Category Archives: Cable Assemblies

The Ultimate Guide to Different Cable Colors and Their Purposes

At Meridian, we are asked all the time if the colors for different wires and cables follow any industry standard. The Institute of Electrical and Electronics Engineers (IEEE), a worldwide trade association, does, in fact, issue guidance for standardization in electrical design, but the key point is that their standards don’t actually get into the details of specifying cable colors as they pertain to a specific purpose or function. Rather, the push for standardization in this arena has been more on the private industry side, with the telecommunications industry leading the way. Here, we’ll dive into the wide world of cable colors, what they mean, and what purposes they serve.

Cable Color Standards 101

First and foremost when it comes to cable color standards, one must realize that while there are institutions like the IEEE helping to provide some standardization, there isn’t yet a universally-accepted standard or even requirement in most industries. The color scheme used in one industry can be totally different from what’s used in another and can vary significantly depending on exactly when the system was put in place. 

Remember the iPhone and the first true smartphone didn’t make its appearance until 2007, with that came a huge push for new telecommunications infrastructure to support it. So, depending on the timeframe when the cables are installed in their given systems, their color standards will pretty much cover the full spectrum. 

Adding to the lack of standardization in cable colors is the variance from one country to another. With today’s global logistics, a company in the U.S. may be sourcing their cables from several different foreign countries that all use different color schemes. With the guidance issued by the IEEE, the Telecommunications Industry Association (TIA), and other industry requirements, such as those for the DOD, standardization is possible but may be a long time coming. However, next we’ll see how different cable colors can serve specific purposes in different applications. 

What Do Different Colored Ethernet Cables Mean?

Ethernet cables are a very common type of cable used in computer networking. They are used both in residential and commercial applications when a wired network is desired for data sharing and access to the internet. Most often an internet router uses ethernet cables in order to connect to a cable modem and will come with the kit your cable company sends you when you first sign up for services. 

However, if you’ve ever had more than one cable company or even have had one service for a number of years, you know that the ethernet cable color can vary. So, what do the different colors mean for ethernet cables? Are different colors faster than others? To find out, we’ll take a closer look at color coding specifically for ethernet cables.

  • What Color is an Ethernet Cable?

Like all cables, ethernet cables can come in several different colors. One color isn’t “better” or “faster” than another cable, but the colors can help denote the intended application. The most common colors seen with ethernet cables are grey, blue, yellow, orange, and white. If the ethernet cable is destined to be outside, it will often be black and waterproof to help it survive longer in the elements. 

  • Ethernet Cable Colors Meaning

As we’ve seen, the meaning of the color of an ethernet cable can vary depending on the where, who, and why of the intended environment. For example, with the Department of Defense (DoD), the government uses different colors of ethernet cords in order to assign a given level of classification for the data being transmitted within the cable e.g. yellow for top secret, red for mid-level, and blue generally for unclassified data.

  • Color Code for Ethernet Wires

Again, while there is no direct industry standard for one color over another, there are a few consistencies worth mentioning: 

  • Gray Ethernet: Ethernet cables that are grey are often representative of a “standard” ethernet connection such as is found in residential and commercial networks. 
  • Green Ethernet: Green ethernet cables can be used to classify a crossover connection, which are used to connect different computers and/or devices directly together.
  • Yellow Ethernet: Yellow ethernet cables are generally used for what’s known as “power over internet” (POE) connections. Interestingly, this standard was developed by the IEEE in 2009 to help classify these cords which deliver a 30W current at the level of the port when used with an ethernet twisted cable pair.
  • Blue Ethernet: blue ethernet cables are usually used for terminal server connection. A terminal server makes connections to multiple systems to a LAN network possible without having to use a modem or other network interface.

The TIA is accredited by the American National Standards Institute (ANSI) to create and maintain industry standards, including those for color-coding used in cable manufacturing. While these are some of the closest to standards that exist today, most of the TIA’s wiring color management schema is still viewed as a recommendation rather than a requirement. Until universal adoption takes place, there will most likely be many different colors used in ethernet cable colors. 

Patch Cable Color Standards

As we’ve come to expect, patch cable color standards may be published by ANSI/TIA but within these recommendations, there has yet to be universal adoption. With patch cable color standards, the University of Wisconsin Network Services Department is leading the way through example by helping to define what colors are to be used for every cable system on their campus. 

The standard colors used with patch cord jackets by the University of Wisconsin include:

  • Grey – used for standard ethernet connections
  • Green – used for crossover ethernet connections
  • Yellow – used for POE connections
  • Orange – used for analog non-ethernet connections
  • Purple – used for digital non-ethernet connections
  • Blue – used for terminal server connections
  • Red – used for IP cameras
  • Black – used as a general color 
  • Pink – used as an additional color option
  • White – used as an additional color option

Depending on the client and the application patch cable colors can vary. The key, however, is simple – consistency. With any new system, staying with a consistent color scheme can help save time and money with implementation and maintenance, as well as prevent a lot of headaches in the future.

Cat6 Cable Color Standards

Whether it is a Cat5, Cat5e, Cat6, or even Cat6a ethernet cable, the color code of the outside of the cable should not be confused with the internal twisted wires that have their own color code. The outside color scheme is far more generic, simply helping to draw attention to the purpose of the connection. While a Cat6 cable is a twisted pair network cable that’s used for ethernet networks, it is also backwards-compatible with other Categories like Cat5 and Cat5e. However, once again we see that industry standards that are used across the board are hard to come by. 

Some of the more common color standards for Cat6 cable include:

  • Blue – denotes network connectivity
  • Yellow – generally used for wired security cameras 
  • White – also used for wired security cameras
  • Grey – used as an interconnection, also known as “jumpers”
  • Black – generally used for equipment, peripherals, and/or workstations in a network
  • Red – commonly used with VoIP phone systems or other emergency communications systems.

Network Cable Color Chart

If you’ve spent anytime looking for network cable color charts online, you may have been frustrated at the lack of continuity with different schemes. As we’ve hit on, the color standards vary widely, but the ANSI/TIA did help this endeavor with their lengthy standard – Administration Standard for the Telecommunications Infrastructure of Commercial Buildings or ANSI/TIA/EIA-606-A. 

While the standard goes into tremendous detail for labeling and ease of identification, an actual color chart is hard to come by. Scouring the web, we were able to find a third-party site that published their version of the ANSI/TIA/EIA-606-A standards. 

Being from a third party, this chart is for informational purposes only, to help give our readers an idea of what a network cable color chart can look like:

A Final Look: Cat5e Blue vs. Grey

While the topic of many different internet forums, the difference between Cat5e blue and grey is the same as with the other cable colors we’ve looked at. The deciding factor here is only as far as the design engineer choosing a given color. This is highly subjective and depends on the many factors we’ve already discussed such as when the Cat5e cable was manufactured, where it was manufactured, and the industry it was manufactured for. 

Getting a Custom Cable Assembly Color-Coded Correctly

At Meridian, we custom create more than 70 percent of the products we produce. That means each custom cable is made to the exact specs of the client, to work as intended within whatever electrical system the assembly is destined for. One of the keys to our success here is in our ability to create a unit that is easy to integrate into the client’s existing systems. With decades of experience and some of the very best capabilities within custom cable manufacturing, we can design a color scheme that makes sense and that can be seamlessly integrated. 

Contact our team to go over your project’s specs today.

Everything You Need to Know About the SMA Connector

SMA Connector for RF Signals

The SMA connector is an incredible workhorse, offering a wide variety of applications from which it can provide the perfect solution. Because of its versatility, the SMA connector is used in every industry from telecommunications to medical. In today’s spotlight series, we’ll hone in on the venerable SMA RF connector, which provides a critical function in today’s cutting edge medical devices.

What is an SMA connector?

First off, SMA stands for sub-miniature type A. Subminiature connectors are small, hence the name, and are useful in high-frequency applications. This is because SMA connectors are able to provide a steady broadband connection from the KHz range on up to 18 GHz. The inherent reliability of the SMA connector is achieved from a constant impedance of 50 ohms and also because of its low reflection. Electrical impedance is simply a measure used to find the level of opposition that gets applied to a current inside a circuit when the voltage gets applied to it. 50 ohms is considered a good middle ground in the realm of standard characteristic impedance. 

SMA connectors can achieve low reflection and good attenuation because of their shape, which helps to maintain a uniform connection contact. The SMA is coaxial, with the characteristic screw-type coupler; however, these should not be confused with standard coaxial hooking up a home’s cable or internet. To hook up an SMA to a coax requires a special adapter. 

Standard SMA Connector Specs Snapshot:

  • Utilizes a one-quarter inch and 36 thread type coupler
  • Male SMA connectors use a five-sixteenths inch hex nut. This allows the application of torque by a standard one-half inch wrench. The applied torque can be used to easily tighten or loosen the connector.
  • Female SMA connectors utilize a thread for coupling that is 4.32 millimeters long.
  • Employs a special silicon rubber O-ring. This helps to provide separation between the body and the coupler which in turn creates a barrier to outside environmental factors like dust.

Even within a specialized connector like the SMA, there are several different types. Next up, we’ll focus on a Meridian specialty, the SMA RF connector, which provides the crucial connection many different devices in the medical industry rely on to run effectively.

How SMA RF Connectors Help Medical Breakthroughs Happen

RF stands for radio frequency and applies to a range of coaxial electrical connectors. The SMA is one of the most used of the RF-type connectors. Because of the screw-type coupler, the SMA is sturdy mechanically and offers durable performance throughout the life of the system – really important considerations for life-saving medical devices. 

SMA RF connectors come in a male and female variety to provide the crucial connections high frequency medical devices need to consistently send and receive power and data. Male SMA connectors are easily recognizable because they resemble a standard coaxial connection with a center pin inside of its threaded barrel. The female connector acts more like a sleeve which helps provide a good, sturdy connection between the types. Female connectors are usually affixed to a stable device and the male is then used in a removable wire connection for the greatest flexibility within the electrical system.

The sturdiness of construction, extremely reliable performance, and how it fits perfectly into the electrical system is what makes the SMA RF connector the go-to for fields with complex requirements like the medical industry. We produce tens of thousands of SMA RF connectors for medical devices each year. Designing and producing each to exacting standards, we are able to power the devices medical staff rely on to diagnose and treat patients every day. 

Designing the Perfect SMA RF Connector

SMA RF connectors can range from a single connector, customized to provide the perfect connection in an existing system, to a custom cable assembly that provides multiple SMA connections and adapters for providing the greatest range of application. Many SMA RF connectors available today utilize a right angle design but there are also straight angle designs available, all depending on the circuit. Right angle design is a popular choice because it helps maintain the impedance we discussed earlier at a standard level. 

Meridian’s gifted engineering and design team has to calculate the dimensions and structural components of the connection to incredible preciseness. Further, our production team must be absolutely flawless in their assembly, with special attention to the soldering. Too much soldering can lead to what’s known as an impedance mismatch. Impedance mismatch can also occur when the dimensions aren’t exactly right, a mechanical failure, or even when too much air surrounds the contact within the connection. 

Imagine if any of these were to occur during a risky surgery, where hospital staff is dependent upon the many medical devices around them utilizing SMA RF connectors. 

Different Ways to Mount SMA Connectors

  • Panel Mount: this is a female mount made for tough conditions like in the military and industrial settings. With a two-hole or four-hole configuration, panel mounts are easily applied to instrumentation and wireless infrastructure.
  • Bulkhead Mount: female mount with a thread length that is usually longer than the typical 4.3 millimeters to more easily attach to a wall or panel using a nut and washer.
  • Through-Hole Mount: can be vertical or 90 degrees and comes in non-magnetic varieties that are used often in the medical field.
  • Edge Mount: vertical mount that comes in both a standard and drop in variety. 

Losing signal or power mid-procedure isn’t an option which is why our clients have come to know they can depend on Meridian for a quality product that is designed to function as intended cycle-after-cycle.

Does UL-certification matter with SMA RF Connectors?

Creating a product for a device that literally can mean life and death for a patient is a matter no custom cable manufacturer should ever take lightly. We’ve already seen where small deficiencies in the connection can lead to catastrophic failure. This is one of the many reasons we utilize UL-certified components in all of our products, including the SMA RF connector. 

UL-certified components have been tested and verified for their structural integrity, durability, and overall functionality. This allows our design team to utilize components that have known and very specific operating ranges. In this way, we can piece together the perfect amalgamation for even the most complex custom cable assembly

Meridian is proud to utilize UL-certified components and to maintain status as a UL-approved manufacturing facility, having met the stringent quality assurance and quality control (QAQC) requirements of Underwriters Laboratories (UL). We also are proud to have had and continue to maintain our certification as ISO 9001:2015. This difficult to achieve certification requires demonstrable and exceedingly high QA/QC programs that focus not just on quality of the product, but of the entire process – which includes cradle to grave design, sourcing, prototyping, mass assembly, testing, but also emphasizes customer service/satisfaction. 

Making an SMA RF Connector That Performs Flawlessly in its Application

Impedance matching is a crucial step with custom SMA connectors. The design and test teams of Meridian rely on decades of experience in custom cable manufacturing to select the perfect SMA connector to do the job, in the environment, and in conjunction with the other elements of the system – especially terminations. These different components all must work in perfect harmony for the electrical system to perform as it should. 

To produce a one-of-a-kind solution that works perfectly in its intended environment, we are fanatical in our approach to quality. As discussed, quality starts with the very first client contact, through every step of the design and manufacturing process, and then beyond with an industry-leading product warranty. We test each and every product that rolls off our assembly line so that our clients know the product they receive will perform under their exact specifications. 

How do you test SMA RF connectors?

It is indeed rare to go from design straight to volume production without many periods of testing and prototyping in between. Prototyping allows our design team to test several different configurations of the same SMA RF connectors in harsh real world conditions. Often these are even tougher than the actual circumstances the system will face every day. We call this our “advanced life testing lab” which subjects the components to all manner of freezing temps, scorching heat, salt, and other environmental factors that need to be mitigated against during the design phase. 

Aiming for as close to perfection as humanly possible, we also employ highly accurate, automated Cirrus testers. However, there are times such as when the product is entirely unique, that we must design a correspondingly unique and entirely-custom testing unit to ensure the component’s functionality, structural integrity, and above all, safety. 

How to Get a Custom SMA RF Connector Project Started

When you need the perfect solution for a medical device requiring a SMA RF connector, our team is readily available to complete the project on-time and on-budget. Our design managers work with you to understand all of the complexities surrounding your project, set production milestones, lock out the appropriate tools from our massive tool crib, and manage the entire process to ensure the product is made to your absolute satisfaction. Contact us today to go over your specs and outline your options with our dedicated sales team.

The Ultimate Guide to Wire Harness Manufacturing Terminals

In today’s spotlight series, we’ll look at an easily overlooked but absolutely vital component of the wire harness manufacturing process – the humble terminal. We’ll explore how terminals provide the perfect match for conquering the connection needs of the project and are just an important consideration for our wire harness design team as any other piece in the system.

What is a terminal in wire harness manufacturing?

Simply put, wire terminals terminate conductors. Coming in a wide variety of shapes and sizes, wire terminals are specific for the connection that is required for the application. Within the greater wire harness manufacturing process, wire terminals play a critical role in establishing the necessary connection. Wire terminals have to be designed within the constraints of the project, which requires extensive expertise in custom wire harness manufacturing in order to meet the time and budgetary constraints established. 

Different Types of Wire Terminals for the Task at Hand

Getting up to date with your terminal terminology is crucial for understanding how selecting the best components for the task at hand helps the entire system run cohesively, cycle after cycle. There are many different types of terminals, including an array of specialty terminals made just for a very specific task. The most common wire harness manufacturing terminals include:

  • Push-on Terminals: these terminals are made for connecting quickly and can be configured as a male or female connection. They also have a wide variety of available options to cater to the individual application. These include considerations such as heat shrink, vinyl, nylon insulated, non-insulated, high temperature, and completely customized. We’ll dive a little deeper into the unique advantages gained from each of these options later in this post.
  • Butt Connectors and Splices: providing a wire to wire connection, these terminals are used to connect or splice two, or more, wires together. This could be to lengthen, change, or repair a certain wire. Butt connectors come with available options such as nylon or vinyl insulated, non-insulated, heat shrink, and high temperature.  These can be used in the field for repair work should a wire need splicing or repairing.
  • Ring Terminals: ring terminals are crimped or soldered and are used to connect a wire to a stud or a post.  When attached to large gauge wires they are sometimes referred to as Lug Terminals. Ring terminals are commonly used for power or ground connections. Ring terminals are usually made of a copper alloy, making them easier to solder or crimp to provide a secure, protective connection. Ring terminals come in a variety of types depending on the application such as non-insulated, vinyl, nylon, heat shrink, and high temperature.  
  • Spade Terminals: these terminals are used to connect a wire with a stud or screw to make an electrical connection. The spade terminal is common in automotive applications. Spade terminals come in a wide variety of sizes and options as well. Some of these options include non-insulated, vinyl, nylon, and heat shrink. 
  • Fork Terminals: used to connect wires to components that use a clamping hold down. Because of its shape, the fork terminal is easy to install and uninstall. Fork terminals can come non-insulated, with vinyl or nylon insulation, and with heat shrink. 
  • Bullet Terminal Connectors: bullet connectors are used a lot in automotive environments because they are pretty easy to connect and disconnect. One very commonplace they are used is in the plugs connector a trailer to a vehicle.  Another useful aspect is that they can come fully insulated to prevent moisture intrusion. Bullet terminals can be vinyl or nylon insulated or heat shrunk to meet the requirements of their intended system.
  • Bare Copper Eyelets: these unique terminals are generally used in the automotive industry as a connection for battery cables to electrical equipment. These connectors have to be able to safely conduct high voltages hence they are made of pure copper, which is an excellent conductor. 
  • Terminal Blocks and Terminal Strips: these support elements help to organize the mass of wires to different electrical circuits. This is what allows multiple wires to all be connected within the same circuit. 
  • Flagged Terminals: simple terminals that provide a secure connection in tight spaces or when another terminal such as a quick connection is not ideal. These are often called Quick Connect or Quick Disconnect terminals. Flagged terminals are easy to connect and disconnect and can be either insulated or non-insulated. They are often used to connect a wire to a circuit board that has a mating spade terminal.
  • Hook Terminals: the open-ended connector is simple, but extremely durable and effective and can be used in a variety of applications. Resembling the shape of a small hook, it can easily attach to a stud or screw. 
  • Quick Disconnect Terminals: as the name implies, this terminal is produced to easily be connected and disconnected. These are often called Flagged/Flag terminals.  The terminal can either be insulated or non-insulated, depending on the environment. Our team has integrated this type of terminal in the projects of many different clients, but primarily they are used in the automotive or industrial sectors. 
  • Specialty Terminals: at Meridian, we have decades of experience in providing custom solutions to clients. With that expertise, we can design the perfect custom terminal to meet the requirements of the project. Custom adapters and connectors like “X” and “Y” connectors help solve the complex connection aspects of the project.
  • Most terminals are crimped on the wire.  The tooling required to properly crimp a terminal is critical.  At Meridian, we have the correct tooling to crimp terminals from most major suppliers, including, but not limited to Molex®, Amp®, Amphenol®, JST®, Souriau®, Deutsch® and Panduit® to name just a few.

As you can see, the possibilities for different connections and terminals doesn’t stop at type. After our engineers figure out the perfect type of terminal to provide the desired result, then they must piece together many different available options that serve to protect and preserve the connection. We’ll cover the options for wire harness manufacturing terminals in greater detail next. 

Choosing the Best Design Options for Wire Harness Terminals

You have many different choices when it comes to your terminal’s design. Depending on the environment, there are a variety of considerations to make:

  • Heat Shrink – made for high performance, heat shrinking provides a watertight seal to the terminal connection so is best used when water, salt, or steam exposure are probable environmental risks. Resistant to abrasion and the effects of aging, heat shrink also helps with pullout strength and strain relief.
  • Vinyl Insulated – when insulation is required, vinyl affords the most economical route to go. The insulation helps to protect against short circuits.
  • Nylon Insulated – nylon insulation is more durable and can withstand higher temperatures making it ideal when the environment is hot and tough, such as might be seen by our military.
  • Non Insulated – this type of terminal is typically the most economical of the design choices. It is often used when the project does not present any special characteristics or additional protections.
  • High Temperature – typically an element like nickel plated steel is used in the terminals construction to help it withstand temperatures in the realm of 900 – 1200 degrees Fahrenheit. These can be found in common consumer applications like ovens, cars, and light fixtures.
  • Overmold – this is done when either a special shape is required, a group of terminals need to be in one package or if a certain shape is desired for cosmetic reasons.

How Terminations Get Insulated

Nylon insulation and vinyl insulation are both great options for providing protection for the terminations in your custom wire harness. Vinyl insulation is the more economical of the two but still affords great protection. That’s because vinyl insulation employs a PVC sleeve that’s tapered permanently to the barrel to protect against vibration and also provides mechanical stress relief. If you need to kick it up a notch, nylon insulation is made extremely rugged to provide maximum performance protection against high vibration and stress.

Wire Gauge Sizes for Wire Terminals 

When exploring your options for different wiring terminals, it is important to remember that there is a correct size for every wire gauge and it will always have a crimping die to match. Insulated terminals come in common sizes that correspond to a color system. Most times, wires larger than 10 gauge will be required to have a terminal that’s not insulated. Your Meridian design team will skillfully employ the perfect gauges with the appropriate terminal to efficiently solve your project’s requirements.

Why a UL Rating Matters for Wire Harness Manufacturing Terminals

Underwriters Laboratories (UL) certification is something you’ll hear us discuss often because it is such a vital piece of the manufacturing puzzle. Using UL-certified components and being a UL-approved manufacturing facility means the client benefits by knowing the things going into their product, as well as the manufacturer behind the product, have met high levels of quality assurance thresholds. Quality is determined based on testing components to know their exact specifications and tolerances and then to provide this as a standard across the industry. 

When a facility doesn’t use UL-certified components in their design they are taking a gamble with something that hasn’t been tested and retested for functionality, durability, and integrity. As a UL-approved manufacturer, our manufacturing processes have been scrutinized and have been found to be of the professional caliber required to maintain this high honor. This all translates to better products for our clients. 

With clients in industrial controls, telecommunications, military, medical, and other critical sectors, each and every product off our line is designed, tested, and retested under the most stringent of conditions so that we know it will keep on performing as intended cycle-after-cycle.

Picking the Best Terminals to Get the Job Done

Our team prides itself on solving our client’s most complex wire harness problems with a small team of elite professionals each working together to bring your project’s tough specifications to life, both on-time and on-budget. When it comes to designing the perfect product, our team excels at perfecting the minutiae, while effectively managing the ‘big picture’. Contact our team now to go over your options for a custom wire harness that perfectly meets the project’s needs.

Cable Harness Assembly from Prototype through Production

Wire Harness Components

With over 5,000 existing tools at our disposal, chances are good we’ve got everything we need to produce even highly complex and completely customized solutions. However, there are many instances where we’ve had to design a totally new tool or testing mechanism when a solution is a never-before-seen amalgamation. We leverage decades in the industry to produce products for our clients that we know will stand up to whatever application they will be utilized in and also can be delivered within a viable framework, given the time and budget constraints of the project. 

Aerospace, automotive, lighting, and alternative energy are just some of the many different industries we stand ready to serve with our custom solutions to even the most complex problems our clients present us with. While solving problems is something our design engineers are really good at, the solutions are only viable if all the pieces of design and production can meet both the budget and timeline set forth for the project. With strict adherence to kanban manufacturing techniques, just-in-time ordering, and efficient, worldwide logistical support, we are able to deliver full-functional and repeatedly-tested cable assemblies and wire harnesses to clients anywhere in the world.  

Cable Harness Assembly Design and Manufacturing

Our design and manufacturing process follows a set protocol towards maximizing a project’s budget, meeting project milestones and ensuring the absolute functionality of the final product. Here’s a quick snapshot of a few key elements of the process:

  • Needs Assessment: we will examine all of the specifications for your project and seek to understand all of the elements at play for how and where the system will be employed. This is where initial design elements are started to be placed together which will later be developed into working prototypes. 
  • Extruding: our in-house extruding machine can extrude conductors as small as 34 gauge and all the way up to 12 gauge. These conductors make up the building blocks of both cable assemblies and wire harnesses. They can be stranded or braided, filled with insulation, wraps, shields, and other components depending on the project needs. Connectors, overmolds, terminations, and housings help bring the cables and wires together within an electronic system.
  • Prototyping runs: we will usually produce several iterations to not only test a unique combination of components for accomplishing a given task, but will also look at how those components are sourced to see if a given assembly is viable. 

Why Certifications Matter

One of Meridian’s greatest strengths lies in our Quality Assurance program. Each and every product that rolls off our assembly line will be tested through multiple iterations to ensure continuity, integrity, polarity, and functionality. Prototyping allows our design staff to gauge different configurations and sourcing in order to find the most efficient means of solving the problem at hand. 

Maintaining an ISO 9001:2015 is no easy task and certification to which we are extremely proud to have held for nearly 20 years. ISO 9001:2015 requires a company to demonstrate they have advanced quality assurance processes in place and also mechanisms for continual improvement in both product and production, but customer service as well. Additionally, we are an Underwriters Laboratory (UL) certified production facility and predominantly use UL-certified components. UL certification means our products have been independently-verified for structural integrity, functionality, and safety. This allows our design staff to utilize a component with a known specification, that’s been stringently tested, rather than creating a whole new component from scratch.

If your cable or wire harness supplier isn’t ISO certified and doesn’t utilize UL-certified components, they have not made a solid commitment to quality assurance and you will be taking a huge risk with the products they produce.

Cable Harness Assemblies for Industrial Controls

Industrial control systems, or industrial process controls, require a complex array of signals, data, and power to be sent at just the right time in the production process in order to provide the intended function. These systems provide almost complete automation for the operations and performance monitoring functions within many critical infrastructure systems like water, power, and civil transportation systems, as well as in manufacturing settings like a bottling plant. 

Meridian’s custom-built wiring harness and cable assemblies provide the necessary infrastructure for these process controllers to perform at their best. Particular considerations for industrial control systems include incorporating components that ensure the fidelity of the process. For example, engineering in radio frequency interference (RFI) avoidance measures, which can include specialized shielding, helps to avoid costly delays within an industrial control system when a wrong signal is sent/received and causes some crucial function to not be performed. Even small delays in an industrial setting can be incredibly costly. Hermetically-sealed connectors, strain reliefs, and cable stops are all utilized to ensure the system operates as intended cycle after cycle.

Cable Harness Assemblies for the Military

Cable harnessing companies operating in support of providing our military with crucial electronic systems components knows their products will more than likely be deployed in some pretty extreme environments. Not only must they contend with extreme temperature swings, sand, dirt, dust, and mud, but also exposure to water, salt, and corrosive materials must be accounted for in the cable assemblies and wiring harnesses being used for military purposes. Our men and women in uniform count on our products to assist them in everything from navigation to communication, and increasingly are being utilized to empower unmanned systems such as UAVs. Special considerations in design can include incorporating Kevlar into the sheathing material to prevent cutting and aluminized mylar to prevent interference.

In support of their mission, our design team comes together to produce a solution that works within the usually tough parameters set forth by our clients in military contracting. We are adept at meeting project and budgetary milestones to deliver the perfect solution to the complex problem at hand.

Cable Harness Assemblies for Other Industries

Aerospace, automotive, lighting, and alternative energy are just some of the many different industries we stand ready to serve with our custom solutions to even the most complex problems our clients present us with. While solving problems is something our design engineers are really good at, the solutions are only viable if all the pieces of design and production can meet both the budget and timeline set forth for the project. With strict adherence to kanban manufacturing techniques, just-in-time ordering, and efficient, worldwide logistical support, we are able to deliver full-functional and repeatedly-tested cable assemblies and wire harnesses to clients anywhere in the world.  

Ready to Go Over Your Project Specs?

Our team stands ready to review your project’s unique specifications and will deliver a solution perfectly suited to match your needs. Contact us now to start the design process

Custom Cable Manufacturers: Creating Endless Possibilities With Your Custom Cable Design

Based on the combinations of each level of design of a custom cable assembly, there seems to be an endless number of possibilities for creating a unique, never-seen-before amalgamation of cables, wires, and support materials. These innocuous materials come together by fanatical design to pull-off some of the most demanding jobs on the planet. From supporting our military men and women on tough missions, providing for the possibility of cutting-edge medical equipment to be employed by a skilled surgeon in a complicated surgery, or enabling the manufacture of millions of other products in an industrial setting, it all starts with humble cables and wires. We’ll explore how the different design layers come together to create a masterpiece of modern engineering that is the custom cable assembly.

Conductor Size Matters

Extruding conductors sounds like the name of a cool sci-fi flick but it’s actually the foundation of any cable assembly. Conductors are simply materials that are good at conducting; think copper, aluminum, or nickel. Extrusion is a series of processes where parts of cable assemblies’ cross sections are made. The conductor material of choice is fed into a large vertical hopper that in turn feeds the extruder machine. The extruder looks like a large screw with a barrel that’s heated so it can mix, melt, and pump the material into a die. Meridian’s brilliant design staff can extrude conductors as small as 34 gauge – about six one-thousandths of an inch, or as large as 12 gauge. Even cooler, oftentimes different gauge conductors are put together to accomplish different tasks within an electrical system. This type of cable is referred to as the mixed-gauge cable. Custom cable manufacturers mix and match gauges to meet the exact requirements, as well as, confines of the project.

Colors of the Rainbow

Color may seem a purely aesthetic choice but far from trying to keep up with the latest season’s fashion, colors help designers and installers keep track of the many different conductors within the cable assembly. At Meridian, we often make cable assemblies with well over 50 different conductors. Just to keep track, we have to use a color system. Colors and custom markings help ensure the right conductor goes exactly where it’s designed to within the cable assembly. The best cable manufacturers reverse engineer cable assemblies from their given applications so that installers can efficiently utilize the assembly in their unique circumstances. Color coding is one way to ensure the product works as intended from design through implementation. 

Leave No Strand Behind

Stranding is the process by which individual conductor strands are joined together. Using a really cool stranding machine, we take strands of wire and rotate them around a common axis to create a super strong and flexible cross-section. When using UL-certified wires, we know the industry specifications of each individual wire and produce a custom cable that performs under the given set of circumstances we plan for. The strands themselves can be an incredible array of different materials and sizes, depending on the level of connectivity an electrical system requires. Cable manufacturing companies typically leave no strand behind unless a single, large strand is the best conductor for the given objective.

Why Insulate a Cable Assembly?

Insulation provides the first line of defense for a cable. Insulators are non-conductive materials that act as separations for the conductors within the cable and also from the environment that could downgrade the effectiveness of the cable if exposed to the elements. Electrical and signal transmission cables will both use insulation to protect conductors from things like extreme temperature variants, friction, current/signal degradation, and moisture. Insulators themselves come in many different types of materials that then each have their own set of design specifications, like hardness and softness, that can be tweaked on a given project. Meridian offers a wide array of insulation materials to meet both budget and performance requirements of each project. Each insulator we employ in a custom assembly will have the specific properties needed to perform under the circumstances. Mechanical properties like operating temperature ranges, resistance to abrasion, and flexibility, electrical properties like dielectric loss (ability to dissipate electromagnetic energy), and physical properties like thermal expansion and resistance to moisture all need to be considered in the cable assembly’s design. Meridian’s design engineers are intimately familiar with each of our insulating materials’ inherent properties so they can hand-pick the perfect combination that meets the project’s unique requirements.

Fillers Can be a Good Thing

Like insulation, fillers are used to prevent abrasion between cables which can degrade their construction over time. Basic cotton and fleece are great low-cost options for fillers that provide protection for the cables, help maintain the cable’s shape, and strengthen the cable through thousands of flexings. For applications requiring more beefy specifications, Kevlar is a great insulator for its inherent strength and durability – not to mention its sweet ability to stop bullets in other applications. Custom wire and cable manufacturers utilize even simple materials like fillers to create the perfect set-up for the intended application of a cable assembly. Far from being just a “filler” within the assembly, cable assembly fillers play a critical role in both form and function.

Cable Armor: Wraps and Shields

Adding to the layers of protection and durability, cable wraps and shields are used to create a cushioned, pliable barrier between the conductors and the final outer jacket. This helps prevent friction, increases strength, and adds to the overall durability of the cable assembly. Also, many electronic cables need special shielding to prevent interferences like electromagnetic interference (EMI) and radio-frequency interference (RFI). This happens when an external source, both man-made and natural, directly affects the electrical circuit, which can degrade the current or cause it to cease altogether. Engineering in an avoidance system to EMI and RFI, our design team is able to create a cable system that can operate unimpeded through many useful cycles. EMI can be an intentional act such as the case with radar-jamming in military applications. Specialized shielding like aluminized mylar helps to block EMI, which allows our soldiers to openly communicate with each other on the battlefield.

Last Line of Defense: The Cable Jacket

The cable jacket acts as a final insulator and a protective barrier from the elements. The jacket can be made in myriad materials ranging from hard to soft to give our clients the protection of their custom cable assembly project needs. Simple materials like polyvinyl chloride (PVC) ranging to Polytetrafluoroethylene (Teflon), recognized for its use in non-stick, high-end cooking, can be utilized to create the perfect jacket to insulate all of the components from the elements in which they’ll be deployed. Nature throws a lot at cable assemblies like heat, oxidation, and moisture that would rapidly deteriorate the conductors and insulation materials without a robust jacket encasing the assembly.

Bringing it all Together

Each step in the production process requires an incredible level of detail to tweak the material to the exact specifications of the project. Our design engineers love being brought an unsolvable problem and putting together a solution that works for both budget and performance. These materials by themselves are just a bunch of seemingly commonplace components, but together, they can be formed into the cable assembly system to power a fighter jet or an electrical system for a Grand Prix race car. We combine the right materials for the right application to produce a one-of-a-kind solution that works. Simply put, we are passionate about exceeding our clients’ expectations and our passion is continuously showcased in our products.

Meridian Knows Custom Cable Assemblies

We know you have many choices in the cable manufacturing industry. Custom wire and cable manufacturers around the world boast of superior products and services. So why Meridian? First and foremost, we have almost three decades of experience in international manufacturing in order to bring our customers around the globe the perfect product, by the most judicious means possible. Our design staff has created cable assemblies for some of the most demanding applications the Earth has to offer. From military to medical, we take the trust placed in our products seriously so produce the very best we possibly can. We also have garnered incredible knowledge in pre-project planning so create an incredibly lean manufacturing process – saving our client’s time and money and producing an ROI time and again. Lastly, we place a huge emphasis on quality. We only use UL-certified cables and wires and even created our own testing lab to ensure each and every product that rolls off our assembly lines perform under the exact specifications to which it was designed. Our products are simply too vital to electrical and signal components to fail prematurely. Our continuing and unwavering commitment to quality is what’s earned us ISO 9001:2015 certification. 
When you’re ready to meet with an engineering team that loves solving even your most complex cable assembly design problems, give our knowledgeable sales and marketing team a call. They’ll help start the process of getting you the perfect custom cable assembly that meets your exact specifications.

Top 10 Benefits to Creating a Custom Cable Assembly

custom cable assembly manufacturer

Standard cable out of the box is usually mass-produced for a very simple purpose. When the application varies in even the minutest details, these standard cables will often fall short. Even for a simple application like hooking up a home theater system, the different connections from speaker, to power source, to audio source can vary significantly with the myriad of different brands on the market and usually require a custom coax cable assembly. A failure here can lead to a frustrating cinematic experience. Imagine if that failure were to occur during a critical mission with the military or during a large-scale production run in an industrial setting. Failure during these events could prove incredibly costly. And so, custom cable assemblies, crafted exactly for the task at hand, produce a return on the investment time and again. We’ll highlight below our top 10 benefits to creating a custom cable assembly with Meridian.

Top 10 Benefits of Custom Cable Assemblies

1. Ability to Prototype

Prototyping is the process of creating a “test” assembly from which our design staff can run a particular set of cables, connectors, and ancillary components through a multitude of tests in real-life situations to ensure the assembly meets the design requirements. Multiple iterations produced at the same time allow for different prototypes to be tested simultaneously. Seeing the product perform in the real world gives our design staff and clients insight into different attributes that may need to be tweaked. One desired function may not work when different components are put together creating the need for a redesign of an original idea. Also, a prototype will help the manufacturer understand where, when, and how source materials will come together. If these components aren’t feasible, or economically viable, to source given the current configuration, designers can go back to the drawing board way before mass production ever takes place. Prototyping can prove incredibly cost-effective for production in the long-run of product development.

2. Product Testing

Meridian’s custom cable assemblies, whether prototyped or not, will undergo rigorous testing to ensure uniform functionality and quality. At Meridian, we even maintain our own testing laboratory that does nothing but test each product as it comes off the assembly line. Sometimes this requires inventing a whole new way of testing if the cable assembly is a completely customized project. Testing helps to ensure the client receives a product they know they can depend on, in whatever application they are planning on using it in. From military to medical, these assemblies are simply too vital to fail prematurely. Another important element of testing is being able to test the product in the elements; that is, putting the product in the environment it will be used in. Harsh conditions like salt water exposure or being subject to extreme temperatures will increase the need for effective insulators, fillers, wraps, and jacket materials. Testing allows custom cable assembly manufacturers to see how a particular amalgamation of components will stand up to the environment where it will be utilized. 

3. Reduce Overall Costs

Rather than trying to configure an off-the-shelf cable assembly to meet your specific needs, custom cable manufacturing allows you to create the perfect set-up. As we’ve discussed, prototyping and testing help ensure the final product has the form and function required of the cable assembly system, while still being economically viable. Our design staff and in-house engineers love solving our client’s complex problems. They’ll take into account how the cable is being used, the voltage or signal required, and even variables such as length to produce the perfect cable and cable assembly components. Knowing the costs, production times, and functionality of a custom assembly saves an incredible amount of time, which in turn, provides the best utilization of capital for our clients.

4. Perfect Fit

Oftentimes, our clients bring us very specific design criteria for use in their electrical systems. As discussed, these systems are used in an incredible array of industries. With such diversity, finding a premade cable assembly to fit your exact project requirements will be difficult, if not impossible. For example, our molded cable assemblies have a mold that’s created exactly to the project’s specifications. This creates a perfect, stable fit for the assembly to the equipment and provides the protection to stand up to the elements that may be subjecting the assembly and connections. Another example is the ability to color-code cables and wires. Color-coding greatly reduces the chances that an element is incorrectly installed, making sure the custom assembly remains the perfect fit from production through implementation. 

5. Faster Turnaround Time

Utilizing a custom cable assembly means all of the project source materials are known ahead of time. This reduces the chances for sourcing hiccups that can occur from trying to source materials on-the-fly. Also, running the cable assembly through prototyping and extensive QA/QC testing helps ensure the product is the perfect fit for the function to which it is intended. All of which helps decrease the chances that a product isn’t delivered on-time, as planned. Pre-production, our engineers and design staff put together a complete production plan that even takes into account the specific tools needed to complete a job. Tools are reserved from our custom tool cribs in order to make sure they are available at the precise moment they’re needed in the production process, which also eliminates time waste. Meridian is a firm proponent of Kanban production, which seeks to eliminate these types of waste throughout the production process in order to stick to the predetermined project schedule. 

6. QA/QC

Quality Assurance/Quality Control (QA/QC) lies at the very heart of everything a custom cable manufacturer does. In order to obtain and maintain our ISO 9001:2015 certification, we have to demonstrate a consistent commitment to the improvement of our processes. Demonstrating the integrity of our products, each and every production run, and our commitment to total client satisfaction, allows for production runs to go smoothly, issues to be addressed quickly, and the overall product quality to remain consistently high.

7. Experience in Similar Applications

A cable assembly manufacturer worth their weight will have produced thousands of different cable and wiring assemblies for a variety of different industries and applications. Meridian’s clients benefit from nearly three decades of intrinsic knowledge in custom cable assembly. We produce products that work right from the get-go, with each and every product manufactured off our lines. All of this experience equates to faster turnaround times, better products, and the ability to utilize our client’s budget in the most judicious means possible.

8. Better Materials

By going with a custom cable assembly and cable harness manufacturer, you get the benefit of qualified engineers sourcing the best materials for the actual application you intend the product for. At Meridian, we use UL-certified cables and wires so that we get both a uniform functionality, as well as, uniform quality to our products. This allows the final product to have a known range of specifications and likely failure points, allowing for clients to better plan for asset decay. Bottom line, better materials means better products.

9. Ability to Scale Production

Most projects usually go from concept, through design, to prototyping, testing, and finally roll off in small lots. However, we have the capability and experience to produce incredibly high volumes of cable assemblies, coil cords, molded components, and wire harnesses in our production facilities. Having two, wholly-owned production facilities located around the globe allows us to quickly ramp up production to get our products quickly to clients anywhere they may be.

10.  Control Over the Process

At Meridian, we control the entirety of the day-to-day operations in both of our production facilities. That means complete oversight over the complete production process. We have a fairly fanatical dedication to making quality products. The applications where our cable assemblies find themselves is simply too vital for us to produce anything less than great products, with known specifications, so that operators know they can count on the product wherever it’s being employed. You simply won’t get this level of control over product quality from an off-the-shelf cable assembly.

Why Meridian?

Custom cable assemblies are a vital component to most any electrical system you can think of. We know you have a wide range of choices when it comes to cable assembly companies and cable harness manufacturers. At Meridian, we’ve developed a manufacturing process that utilizes the very best techniques in supply chain management and manufacturing, such as Kanban and just-in-time ordering. After nearly three decades as a cable and wiring assembly manufacturer, we’ve gotten pretty good at the process. This means putting client needs first to deliver a truly superior product, in a cost-effective manner. We value the trust placed in us by our clients so continue to seek ways to improve our processes. When you’re ready to go over your project requirements with a knowledgeable support specialist, call 1-866-866-0544 or email us at sales@meridiancableassemblies.com. You can also utilize our convenient online contact form.

What Do Wiring Harness Manufacturers Do, Exactly?

wire harness manufacturer

What Do Wiring Harness Manufacturers Do, Exactly?

The custom harness that was designed especially for all the different electronic systems you own and come into contact with on a daily basis, required some pretty sophisticated engineering. At the micro-level, the engineering that went into the engineering i.e. the machines that create a custom wiring harness also required a great deal of design and thought. After nearly three decades designing and manufacturing wiring harnesses, we’ve gotten pretty good at what we do. So what exactly does a manufacturer of wiring harnesses do? Read on as we explore what it takes to create this vital and oft-overlooked support system for nearly every type of electrical system in use today.

From Hand Tools to Precision Robots

Even down to the hand tools we use, our exact specifications have gone into every step of the manufacturing process. For manufacturing wiring harnesses, cable assemblies, wiring assemblies, and however else you refer to the systematic binding of cables and wires, our tools have to be extremely precise. Depending on the exact level of precision needed, we can deploy hand tools, semi-autonomous machines, and fully automated machines to meet the project’s design requirements. While our manufacturing engineers are extremely accurate and really good at what they do, when a design has to be absolutely correct, we rely on automation to do the job. However, even with automation, a lot of the assembly is still done by hand due to the complexity of steps that goes into even making a simple wiring harness. 

Tool Cribs Not For Sleeping

When you’re in the middle of a project, not having the tools you need at hand can be a real time-killer. In a production setting, delays can cost thousands of dollars and cause tight deadlines to be missed. That’s where a tool crib comes into play. Far from just a ubiquitous toolbox, a tool crib is an ordered, efficient storage of the myriad of different specialty tools we require on a job. Most often, these tools are not utilized all that frequently, but when needed, costly delays are avoided because the tools are available and ready to use right when they’re needed. When a project comes in, our project planners will detail all the tools required to do the job in a set amount of time. This includes “checking out” the specialty tools in the tool crib so that they are available for this particular job and don’t accidentally get pulled for another product run. We ascribe to kanban manufacturing techniques, which takes advantage of just-in-time ordering and lean manufacturing principles in order to economically produce the best products for our clients. Without the vital support of systems like the humble tool crib, we wouldn’t be able to produce wiring harness assemblies at a reasonable pace or price.

Great Recipes Begin with Quality Ingredients

The cable and wiring we use are all United Laboratories (UL) certified. ULⓇ certification means the components have been uniformly tested and certified for safety and function. UL is one of only a handful of U.S. corporations approved by OSHA to provide this rating to products. Even when we apply one of more than 50 colors available for wiring and vary the striping employed, we can still maintain ULⓇ certification on our wires and cables. Starting with the industry’s best components ensures the final product is both safe and will serve its function through many life cycles. 

Custom Creations

When we create a custom design, two factors presented to us by our clients have the greatest impact on the overall design. First, is the space we have to work with. Imagine the difference between a remote-control car’s wiring and the steering wheel assembly in a NASCAR race car. Both require precise electrical and signal transfers, but space, where these occur, is night and day and our engineers expertly work within the physical confines of the project. The second factor affecting the design is the project’s electrical requirements. This can determine wire size and thickness, and also affects additional design requirements like insulation and all the different materials needed. With these two factors in mind, our in-house engineers’ design and manufacture small batches of harnesses that will be tested and retested to ensure durability and longevity of the components.

Ready to talk over your project specs?

At Meridian Cable, we pride ourselves on listening to your exact needs and designing the perfect assembly to meet those needs. Our greatest advantage lies in our custom solutions. On-staff engineers, planners, and designers come together with our expert manufacturing team to produce a one-of-a-kind product, built to the highest industry standards, to meet the rigors of the job. From Military, Industrial, and Medical applications, our products are simply too vital to produce anything but our very best. Our wiring harness specialists are ready to review your project specifications and start building you the perfect components for your project. Contact us today to start the process. 

3 Reasons to Work with Cable Assemblies Manufacturers on Prototyping

3 Reasons to Work with Cable Assemblies Manufacturers on Prototyping

Partnering with cable assemblies manufacturers to prototype can help you ensure a more successful solution.

Working with cable assemblies manufacturers on prototypes is a great way to keep your production process running smoothly and end up with a cable assembly that performs the way you expect. While there are situations where an off-the-shelf cable can be used, it’s common that equipment has specialized requirements that can’t be met with a standard cable. When dealing with these kind of specialized needs, working directly with cable assemblies manufacturers to create a prototype has many benefits. Here are a few of the more common ones.

Working with Cable Assemblies Manufacturers Reduces Costs

Anytime someone says the word “custom” many of us hear “expensive.” However, when talking about prototyping cable assemblies, that isn’t always the case. In fact, many times you can actually save money by working with a cable assemblies manufacturer on a custom prototype. One of the first ways prototyping can help reduce overall costs is when it comes to the price and availability of components. Creating a prototype can help you identify issues with the supply chain for components before you go to a full production run. Unavailable or overly expensive components can make a significant difference in the cost when producing a large quantity of units. Understanding these costs at a smaller scale allows you to make more informed decisions or adjustments before it’s too late.

prototypes with cable assemblies manufacturers

Prototyping Simplifies the Production Process

Aside from the availability and price of components, prototyping also allows you to get a clear picture of the overall production process. It’s not unusual to discover problems with the production of a cable assembly after the design phase. Producing a prototype gives you a much better idea of what it will take to create a larger number of products without making costly mistakes. By paying attention to the production process when creating a prototype, cable assemblies manufacturers are able to identify ways to streamline production. This, in turn, can make turnaround times much quicker when producing the desired quantities of the finished product.

Product Testing

Testing a finished product is the best way to understand how effective it will be. By working with cable assemblies manufacturers to create a prototype, you are able to do thorough testing on a fully functional version of your product. This will allow you to get the clearest assurance that your finished cable will function as planned and whether it will be able to withstand the environmental conditions it will be subjected to during normal usage.

Conclusion

There’s no question that working closely with cable assemblies manufacturers on prototypes allows you to produce cables that will work seamlessly with your equipment. Choosing a manufacturer with a great deal of experience with prototyping is a great first step toward producing a finished cable that functions as expected for as long as expected for a price that matches your budget. When you are ready to discuss your next custom cable prototype, contact the team at Meridian Cable. We look forward to talking with you!

5 Benefits of Custom Cable Assemblies

5 Benefits of Custom Cable Assemblies

Custom cable assemblies offer many benefits over off-the-shelf products…including cost.

It’s possible there’s a standard cable that matches the needs of your equipment perfectly. However, it’s much more likely that you will have to make do with something that is almost right, which can lead to technical issues that can cause bigger problems down the road. This is especially true when your project’s requirements are specialized or complicated. While an off-the-shelf cable might seem like a quick and cheap option, custom cable assemblies have many advantages…and cost is one of them.

Cost Saving

Your first impression may be that custom cable assemblies are automatically more expensive than standard cables. This is not always the case. While a custom solution might be more expensive up front, better performance and longevity can save money because you don’t need to replace the assembly as often.

Time Saving

At first glance, you might think it’s faster to pick a cable up off the shelf and simply connect it to your equipment. Unfortunately, it’s usually not that easy. In many cases, it’s a struggle to make off-the-shelf cables work for any but the most simple applications. Trying to retrofit standard cables takes time and money that could have been saved by working with a manufacturer to create a custom cable assembly.

Better Performance

This one seems obvious, but custom cable assemblies are designed to work with your equipment and environment in mind. This means that they can not only take all of your requirements into account, but also be extensively tested with those requirements in mind to ensure a successful finished product. Because of this, you get a cable assembly that will function and last as expected.

Customized Appearance

custom cable assemblies

With an off-the-shelf cable, what you see is what you get. When producing custom cables, you are able to specify color, texture, and whether you need any type of labeling. This allows you to brand the cables or choose a color that makes it easier to identify. Color coding not only creates a more professional appearance, but also makes installation easier and repairs safer.

Availability

We’ve covered some great benefits that custom cable assemblies offer over standard cables, but the most significant is that you have a product that does what you want it to do. There are applications that are too specific or complex to be adequately served by an off-the-shelf cable, but with a custom product the options are nearly limitless.

Conclusion

There is certainly a time and place to use standard cables. However, there are also circumstances that call for a more custom option. With custom cable assemblies, you can be sure that your solution will meet the needs of your equipment and function how you expect. Working with a reputable, experienced cable manufacturer like Meridian Cable gives you even more peace of mind that you will get the performance you need. When you are ready to discuss your next custom cable project, don’t hesitate to contact us. We look forward to talking with you. 

Wire Harness 101 with a Wire & Cable Manufacturer

Wire Harness 101 with a Wire & Cable Manufacturer

Wire harnesses can be tricky without the help of an experienced wire and cable manufacturer.

At its most basic, a wire harness is an effective way to organize wires or cables by grouping or bundling them together in order to transmit signal or electrical power. They can be used in almost any application that requires multiple wires or cables. While many of these harnesses are complex with multiple wires and components, they don’t have to be. A wire and cable manufacturer is able to design and produce a wide variety of complex or simple wire harnesses that are truly tailored to the needs of your project.

Benefits of Wire Harnesses

Complex equipment and machinery often require a great deal of wiring to function. Running each and every one of these wires separately can be time consuming. Additionally, that many wires can be bulky if there are space constraints, and keeping multiple wires organized and running in the right direction can be challenging. Integrating the component cables and wires into a single harness allows for faster, easier installation that doesn’t take up more valuable space than necessary.

However, there’s more to it than just a neat and tidy wiring system. In some cases, it is extremely important to prevent certain wires from coming into contact. Designing a wire harness instead of running individual wires allows a wire and cable manufacturer to better protect the conductors from environmental issues like vibration, moisture, heat, cold, and abrasion. Bundled wires can also be further protected from shorts and electrical fires by using non-flexing or flame retardant jacketing materials.

Manual Assembly

Believe it or not, a wire harness is more efficiently manufactured by hand. There are steps during the pre-production stage that can be automated, but the assembly process can be complex. Depending on the needs of the project, production can include multiple steps, such as:wire harness

  • Taping Breakouts
  • Binding Components with Tape, Cable Ties, or Clamps
  • Conducting Multiple Crimps
  • Routing Wires through Sleeves

This makes manual assembly more economical, especially when working in small batches. The manual assembly process also means wire harnesses can take a little longer to produce than individual wires. It’s vital to work with an experienced wire and cable manufacturer that understands how to keep the production process on schedule.

Testing Performed by a Wire & Cable Manufacturer

No reputable wire and cable manufacturer would deliver a wire harness that has not been fully tested. However, the sheer number of cable and wire components makes this process a little more involved than testing individual wires. That’s where a pre-programmed test board comes in. By programming the test board with the required electrical characteristics for the project, we are able to plug in the finished wire harness and test the components individually or in groups as needed making for a safer, more stable final product.

Conclusion

An experienced wire and cable manufacturer is a valuable partner when you need a well-designed wire harness. Not only are they able to design a harness that meets all of the requirements of your equipment, but they are also knowledgeable enough to understand the time and budgetary challenges involved in producing a complex solution. When you’re ready to start your next project, contact the team at Meridian Cable. We look forward to talking with you.