Safety Considerations for Custom Cable Assemblies

Safety Considerations for Custom Cable Assemblies

Safety should always be the top priority when creating custom cable assemblies.

Sourcing custom cable assemblies from a reputable manufacturer is the best way to ensure your equipment or product is free of safety issues. While there are situations when an off-the-shelf cable assembly makes sense for your budget and the cable’s application, it is essential to carefully consider how using an assembly that is not customized will affect the overall success of the project.

Any time you are dealing with electricity, safety is key. Faulty cable assemblies made from improper materials can cause equipment damage, which can lead to expensive repairs. In addition, you will experience lowered productivity while the damaged equipment is being repaired. That may be the best-case scenario. Low quality cable assemblies can cause bigger problems, like environmental harm and safety issues from toxic smoke or electrical fires.

Ask Questions

The best way to prevent these issues is to make sure you are using a custom cable assembly designed by a safety-focused cable manufacturer. But how can you know a manufacturer is focused on safety? One of the best ways is to be sure to ask about certifications as well as testing procedures when you are discussing your project. An honest conversation about how the manufacturer ensures a safe product can save you more than just headaches. It could prevent lawsuits or even serious injuries.

Safe Materials for Your Custom Cable Assemblies

When going through the design process, be sure to discuss materials that will be used in your custom cable assembly. Choosing the right gauge and material for the conductor is key for functionality and safety. However, making good decisions when it comes to insulation and jacketing can also be the difference between a safe custom cable assembly and one of questionable quality. While there are many components that could affect the safety of custom cable assemblies, talking about conductors, insulation, jacketing, connectors, and strain relief is a great start.

Conductors

Copper is the most commonly used conductor, but that doesn’t mean that it’s the right material to use for your project. Because it is prone to corrosion, it is necessary to consider whether plating or copper alloys might be more appropriate choices. Another consideration is whether your equipment would be better served with a solid or stranded conductor.

Insulation & Jacketing

Clear industry standards exist for the appropriate insulation and jacketing to use in specific applications, so be clear about the conditions your finished cable will be operating under. Does the cable need to perform in extreme temperatures? Under heavy pressure? In wet environments? The answers to all of these questions will help your cable manufacturer choose the right materials.

Connectors & Strain Reliefcustom-cable-assemblies-connector

The terminal points of a cable can be common failure points due to the additional stresses in those areas. While the technical needs of the equipment often drives the choice of connector, additional strain relief can prevent termination failure.  If additional strain relief is needed, the cable assembly designer can add a transition point that alleviates some of the added stress.

Conclusion

Using custom cable assemblies is often the best way to build safe products or maintain safe equipment. When you are talking to a custom cable manufacturer, don’t be afraid to bring up safety. Engineers should be ready and able to discuss how they are ensuring a safe product.

If you are ready to talk about a new project, please get in touch with the team at Meridian Cable. We would love to hear from you.