Wire assemblies are used magnanimously in different industries and applications like electronics, telecommunication, automobiles, aerospace, aviation, and military. Based on the application and design, a wire assembly can have multiple wires and components, consisting of several branches and terminals. Through all these wires and components, information is allocated, transmitted, and directed through electric signals or currents throughout the entire system. But, which components are to be installed into the system, that is of utmost importance. There are a few considerations to be made in order to decide as to which components need to be installed, and how.
Considerations to be made
Location and placement of the assembly – First and foremost, it needs to be identified where and how the wire assembly is to be installed. Is it an indoor or outdoor application? What kind of temperature and environmental conditions will the assembly face? Further, will the assembly be in touch with any sorts of gases, liquids, or chemicals? All these minute details are very important to be able to decide on the kinds of components that can be effectively installed so as to enhance the performance of the assembly within the application conditions.
Dimensional and engagement attributes of the assembly – So, you’ve checked on the location and environmental conditions of where the assembly needs to be placed. But, that’s not all. There is more to it – the installation. You need to understand the length and diameter of the wires and assemblies required. How long or short does the wire need to be? In addition, also check whether the assembly will be placed flat into the application, or will it be twisted, pulled, or elongated to fit in? Depending upon the required length, width, and placement, the kinds of wires and components can be decided upon.
What kinds of wires and components can be used?
Indoor/outdoor applications – Indoor applications are much safer as compared to outdoor ones. If the wire assembly is to be used in outdoor applications, you will need stronger cables that are more durable and have a longer life with enhanced performance. Your assembly will also need multiple insulation layers to withstand all sorts of wear and tear. Some of the best options for assemblies to be used in outdoor applications are shrink-wrapped thermoplastic, thermoplastic rubber, and vinyl.
Temperatures – Coming to the temperatures that the assemblies will encounter, there are again a few things you need to understand. For instance, for extremely cold temperatures, you must make sure that the coating does not become rigid; they should be able to expand and contract as and when required. Similarly, for extremely hot temperatures, you must check for the heat tolerance of the assembly components, such as the coating, jacketing, and insulation.
Types of components basically used
Conductor – The conductor should be able to sustain specific conditions without corroding or overheating. Moreover, it should also have high tensile strength in order to sustain mechanical stresses. Copper is one of the best materials used because of its conductivity, but it is easily prone to corrosion. You must thus consider every aspect before deciding on your conductor material.
Connectors – Connectors can help bring different wires together, either being permanently attached to the system, or being temporarily affixed so that they can be removed when they require interchangeable parts.
Terminals – These are the points at which the wires end. Based on the purpose and location, the terminals may be either connected to another element, or may be capped off.
Grommets – These components keep the wires secured in their place, thus maintaining a structured system. This helps make the installation and maintenance of the product more seamless.
As you can see, there are lots of considerations to be made while choosing the materials for a wire assembly. And this is why you need to approach those wire assembly manufacturers in India who not only understand how wire assemblies work, but also the kinds of assemblies that can suit your business and application requirements perfectly. Miracle Electronics is one such manufacturer who has complete knowledge about the same, and also the skills and expertise to undertake requests for customized assembly designs and developments.