resistance to provide protection. It also has a high-temperature component peripheral guard.
Dual Wall Adhesive Heat Shrink Tubing From Polyethylene
This tubing comprises an outer polythene layer and an inner layer of hot melt adhesive. It fits closely on wires, smoothing rough edges and providing electrical and thermal insulation.
The adhesive tubing ensures a tight seal against moisture and chemicals that could corrode the harness. However, it’s challenging to apply and requires a heat gun, which increases production time.
Cable Expandable Sleeving From Polyester Monofilament
This sleeving is often used to cover wire harness tubes, industrial hoses, and cables. It can maintain complete flexibility in any direction, regardless of low temperatures. Also, it allows for repeated flexing of cable assemblies and wire bundles without causing damage.
Fiberglass Braided Sleeve
The fiberglass braided sleeve has a temperature classification of about 2000C and self-extinguishing capabilities. In addition, it has a high voltage resistance and a wide temperature range. It’s widely used in motor peripherals and generators.
Conclusion
Harnesses must ensure smooth transmission of signals and connection of circuits. You need a properly calibrated and reliable system to prevent electromagnetic interference on circuits and eradicate short courses. Thankfully, a wide selection of components is available, so you can choose one that better serves your needs.
Cloom Tech provides all wire covering and cable protection services, from heat shrink wrapping to expandable tubing. Our team of experts is always ready and equipped to handle all your requirements in all applications.
When your phone is ringing, you grab it off its stand and drag it towards you. Here, curly cords ensure that the wire does not bounce right back after you go to the end of the line. And the handset’s coiling cords neatly retract into the base when it’s put back. The cable’s expansion is due to the presence of coiled conductors. Without it, you’d have a huge mess of wires behind your telephone. So, how important is the curly cord?
Curly Cords Basics
You can get a curly cord everywhere, from a car charger for your phone to a cheap key chain at the corner store. One widespread application is the telephone, which uses curly cords to connect the handset to the base unit. “Curly cords” connect two devices when one or both need to move relative to the other.
Besides their more common names, curly cords can also be referred to as:
Coiled Cable
Coiled Cord
Spiral Cable
Retractable Cable
Coil Cable Retractile
Retractile cord
coil cords
These power cords get their names because they go back into a tight coil.
Caption: Wire around a plier
Two Basic Categories of Curly Cords
There are two kinds of curly cables, mainly cycled and stationery.
Cycled curly cords
The first group, or cycled one is for medical devices. It is because you have to use them many times and can’t fail at all; hence, they are built differently. So, the process for making stationary curly cords is very different from the process for making reliable curly cords.
Stationery curly cords
As for the stationary one, these curly cords can stretch only once. It means you can use them when one of your devices is in a fixed position while the other keeps moving away. Moreover, you cannot go back and forth with stationary cords. Instead, you will always use them to connect a stationary and a moving device. These kinds of coiled cords would be made for a purpose that keeps them mostly still.
Caption: Silver gray curly cords
Spiral cables penetrate many industries.
You can find the curly cords just about anywhere.
Medical setting
As mentioned above, medical devices need curly cords for convenience.
Electronics industry
The two most popular locations are the house and the car. For example, the convenience of your phones would not be there if spiral cables were not present. So is the phone car charger.
Telecommunications business
Spiral cables join cell phone connectors and the cigarette lighter adaptor plugs that power them in cars. Also, you will look for everything from GPS to radar detectors and cooling systems that you attach to a car’s cigarette adaptor.
Retails
Additionally, curly cords prevent the theft of high-priced merchandise from store displays. It tethers the products so that customers may drag them only a short distance before the wire snaps. Hence, the retail sector joins the ranks of those that place a premium on spiral cables, such as the cellular phone sector, the public safety sector, the medical sector, and the GPS/radar detection sectors.
Automobile industry
You may have seen the curly cord in every car production plant that employs robotics and power tools.
Building industry
On the highway, if you come across a construction site, you’ll likely find spiral wires linking GPS units to tiny computers on the machinery used to move or pave the earth. They communicate the data such as elevation data, dirt and concrete volume, and other construction site metrics. Moreover, it allows you to observe the procedure from afar. Thus, curly cords with many turns enable this entire system.
The benefits of the Curly Cord
Mobility – As mentioned in the phone example above, spiral cables can be readily bent and moved to access areas that normal wires can’t. Hence, more freedom at work through mobility equals more output.
Durability – Spiral cables are often thicker than ordinary cables, making them more resistant to durability. Because of their thickness, they sustain little harm when gliding over uneven ground.
Compatibility – Standard cables take up more room in storage than their spiral counterparts. However, curly cords don’t take up as much room as other wires because of how easily they coil up.
There are some benefits and cons to using spiral cables. Though they are lighter than standard cables and can help you save space, they are heavier. The cable might cause injury to nearby objects or people if you stretch it too far and then retract it improperly.
Caption: Spiral electrical wire at the construction site
Specifications of Curly Cords
The following is what must be taken into account when you are choosing a curly cord.
Cores and Conductor size
Spiral Cables are available from 2 to 25 cores with conductor sizes as little as 0.14mm2 up to 6mm2.
Screen
To accommodate the spiral’s expansion, you will use a lapped screen. In such cases, foiled screens are not a good choice.
Material and Color
PVC is inexpensive to produce but has a poor memory; it recoils back after some uses. The range of available colors in these is typically greater. PVC cables have a 3.5x length-to-size ratio when extended.
PUR is highly flexible and has excellent memory. Moreover, it resists most oils. If it were black, it would also be UV stable and resistant to the effects of water. Though typically black, you can also find them in white, yellow, and orange. PUR cables have a 4-to-1 stretch-to-retract ratio, making them extremely versatile.
Rubber is useful in manufacturing settings. Comparatively speaking, it has a greater memory than PVC but is not as good as PUR. It would be impervious to moisture and sunlight. Rubber cables can extend to five times their original length, and usually, they are available in black color.
Retracted length/ Extended length
When retracting, the length of the curly cords is the same as its available length (not stretched out). Here you can stretch it to a maximum of 5m. When you extend it to the farthest, it is the extended length.
When calculating these dimensions, you must additionally account for the cable’s aspect ratio.
PVC – 3.5:1
PUR – 4:1
Rubber Band – 5:1
What type of tails/ What length of tails
The straight ends of any curly cable are known as “tails.” Moreover, these can vary in terms of both length and direction. Two of these directions are the Right angle (or tangent) and axial (or straight).
DIY Coiled Wire
DIY coiling stranded wires are simple and can be done with any vinyl covering the wire. Using a heat gun and basic tricks in less than 10 minutes, you can transform any straight stranded wire into a spiral one.
Now, you will wonder why stranded wires and not solid ones. The answer is simple; as stranded
wires are more flexible, they can curl without breaking the core conductor. On the other hand, the solid wire has one single core that does not accept bending and can break.
So let’s see what you will need to have on your hand.
Material Needed
Dowel or stick around which you will form a coil
Electrical Drill
Cable Cutters
Heat Gun
Pliers
Method
Secure one end of the wire on the dowel with the help of tape. Later, you can cut the straight end or join the plug with it.
Start wrapping the wire from the fixed end tightly on the dowel stick. Keep pushing the winds next to each other as you proceed further. Moreover, you can do the work either clockwise or anti-clockwise.
At the end of wrapping, secure the other end of the wire on the dowel with the help of tape.
As the wrapping is done, you will now heat it using a blow dryer or heat gun. Now, you don’t want to melt the sheathing, so you need to maintain a good distance from the wire. Also, uniformly distribute the heat by the constant movement of the gun.
After a few minutes, you will see that the jacket is becoming shiny. It has now become a spiral and accepted its new shape. Let the wire cool down, and then remove it from the stick.
In the end, inspect the wire for any scratches and burning signs. That way, you can ensure that the quality of the wire is not compromised and is ready to go.
And there you have it; your DIY coiled wire.
Caption: Spiral wire 3D illustration
What to Consider When Designing Specific Curly Cords
If you are an OEM searching for a long-lasting coiled cord solution, we advise you to consider several factors before placing an order with a supplier.
You should first consider the setting in which you will be using the cables. Designing a curly cord for an industrial setting differs from designing one for a medical or retail setting.
Then, determine the lifespan and level of activity you desire for your ringlets. If, for some reason, you need coiled cords with a lifespan of 100,000 cycles, you’ll want to make sure those requirements are baked into the design from the start.
Another example would be if you needed your curling cords that will last forever and be put through 30 washes a day, you’d want to be sure your supplier could accomplish that. In one extreme case, a coiled cord must withstand 500 motions daily for an entire month (15,000 cycles total).
Conclusion
Curly cords are important in places where you need durability and mobility. While compacting the wire’s length, they do not break when pulled extensively. There are different conductors diameters from which you can choose the cord. After determining the conductor diameter and number of cores, you must select the insulation and sheathing materials best suited to the application. Custom orders for the spiral’s retracted length are possible up to 5 meters in length. Moreover, you can make it at home with simple stranded wires and use it for your next wire harness project. Here at Cloom, we offer any wiring harnesses and cable assemblies to make your connection safe and reliable.
