What is the purpose of a control cable?

As modern industry has progressed, control cables have become an essential part of operational production. Designed to transmit electrical signals that regulate the operation of equipment and operational systems, control cables and control cable assemblies help components such as sensors, actuators, and controllers communicate with one another. Control cables are designed with ultra-precision, making them a crucial component to operational safety, reliable signal communication between equipment, and uninterrupted performance in production systems worldwide. Meridian designs every custom control cable assembly to function flawlessly and reliably, considering the environment and operational requirements. Our engineers carefully craft each control cable with the most precise detail in mind.

What is a cable assembly?

A cable assembly is a collection of connectors and cables designed for a specific electrical system. Although they come in many shapes and sizes, cable assemblies typically include multiple cables with particular connectors designed for reliable signal flow, uninterrupted power transmission, and secure connection solutions. Multiple design elements go into a cable assembly, including cable type, connection components, molded elements, cable length, protective elements, and routing considerations. There are no universal cable assemblies that work with every operational system. The best type of cable assembly is customized to the specific needs of the environment, equipment, and operational systems, which is exactly what we do here at Meridian when we design a custom cable assembly.

Where is a control cable used?

Control cables and control cable assemblies are used in a wide variety of industries and applications. However, they are most commonly found in industrial environments and industries requiring heavy machinery. Because of their usefulness in binary command signal transference, control cables are well suited for operating heavy machinery with an on/off function, simple commands, or operational systems that don't require a consistent signal, such as monitoring systems. Control cables and control cable assemblies are often used in industries that require precise control over their machinery. These industries may include industrial manufacturing, robotics facilities, conveyor systems, and production facilities. Additionally, control cable assemblies may be found in infrastructure applications, such as HVAC systems, lighting controls, security systems, and other immobile or mostly fixed locations.

What are the different types of control cables?

Control cables come in many shapes and sizes, depending on their intended purpose, environment, and industry. Some of the most common types of control cables include: A YY control cable: These flexible cables are typically unshielded and used in fixed or semi-fixed systems in low-stress environments. A CY control cable: These cables are better suited for environments with heavy electromagnetic interference (EMI) and contain shielding for better protection against signal loss. A SY control cable : These control cables include shielding and galvanized steel wire braiding for additional protection in harsh environments, such as industrial manufacturing or facilities using heavy machinery. Control cables are categorized by their construction materials and environmental situations. For a control cable assembly to operate successfully, it must accommodate any environmental hazards and operational concerns it may encounter.

How do I choose control cable size?

Numerous factors go into selecting the appropriate control cable size for your control cable assemblies. During the design phase, it's important to ascertain the specifics of your power and signal transference needs, the equipment you'll use, and the environment in which your equipment will operate. Each of these components can significantly impact the efficiency and reliability of your control cable. Whether you're using a low-voltage signal cable or require higher power capabilities in your control cable, getting the size just right is critical. Your specific equipment and environment can help determine what size control cable you need, whether it's a YY cable or a SY control cable. If you're unsure, our engineers can help you determine the appropriate cable size for your control cable assembly.

What is the difference between a control cable and an instrumentation cable?

The primary difference is in the signal they transfer. Control cables transmit various types of binary control features, such as on/off commands. While they could be used to transmit machine operation commands, they typically carry low-voltage power to various components of industrial systems. Control cables and control cable assemblies are typically designed for mechanical environments that demand durability and defense capabilities. On the other hand, an instrumentation cable is specifically designed to transmit consistent low-level signals, such as measurement readings, monitoring instruments, and other informational systems requiring pinpoint accuracy and sensitivity. These types of cables are typically attached to sensitive equipment such as sensors, meters, and gauges, where precise data transmission and consistent signal integrity are required. Due to the signal demands for instrumentation cables, they are often equipped with greater shielding than control cables.

What is the difference between a control cable and a signal cable?

Although similar, control cables and signal cables are very slightly different in purpose and construction. Control cables transmit command signals, like on/off, between controllers and Industrial machinery. These pivotal cables are the linchpin of smooth operation and manufacturing reliability for industries worldwide. Typically, control cables carry a low-voltage signal for applications that do not require consistent energy transference. Additionally, a control cable assembly may be used for large industrial complexes, requiring enhanced durability and environmental protection. Conversely, a signal cable is designed to transmit low-voltage data communication with high accuracy. A signal cable is primarily constructed for signal integrity, ensuring a consistent transmission of data and low-voltage power. These cables are typically outfitted with protections against electromagnetic interference (EMI) and radio frequency interference (RFI) to defend against potential data corruptors. A signal cable is often found in communication applications, audio-visual systems, and delicate operations. Furthermore, a signal cable is typically lighter weight and requires a slightly more delicate design than a control cable.

What’s the difference between a SY control cable and a YY control cable?

The primary difference lies within the application and environments with which they operate. A SY cable typically includes a galvanized steel wire braid between the outer sheath and inner insulation, providing mechanical protection for physical strain or hazards. A YY cable, on the other hand, is typically unshielded and consists of plain copper conductors with PVC insulation and sheathing. These cables are lighter and more flexible, making them adaptable for minimally stressful environments and applications, such as office equipment or conveyor systems.

Why might I need a shielded signal cable assembly?

Shielding provides a layer of protection around the conductors within a control cable, protecting it from various environmental hazards that could corrupt data or interrupt the signal flow. While not every industrial environment demands this protection, many do. For example, any situation where the environment is electronically noisy or contains a high risk of electromagnetic interference (EMI) or radio-frequency interference (RFI). These types of environments demand additional protection to defend against poor signal flow or signal loss, which could be catastrophic to most equipment and operational systems. Of course, if you're having trouble determining whether or not your environment might need a shielded signal cable, our engineers can help you make the right call for your control cable assemblies. We'll take into account your environment and signal needs to design the ideal connection solution for your situation. Just get in touch with our team if you have any questions or want to begin a control cable assembly project of your own.

How are control cable assemblies tested for quality?

Every wire harness, cable assembly, and cable that leaves our doors undergo rigorous testing to ensure the highest quality, functionality, and reliability. We do this testing in our state-of-the-art testing lab, which puts cables through the wringer of examinations and standard quality tests of all kinds. When designing your custom control cable assembly , we first run a digital rendering using cutting-edge design software. This first step is crucial because it allows us to identify and correct any potential design flaws or missed elements within your control cable assembly. Once we are satisfied with the digital version, we’ll move your product into the next phase of production, which may include prototyping before completing full-scale production. Every step of the way, your custom cable assembly is scrutinized by our expert engineering team and impeccable production staff. You can enjoy total confidence in our extensive testing process and unparalleled commitment to quality.

What warranties come with a control cable assembly from Meridian?

We firmly believe your custom control cable assembly should be free of doubt or worries. That's why we back everything we design and produce with a commercial warranty. This warranty lasts a full year and ensures your product is free from manufacturing and material defects. It gives you peace of mind that your product is up to snuff and on par with industry standards. Our team is always here to help if any issues occur. We’ll gladly walk you through any troubleshooting or installation needs you have and treat you the way we’d like to be treated. We're here to help you succeed and enjoy your custom cable assembly with as little strain and stress as possible.

What are the types of coaxial cables?

Coaxial cables come in many types and varieties , depending on your equipment and transmission needs. Common types of coaxial cable include: RF: Radio Frequency (RF) cables commonly used in television connectors. These types are best used for short-distance connections. RG: Radio Guide (RG) cables are typically used in applications such as cable televisions, broadband internet, and commercial radio. These cables feature a numerical designation, indicating the diameter and specifications of the cable. LMR : Land mobile (LMR) cables are designated for wireless communications, with flexibility and communications networks. Twinaxial: A specialized form of coaxial cable commonly used in data transmission locations requiring high-speed capacity. These cables feature dual inner conductors, giving them higher capacity than the standard single conductor in a coaxial cable. Triaxial: Similar to twinaxial cables, these cables feature three inner conductors, amplifying their capacity and signal reliability. Each type of custom coaxial cable assembly can contain multiple cable types, including specific RF diameter designations.

What is the difference between RG6 and RG8?

RG6 Cables and RG8 Cables are both types of radio guide cables designated for distinct applications. With RG cables, the numerical designation indicates the cable’s diameter or thickness. RG6 cables are thinner, hold a smaller diameter, and are lighter in weight, making them well-suited for television installations in both residential and commercial settings. These cables are best suited for applications that require a short transmission distance, like from the cable box to the television. Their short-range capacity and makeup make them durable and reliable for simple and stationary installations. RG8 cables have a thicker diameter and are designed for low-loss, high-power applications, such as HAM radio systems and long-distance transmissions.

What are the main parts of a coaxial cable?

Coax cable manufacturers structure a coaxial cable with four primary components: the core conductor, dielectric insulator, shielding, and the outer jacket. The core conductors are typically made out of copper or a copper alloy, depending on the signal requirements. This primary conductor is responsible for transferring the signal between installations. The dielectric insulator separates the conductor from the shielding, enhancing signal integrity and preventing internal signal interference. The shielding of a coaxial cable offers protection from external signal interference, like electromagnetic interference (EMI) or radio frequency interference (RFI). This element is made of a braided or spiraled metallic material that deflects or grounds external interference. Lastly, the outer jacket is typically made of a flexible, rubber-like material that protects against external hazards, such as moisture, dust, or kinks.

What is a coaxial cable assembly?

A coaxial cable assembly is a collection of coaxial cables arranged in a particular formation. This collection of electrical cables is designed to transmit signals and electricity between various connection points. Custom coaxial cable assemblies can be beneficial in a range of industries and applications, serving a unique purpose for each apparatus. These assemblies can accommodate various designations, including length, performance capabilities, signal integrity, environmental concerns, and connection types. A competent coaxial cable manufacturer, like Meridian, can develop a tailored coaxial cable solution that ensures secure connections and smooth installation of your cable assembly.

Why should I choose a custom coaxial cable assembly over a standard one?

While there are certainly some standard cable assemblies that might work for your needs, the majority aren’t going to accommodate your specific signal needs. An off-the-shelf solution may or may not fit your configuration requirements, leaving you with a partial solution. On the other hand, custom coaxial cable assemblies are tailored to your specific requirements, satisfying all the demands of a complex system. With total control over your customization, you can rest assured that your connectors, cable lengths, and signal capacity will seamlessly integrate with your equipment. For assured functionality and hassle-free integration, there’s nothing like a custom coaxial cable assembly.

What industries use coaxial cable assemblies?

Custom coaxial cables and coax cable assemblies can be useful in a variety of industries for a range of purposes. Primary industries include: Telecommunications/Broadcasting Industrial Military Medical Of course, any residential or commercial setting that requires AV systems, like CCTV, short-range broadcasting, or security systems, could also benefit from custom coaxial cable assemblies. A trustworthy coaxial cable supplier can help you determine if your sector needs a custom assembly.

Does Meridian Cable offer prototyping services for custom coaxial cables?

Certainly! As part of our complete customization and fabrication processes, we offer our prototyping services . Prototyping your custom coaxial cable assemblies can be highly beneficial, especially when establishing a new system, integrating upgraded equipment, or working with unfamiliar technology. When you work with our team to prototype your coaxial cable assembly, you reap the benefit of our expertise and precision prototyping capabilities. The team of design engineers works closely with your engineering team to determine and deliver a one-of-a-kind product that integrates seamlessly into your system. If your prototype cable assembly works for your system, we keep your design on record so we can quickly volume-produce your custom coaxial cables and cable assemblies

Why should I choose Meridian as my coaxial cable supplier?

If you've been on the hunt for the ideal coax cable manufacturer for a while, you've likely run into several options. Meridian has the experience, expertise, and impeccable reputation for excellence. We've garnered a team of the best and the brightest engineers and manufacturers to develop custom coaxial cables and coaxial cable assemblies that tick all the boxes. As coax manufacturers of choice, you can rest assured every protective measure, quality test, and detailed inspection will be performed. This means we put our products through the wringer to ensure their top-notch quality, functionality, and viability. Plus, we back up what we craft with a top-tier commercial warranty , giving you confidence and peace of mind. Discover the difference working with our team can make, and get in touch about your custom coaxial cable assembly today!

If I don't have any coax manufacturers near me, can I have my custom coaxial cable assemblies shipped to me?

Absolutely! A key benefit of working with Meridian is our impressive shipping capabilities. We operate on a global scale, so we can manufacture and ship your custom coax cables or cable assemblies just about anywhere. Whether you're shopping for a simple coax cable for your home entertainment system or need something Industrial for your telecommunication center, we've got you covered with all your connection needs. With our quick-turn and global shipping services , you can count on Meridian to deliver exactly what you need when you need it. We've simplified your interactions with RF coaxial cable manufacturers by delivering a quality product right to your doorstep.

What's the difference between coax manufacturers and RF coaxial cable manufacturers?

The primary difference is the type of cables these manufacturers specialize in. Coax manufacturers produce a wide range of coaxial cables for general applications, such as television systems, internal connections, and short-distance connections. Cables typically have a lower frequency and low voltage transmission. RF coaxial cable manufacturers, on the other hand, focus on cables suited for high-frequency applications, such as microwave systems, long-distance transmission systems, and radio broadcasting systems. These cables are quickly engineered to deliver high-quality signal transmission without corrosion or signal loss. While some coaxial suppliers focus on one or two areas, Meridian operates in multiple arenas with broad production capabilities. We've developed cables for just about any industry and are proud to be both coax manufacturers, RF coaxial cable manufacturers, and far more!

How are custom coaxial cable assemblies tested for quality?

We understand the weight and responsibility of what our cables go through. Engineered and designed a custom coaxial cable assembly, we want our customers to have total confidence in their connection solutions. That's why we strive for total perfection in our products. We use a state-of-the-art testing lab to thoroughly examine every single product we create. We perform a litany of standard tests to ensure a coaxial cable’s functionality, performance, durability, and longevity. Everything we manufacture is held to industry-standard certification to ensure quality and reliability. Although, we're not content with merely delivering a product that does the job. We strive to be some of the best coax cable suppliers in the business, delivering top-notch quality products as quickly as you need them.

How long does it take to make custom coaxial cable assemblies?

As an experienced coaxial cable supplier, we know a thing or two about getting a product out the door. Producing a custom coaxial cable assembly occurs in multiple stages. First, you'll work with our engineering team to design the ideal coaxial cable assembly for your equipment, environment, and signal needs. Once we've created a digital rendering, our team will perform preliminary tests to ensure design functionality and viability. Once the design and preliminary testing phase are complete, we can move your product to production (and prototyping if necessary). The manufacturing process typically takes just a few weeks to build a completely custom product. Once finished, we’ll examine your cable assembly in our state-of-the-art testing lab to ensure it meets our impeccably high standards. After that, your custom coaxial cable assembly is sent to shipping and out the door before you know it. All in all, this process can be completed within just a few weeks.

Are overmolded cables durable?

Because they're made using multiple layers of material surrounding the cable and connectors, overmolded cable assemblies are highly durable equipment components. The extra barrier from the elements and their tough nature make these assemblies an excellent option for outdoor facilities or challenging environments like industrial complexes. The protective layer of plastic on overmolded cables serves to defend the conductors and connections from typical wear and tear while guarding them against the elements. Because of this added durability, these cables can stand up to rigorous tests and harsh conditions. Meridian builds overmolded cables to be rugged, long-lasting, and reliable no matter what the situation or application. You can count on our custom overmolded cable assemblies to endure everything you can throw at it.

Is strain relief needed in molded cable assembly?

Pulling, bending, and other stressors are the enemy of secure connections. The additional strength added to overmolded cable assemblies helps defend against excessive bending or flexing at various areas of the cable. This significantly extends the cable’s lifespan and reduces the likelihood of signal interference from bent cables, broken lines, or damaged connectors. Strain relief is a critical aspect of overmolded cable assemblies used in portable equipment, like military operations or medical facilities. In industries requiring constant movement or rearranging, every bit of toughness and durability counts. The last thing you want is fragile or easily broken cable connections when you're in a hurry. Because overmolded cables have built-in strain protection, they can be trusted time and time again.

Will the overmolding protect against the elements?

Dust, moisture, chemicals, and physical damage can hinder consistent connections and secure data transfers. Dust and moisture can not only interfere with secure connections but can cause data loss and corruption. While these elements can threaten any workspace, they are especially common in outdoor facilities, industrial complexes, medical buildings, and military operations. Protection from harmful elements is an essential aspect of overmolded cable assemblies. With our superior manufacturing quality, we create over-molded cables that repel dust, moisture, and debris so that you can count on your connections day in and day out. We understand the importance of your signal and data. We design and create overmolded cable assemblies to maintain signal integrity, prevent data corruption, and avoid contaminating sensitive environments.

Can Meridian customize your OEM projects?

Naturally, one of the best benefits of working with Meridian Cable is the complete customization we offer. Our top-notch design engineers will work directly with your team to determine exactly what you need from your overmolded cable assembly. You have the option to choose from over 5,000 unique elements and components to build your connection project to the most exacting detail. With the freedom to completely customize your cable assembly , you have the option to incorporate unique overmolding materials, conductors, connectors, and so much more. If you want to incorporate custom conductor colors to identify each cable quickly, we can make that happen. If you need specialized connectors, we have you covered. Our design team will build your cable assembly your way to integrate seamlessly with your equipment and your environment.

How do the cables react to high volume activity?

In situations where there is constant movement or high-volume activities, vibration can cause disconnections, unstable signals, and instability. Our overmolded cables help counteract these variables, reducing the risk of mechanical failure or signal loss. Our team works with you to design cables to suit your needs environmentally and mechanically. Reducing vibration is essential for increased reliability and consistent signals for industries that utilize heavy equipment, such as construction, sound gear, or military applications. Not only do our overmolded cable assemblies help prevent mechanical fatigue, but they also help maintain electrical integrity, prevent signal interference, ensure safety, and maintain performance within harsh environments. In other words, we create our overmolded cable assemblies to help prevent the damage that can be caused by excessive vibration and noisy environments.

Does Meridian color code the conductors?

Of course, you know we can customize just about anything in your cable assembly. One way to avoid misconnections and remain organized is by color-coding your conductors and molded components. We offer unique color combinations and patterns to easily identify each cable within the assembly based on your preferences and connection needs. While this may seem like a minor feature, organizing your cable assembly through color coding can save time and hassle when it comes time to integrate your system. However, the benefits of color coding your cable assembly go beyond mere organization. When your cables are specifically organized and color-coded, this foolproofs them from misconnections, which could lead to damaged or destroyed electrical equipment. In fact, managing your cable assembly could save thousands of dollars in easier cable maintenance, as well as safeguarding against incorrect integration and misconnections.

Does Meridian use enhanced sealing or additional electrical insulation?

Enhanced Sealing In environments where a high degree of ingress protection (IP) is necessary, overmolded cables can help protect connections and prevent signal erosion with superior ceiling glands. Our enhanced sealing method for our overmolded cable assemblies helps increase reliability in harsh environments, extends the cable's lifespan, prevents insecure connections, and protects your equipment from environmental hazards. In applications like the medical field, hermetic sealing is absolutely essential. A proper seal ensures the safety of patients and caregivers and a safe work environment for medical equipment. When you can rely on the cable’s seal, you can help prevent potential hazards arising from loose or faulty connections. Additional Electrical Insulation Overmolded cables have a unique layer of protection that provides additional electrical insulation for connections. The molded components help ensure proper current flow, low signal loss, and consistent connection. This feature promotes safety and reliability for your workers and equipment. This can be especially handy in areas where moisture could potentially interact with equipment or your cable assembly. Naturally, the insulation grade depends on the materials you choose for your overmolded cable assembly. Fortunately, we offer a wide range of materials to choose from, so you can adapt your cables to your equipment, work environment, and budget. We can tailor your connection solution to your specifications and include any protection you need.

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