Customer Wires: The Solution to Your Cable Headaches

Are you having a hard time finding one cable that would be able to connect all your entertainment devices and get them to work? Are you looking for a wire that could solve all your electrical device headaches? The problem is not just finding one that is compatible with all the devices that need certain connections but also finding a wire or cable that has the correct length and the right jacks.

For problems such as those, one of the best solutions would be to use a custom cable assembly or a custom wire assembly. A cable assembly is an arrangement by which wires or cables are grouped using ordinary tape or a sleeve. Grouping wires together helps make it neat and more importantly, protects them from being damaged. An assembly can come in any length that is convenient for you and the best part is that it can be used for all sorts of appliances or electrical devices.

Cable assemblies are commonly used in the electrical wiring in vehicles. Offices that use many computers also need cable assemblies. There are different connectors that may be used. A Molex connector is one of the most commonly used cable assemblies for computers. D-Subminiature and SDL connectors are what are used for connecting computer parts to the CPU. USB connectors have been widely used nowadays for cellphone chargers or other appliances since most people work around the computer. There are also JST connectors, which come in various types and can accommodate many cables or wires with different jacks. There are so many kinds of cable assemblies to choose from and are convenient for different uses. For home appliances, the most commonly used cables are HDMI and SVGA. These are used for people with high definition television sets or play station units that have sophisticated graphic features.

Custom wire and cable is available in hardware stores. It is likely that you can find what you need from a hardware store even though it may be a little too specific or sophisticated. The employees in the hardware store are also familiar with these kinds of cables; let them know what you are looking for so they can help you find the right one for your appliances. Some electrical hardware stores also offer special services where they create a special one that will suit your needs and are specifically made to be compatible with your devices.

When it comes to finding custom made cable assemblies, it might be best to consult with an electrician first so that he may be able to guide you in looking for connectors that should be used and the material that is suitable for your devices.

Medical Cables: Often Overlooked

Medical cables are as important to a medical device as the device itself. Medical device designers many times focus on the device and overlook the wire and cables that is needed for the device to perform its function. Medical cables tend to be more specialized due to the many types of uses and environments it is subjected to. The wire and cable is many times not thought of until the end of the design process, which may be too late. Knowing your medical cable limitations and the options available to you in the beginning is important especially when designing housing or specifying connectors. Some things to keep in mind when specifying wire and cable for a medical device:

• Size- With the size of devices becoming smaller many times smaller gauge wire and cable is needed. Off the shelf wire and cable usually go as small as 28AWG. Fine wire and custom cable designs are usually needed.
• Flexibility- Handheld devices and medical robots require flexible cables which can withstand repetitive flexing. Higher stranded conductors and sometimes alloys are needed to achieve this.
• Sterilization- Sterilization can be done with alcohol, steam or gamma to name a few. Cable jackets need to withstand the sterilization process.
• Bio-compatibility- Medical grade cables are needed depending on the level of contact with the patient. Bio-compatible and implantable grade compounds are available for medical devices.
• Construction- Cables sending signals, power and even gas/fluid can be constructed in on jacket. Constructions can vary from the simple wire to complex hybrid cable.
• Unique- Medical devices are all unique in regards to application, requirements and environment. You should not use an off the shelf mass produced cable designed for to meet the generic needs of a variety of industries for a specialized medical device.
  

Considering your wire and cable needs from the early stages of your product design will prevent problems down the line in regards to failures in the field, design issues and time constraints. Designing custom medical cables for your application ensures you have a medical device that will exceed performance and longevity you require.

Depending on the type of use a variety of medical grade insulation materials are available. Reusable medical cables are built to endure constant flexing and extended cycles of sterilization. Insulation may be Teflon®, TPE or silicone rubber with TPR or silicone jackets. For disposable medical cables PVC and PE are the insulation most commonly used. Discuss your application with your custom cable manufacture in order to choose the right material for your medical device.

Working with a custom wire and cable manufacture is easier than you think. Custom wire and cable engineers work with you every step of the way to determine and suggest the best materials and construction for your medical application. It's like having a wire and cable expert on your team. Cable designs are usually modified throughout the design process to accommodate changes to the device design. Many custom wire and cable manufacturers are able to produce small quantities for prototypes and clinical trials.

Specialty Wire and Cables-Different Types of High Performance Wire and Cables

There are numerous types of industrial strength wires and cables out there for use in a number of applications, from the aerospace to the nuclear markets. To sort through all of these various options, it's helpful to take a look at what some of the most useful types of high performance cables are out there today. A conductor flexible cable, for example, is a popular type of wire or cable that can be used with numerous power applications. Coaxial cables are designed with expanded PTFE dielectrics, and can be used for high frequency or light weight applications.

In the world of aerospace wire and cable, there are many different options to choose from. Aerospace cables have to be tough enough to withstand the needs of high speed aircraft applications. These tend to be small in diameter, light in weight, and able to weather extremely high temperatures. Because aircrafts and other machines that are used in this field are subject to extreme weather conditions, the wires used as well as all other internal parts have to be specifically durable for safety reasons.

For specialty needs, you may wish to look at FEP insulated high temperature wire and cable offerings, as well as PTFE, Tefzel, PFA, or other brands and types out there. These specialty wire and cable products can be used in the design and maintenance of various power applications and appliances that either generate high heat, or are oddly shaped, making them incompatible with standard-issue cables. At times, you may need a customized solution for a specialty project, in which case it's best to speak to a wiring and cabling professional about what your various options might be. Oftentimes, an existing cable can be slightly modified to better suit your specialty project, giving you the highest level of efficiency.

Finally, when you are looking at wiring solutions for applications such as commercial cooking equipment, heating and cooling systems, down-hole systems, and major appliances, you will want to choose the right industrial wire and cable. These can also be applied in nuclear, aerospace, and military functions, in many cases. If you are ever unsure as to what type of cable will work the best for your particular product or power system, it's always best to speak to a professional to learn more about your options, for safety reasons. Using the wrong cable can cause a meltdown and use energy inefficiently.

Custom Cable Requirements for Aerospace, Defense, And Medical Industries

Wire and cable companies have the unique privilege and responsibility of supplying materials to important applications ranging from medical fields to military defense. Common requirements of military or aerospace wire and cables include tensile strength, longevity, temperature resistance, purity of materials, conductivity, and a host of other factors. Let’s examine each of these properties that custom cables and wires must possess in order to serve the function these wires are designed to fulfill.

Tensile strength, longevity, and temperature. In the harsh, zero gravity environment of space, and the unforgiving climate conditions in parts of the Middle East, having equipment that will perform optimally despite adverse temperature, humidity, and impact damage can mean the difference between a successful mission, or the loss of human and equipment assets. In a context closer to home, a team of surgeons assisted by surgical robot machines employing high-tech robotics cables, can help a patient undergoing surgery in ways not previously possible. And it is important to the success of a surgical operation that these robotic components perform at the highest level of efficiency with regards to conductivity and strength.

Conductivity and purity of materials. This refers to the ability of custom cables to convey power and data through their medium within acceptable parameters of time taken and power transferred. For equipment to operate properly, the right amount of data or power within the allotted time required for a wide range of applications. Much of the technology employed by the medical, defense, and aerospace engineering fields run on electric power, and that power is conveyed through various lengths of wires and cables from a power source to the end of a crane’s arm or a space shuttle’s piloting console HUD display.

All these critical qualities of custom wires and cables play an integral role when operational requirements call for specified and tangible results in the context of aerospace, defense, and medical applications. And since these applications by nature have high standards of performance due to the stakes involved for each respective industry, experts in this specific field of custom cables and wires manufacturing are usually the ones who handle these requirements for NASA, government agencies, and various medical practices. For additional information, visit www.calmont.com at 420 East Alton Avenue, Santa Ana, CA 92707 to learn more.

Wire Applications in Military Vehicles: H Model Cougar MRAPs

Applications for custom wires and cables generally fall into one of several categories, one of which being mechanical requirements for military vehicles and equipment. Military wires and cables provide electrical power, communications, and a host of other functions within a given piece of hardware.

As combat operations in Afghanistan and Iraq (Operations Enduring and Iraqi Freedom) intensified, there was a growing need for a series of vehicles designed to survive the explosive threats posed by the Improvised Explosive Devices (IEDs) as well as conventional mining and ambush tactics employed against Coalition personnel. These vehicles were collectively described as MRAP (Mine Resistant Ambush Protected) capable, and would be specifically built to defeat these threats. One such vehicle is the Cougar. Manufactured by Force Protection Inc. employing advanced flexible wire technology, the Cougar has been in production, and in service for the past seven years.

Vehicles such as the Cougar are not new designs. While new to the US military, the Cougar design can trace its origins to the Olifant Manufacturing Company of South Africa, which originally developed the multi-wheeled, "V" shaped blast hull design for use by the South African military in its operations against Angola and Namibia in the 1980s. These vehicles were designed to have good road speeds and endurance (to allow for the long distances traveled, as well as reduced maintenance requirements because of their wheeled design) and were specifically designed with advanced silicone wires and armor technologies to maximize passenger survivability against small arms ambushes and conventionally laid mines and IEDs.

The Cougar MRAP H model is a 19.4 feet long, 9 feet wide (spare tires mounted), 8.6 feet tall (not including turret splash shield.) 3-door, diesel powered, 3-ton capacity 4-wheel drive Mine Resistant Ambush Protected vehicle. The Cougar-H is The Cougar is equipped with an automatic transmission and in addition to the driver and co-driver, has seating for 4 additional passengers. Each seat is equipped with a 4-point ribbon cable shielded pur safety harness. The vehicle is equipped with driver/co-driver doors, as well as double doors for the passenger compartment, and a single vehicle accessibility hatch on the roof. The Cougar is equipped with dual A/C units (24,000/48,000 BTU/hour), is NBC overpressure and filter protected, and is equipped with a 9,000-pound capacity electrically powered winch. The unprepared fording depth is 39 inches, an approach angle of 40 degrees and a departure angle of 50 degrees. The Cougar is capable of travel both on and off road and is equipped with run-flat tire inserts. The Cougar-H is air transportable by the C-17 transport aircraft.

Wire Applications in Military Vehicles: H Model Cougar MRAPs

Applications for custom wires and cables generally fall into one of several categories, one of which being mechanical requirements for military vehicles and equipment. Military wires and cables provide electrical power, communications, and a host of other functions within a given piece of hardware.

As combat operations in Afghanistan and Iraq (Operations Enduring and Iraqi Freedom) intensified, there was a growing need for a series of vehicles designed to survive the explosive threats posed by the Improvised Explosive Devices (IEDs) as well as conventional mining and ambush tactics employed against Coalition personnel. These vehicles were collectively described as MRAP (Mine Resistant Ambush Protected) capable, and would be specifically built to defeat these threats. One such vehicle is the Cougar. Manufactured by Force Protection Inc. employing advanced flexible wire technology, the Cougar has been in production, and in service for the past seven years.

Vehicles such as the Cougar are not new designs. While new to the US military, the Cougar design can trace its origins to the Olifant Manufacturing Company of South Africa, which originally developed the multi-wheeled, "V" shaped blast hull design for use by the South African military in its operations against Angola and Namibia in the 1980s. These vehicles were designed to have good road speeds and endurance (to allow for the long distances traveled, as well as reduced maintenance requirements because of their wheeled design) and were specifically designed with advanced silicone wires and armor technologies to maximize passenger survivability against small arms ambushes and conventionally laid mines and IEDs.

The Cougar MRAP H model is a 19.4 feet long, 9 feet wide (spare tires mounted), 8.6 feet tall (not including turret splash shield.) 3-door, diesel powered, 3-ton capacity 4-wheel drive Mine Resistant Ambush Protected vehicle. The Cougar-H is The Cougar is equipped with an automatic transmission and in addition to the driver and co-driver, has seating for 4 additional passengers. Each seat is equipped with a 4-point ribbon cable shielded pur safety harness. The vehicle is equipped with driver/co-driver doors, as well as double doors for the passenger compartment, and a single vehicle accessibility hatch on the roof. The Cougar is equipped with dual A/C units (24,000/48,000 BTU/hour), is NBC overpressure and filter protected, and is equipped with a 9,000-pound capacity electrically powered winch. The unprepared fording depth is 39 inches, an approach angle of 40 degrees and a departure angle of 50 degrees. The Cougar is capable of travel both on and off road and is equipped with run-flat tire inserts. The Cougar-H is air transportable by the C-17 transport aircraft.

The Cougar-H’s armor package provides all round coverage against 7.62mm ammunition (the glass is 7.62mm multi-strike resistant.) The Cougar-H can survive the detonation of a 30-pound TNT charge under the front and rear axels and a 15-pound charge under the center of the chassis. Ballistic protection is provided for the radiator, tires, battery compartment, fuel tanks, engine and transmission. The V-shaped hull is specifically designed to redirect the blast out and away from the vehicles passenger area. While the vehicle may be disabled by the explosion, its passengers will not be injured, and the vehicle can be recovered and repaired, as the loss of equipment when compared to the loss of life and limb can be considered more acceptable combat losses. For additional information, visit www.calmont.com at 420 East Alton Avenue, Santa Ana, CA 92707 to learn more.

Requirements Information On Custom and Medical Cables

Custom cables are cables specially designed and manufactured to meet specific needs of clients. Companies that manufacture custom cables offer a whole variety of specialist services in diverse fields such as aerospace, telecommunications, radar, military, medical, industrial electronics, transportation, commercial, marine and many other fields. Custom cable manufacturers provide complete control from unique design to finished product, extremely competitive service and lead times that suit their clients. They also work with their clients to find a cost effective solution for all their clients’ custom cable needs.

High performance military wires and cables must meet the most stringent requirements for airframe defense wiring and other on-board applications. Military wire should have high temperature resistance, be small in dimension, be low weight, have low flame propagation and be mechanically tough and chemically resistant. Custom designed cables are used in radar systems, wire and special avionics cables, weapons systems cables, electronic surveillance and others. Custom military wire manufacturers develop, manufacture and market custom designed cables and cable assemblies for demanding military applications.

Aerospace cables are designed to offer optimal performance in the special conditions found in aircraft, where requirements commonly include high reliability, long lifetime, high strength, light weight and wider temperature ranges than standard telecommunications grade fiber/cable. Typical applications of aerospace cables are In-flight entertainment systems, In-flight networking systems, display systems, data transmission, communication systems, high-temperature environments and corrosive chemical environments.

Medical cables manufacturers provide medical wire for the demanding requirements of medical instrumentation. These cables provide consistent and reliable performance. The designs of Medical cables utilize features that are important in health care applications. Flexibility and extended flex life, high strand counts, coolant tubes, flat cables and bonded-zip constructions, lead free insulations, coaxial composite cables, shielding and high strength conductors and shields are some of the important features provided by custom medical wire companies. Medical imaging, diagnostic instrumentation, dental x-ray machines, medical robotics, cardiac instrumentation and precision lasers are some of the fields where custom medical cables are used. For additional information,