How Are Cable Assemblies Manufactured?


How Are Cable Assemblies Manufactured?

Cable assemblies are of various types, ranging in types, sizes, and colours. Some could be as small as comprising of two wires and two connectors, while others may be large and complex, containing more than 5000 wires and more than 100 connectors. No matter how big or small, simple or complex, the basic manufacturing process for all kinds of cable assemblies is generally the same.

Step 1 – Wire cutting and marking

First and foremost, the wires are measured, marked, and cut; every wire individually. One of the most preferred methods used to mark wires is laser marking. In fact, if a good laser machine is used, it can not only measure and mark the wires, but also cut them appropriately.

Step 2 – Wire laying out

Each wire is taken individually and laid out, one at a time, by the assembler onto a Harness Assembly Drawing, which shows how wires are routed from one end point to another. It also shows where a wire breaks out from the main bundle. After all the wires are routed, they are then grouped together using string tie or tape.

Step 3 – Wire termination

This is one of the most complicated processes, where each conductor in a wire is terminated. Any shields on the shielded wires also need to be terminated. They are conductors too after all. The wires are terminated by stripping the insulation away from the, crimping contacts onto the conductors, and inserting them into a connector contact cavity, as per its insert arrangement. Once all the conductors are terminated at all reference designators, the wire termination process is complete.

Step 4 – Testing

Every wire is then tested. Testing before packaging and delivering the assembly to the client is a very important step. Automatic test machines are generally used by advanced skilled aircraft cable assembly manufacturers in India. The main factors that cable assemblies are tested for include manufacturing errors, performance, continuity, and insulation resistance.

Step 5 – Finishing

Once every wire and cable assembly is tested, it is then sent for finishing. The finishing process here could include heating up, shrinking down tubing, locating reference designators, locating cable assembly identifiers, and final inspection. After the final inspection, the cable assemblies are packaged and ready to be shipped.

These five steps are the basics of a cable assembly manufacturing process. There could be many other processes involved in the manufacturing process, depending upon the requirements. You can have all your cable assemblies manufactured at Miracle Aerospace, one of the most versatile and dependable aircraft cable assembly manufacturers in India. Here, you can either choose from readily available designs and types, or have your assemblies customized as per your individual requirements. The basic kinds of cable assemblies available here include EMI shielded, multi-wired, RF, flat, ribbon, power, airborne, and military looms. Whether ready or customized, all the cable assemblies are certified and approved by DGAQA and MSQAA; with the processes being certified for quality to ISO 9001, AS9100C.