Tailor-made cable assembly for reliable connections

What is cable assembly?

Cable assembly involves a multi-stage manufacturing process in which individual cables and connectors are assembled into a complete cable harness or cable set. To create an optimal connection solution, the cable goes through various processing steps such as cutting, stripping, crimping, soldering, labeling and bundling. Each of these steps helps to ensure that the cables are precisely tailored to the respective application and that high quality and long-term reliability are guaranteed.

This complex and precise process is used in numerous sectors and industries. Precisely manufactured cable assembly is essential, particularly in electronics, automotive and medical technology, as well as in aerospace, to guarantee error-free signal or power transmission. Since this manufacturing process requires both specialized tools and technical know-how, many companies decide to outsource cable assembly to experienced service providers.

Professional manufacturing not only ensures the highest quality standards, but also enables tailor-made solutions to be implemented efficiently. This results in precisely fitting cable sets that not only meet the technical requirements exactly, but also offer a long-lasting and secure connection.

What types of cables are there?

Cables are essential components of modern technologies and are used in numerous applications. Depending on the intended use and technical requirements, they differ in their conductivity, shielding, flexibility and transmission speed. Choosing the right cable is particularly important to ensure reliable and interference-free signal or power transmission.

cable types

Data and network cables enable fast and secure data transmission and are widely used in computer networks and telecommunications. These include Ethernet, USB, and fiber optic cables, each optimized for different transmission rates and ranges.

Power cables, on the other hand, are used for energy transmission and are designed for low or high voltages, depending on the requirements. Typical examples are power cables, high-voltage cables, or battery cables, which are required in many electrical devices and industrial applications.

Coaxial cables are particularly well shielded, enabling interference-free signal transmission. This property makes them ideal for use in TV and radio technology, as well as in communications technology. Ribbon cables, on the other hand, consist of several parallel conductors and are often used in electronic devices or computer hardware due to their space-saving design.

Control and industrial cables play an important role in automation technology, reliably supplying machines and systems with electrical signals. These cables must be not only flexible but also resistant to mechanical stress and environmental influences.

In addition, there are numerous special cables that have been specifically developed for demanding applications such as medical technology, aerospace or high-current applications. These cables often offer high temperature, chemical or UV resistance in order to meet the special requirements of these industries.

The wide variety of cable types means that tailor-made solutions can be created for almost any application. Careful selection not only ensures high efficiency, but also a long-lasting and trouble-free connection that optimally meets the requirements of the respective application.

Why is choosing the right cable so important?

Each cable must be adapted to the specific requirements of its environment. Therefore, factors such as bending strength, temperature resistance, shielding and electrical conductivity play a crucial role in ensuring reliable function and a long service life.

What cable connectors are available?

There is a wide range of cable connectors available, which are used depending on the respective application and the technical requirements. The choice of the right connector depends on several important factors, including transmission speed, signal type, voltage, current and the number of contacts. To give you better orientation and enable you to make the right decision, we will present the most important connector types and their respective areas of application in detail here.

What are the cable connectors used for?

• USB connector – Versatile connection for data and power
  USB plugs are an indispensable part of modern electronics. They connect computers, smartphones, cameras, tablets and many other devices. There are various variants, including USB Type A, USB Type B, Micro-USB, Mini-USB and USB-C. USB-C in particular has now established itself as the standard because it enables faster transfer rates and greater compatibility with modern devices.
• HDMI connector – high-resolution image and sound transmission
  HDMI (High-Definition Multimedia Interface) connectors are optimized for the digital transmission of audio and video signals. They are mainly used in televisions, Blu-ray players, game consoles and computers. There are several types, including standard HDMI (Type A), mini HDMI (Type C) and micro HDMI (Type D). While standard HDMI connectors with 19 pins are the most common, mini and micro HDMI connectors are particularly suitable for compact devices such as tablets or digital cameras.
• Ethernet connectors – stable and fast network connections
  Ethernet connectors play a crucial role in data transmission in networks. They enable speeds from 10 Mbps up to 100 Gbps and are essential for LAN connections in companies, data centers and smart home systems. The most common connectors include RJ45, RJ11 and RJ12, with RJ45 being the standard for network applications.
• Audio plug – Clear transmission of sounds
  Audio connectors are used to transmit audio signals between speakers, headphones and sound systems. The most common variants are 3,5 mm jack plugs, RCA plugs and XLR plugs. While jack plugs are used for everyday applications, XLR plugs are mainly used in professional audio devices.
• Power plugs – secure energy supply for various devices
  Power connectors are responsible for transferring electrical energy from a power source to a device. These include AC power cord connectors for connecting to mains power and DC power connectors for direct current applications such as those used in laptops, chargers or portable electronic devices.
• Coaxial connector – Robust connection for TV and radio technology
  Coaxial connectors are used to connect coaxial cables to devices such as televisions, radios and antennas and enable stable and interference-free signal transmission. The most common variants include F-connectors, BNC connectors, N-connectors and SMA connectors. While F-connectors are mainly used in TV and satellite systems, BNC connectors are used in surveillance and video technology.

What is a wiring harness?

A wiring harness is a systematically organized collection of electrical cables and wires that are connected and bundled together to transmit electrical energy or signals safely and efficiently. It is designed to be space-saving, easy to install and particularly reliable - even in complex technical systems.

Where are cable harnesses used?

Cable harnesses are used in many industries because they enable structured and secure cabling. They are particularly used in the following areas:

• Automotive industry: Wiring harnesses connect control units, sensors, motors and many other components, ensuring the reliable operation of modern vehicles.
• Aerospace: Here they ensure safe and interference-free power and signal transmission, even under extreme environmental conditions.
• Heavy industry: In machinery and equipment, cable harnesses help organize cabling and minimize operational disruptions to ensure smooth operation.
• Electronics industry: Wire harnesses bundle various connections in electronic devices and systems, saving space and ensuring error-free operation.

How is a wiring harness constructed?

A wiring harness consists of several components that work together to ensure reliable and long-lasting performance. Cables and wires form the heart of the system, transmitting power or data safely and efficiently.

To ensure a stable connection, connectors and contacts ensure a secure interface between the various devices and components. To protect the wiring harness from external influences, protective materials such as heat-shrink tubing, sheathing, and protective braiding are used. These not only provide mechanical protection but also ensure reliable electrical insulation.

To ensure the wiring harness remains securely in place, fasteners such as cable ties, clips, and brackets are used. They prevent slipping or damage due to movement, thus ensuring a long service life and consistent performance.

Individual planning and production for every application

Each wiring harness is individually designed and manufactured according to the customer's specific requirements. Precise design is particularly important to ensure:

• The required functions, environmental conditions and safety requirements are fully met.
• The appropriate materials and components are carefully selected.
• The electrical load and mechanical requirements are carefully taken into account.
• International norms and quality standards are adhered to.

Cable harnesses are therefore far more than just a collection of wires. They are highly sophisticated and customized solutions that form an indispensable basis for many technical applications.