5 Common Problems With Custom Cable Assemblies And How To Solve Them

Because custom cable assemblies are such a necessary component to just about every facet of modern life, it stands to reason there may be a few malfunctions with the structures. There are a few common ones that are easy to detect if the user is familiar with cable assemblies. Of course, many of the issues associated with these assemblies lie in improper manufacturing techniques. If you understand the initial process, it can help you in solving your current short-circuits.

1. Improper Initial Testing

When a custom cable component is first assembled, it must undergo multiple tests to ensure everything is connected and working efficiently. Improper testing can lead to some expensive and even dangerous defects. A wire should be 100% tested, especially if it involves electrical connectivity. Cables can be initially improperly wired, soldered or terminated causing later problems. These repetitive failures can be easily solved if the custom cable manufacturers conduct positive and thorough initial testing. Unfortunately, though, not all testing will catch malformations. Intermittent failures are much harder to detect, as they do not occur as often or regularly. There are some signs to look for to determine if the failure is a result of repetitive, easy fixes or more difficult intermittent problems.

2. Weak Wires

Wires and cables should be able to withstand a reasonable amount of force. To determine the tensile quality, manufacturers should perform a pull test. This measures the strength of the inner structure. If an assembly is constantly losing connectivity or forcefully breaking, consider the strength of your assembly.

3. Imbalanced Pressure

The crimp pressure refers to the proper setting of a die within a custom cable assembly. If a technician failed to solder the structure or set the die correctly, it could cause inner destruction, including fraying. A pressure test should be able to clarify the issue.

4. Micro-fretting

When certain metals come in contact with each other, they form oxidation upon the surface. If an application utilizes a large amount of voltage, it can cure this problem. Otherwise, tin and lead are particularly problematic. Remating wires can sometimes help, but this is generally a temporary fix. Intact plating can prevent some of these issues in the initial phases.

5. Contaminated Contacts

When cables and wires connect to other sources, they should be in pristine condition and properly soldered and crimped. When custom cable assemblies are not properly soldered, there can be build-up left behind which will eventually interfere with the connectivity.

In short, many of the problems users experience with cables are from improper manufacturing techniques. But even if manufacturing prices were good, intermittent problems can still arise. If you are searching for a solution to your cable assembly problems, contact LodanElectronics.com today!