Looking at a lead wire assembly, one assumes that it allows electrical components to connect to each other. While sort of correct, this negates the operational role lead wire assemblies serve. They also aid in the transfer of power between components, as well as the transmitting of information within a machine or other electromechanical device.
These assemblies can be found in all manner of applications & called upon to do the heavy lifting in everything from appliances, printers, medical devices, and generators. Furthermore, the look, length, and stoutness of lead wire assemblies is also quite different based on the application AND visual distinction specified by the client.
In any industry that depends on the integrity of these connections, making sure that the lead wire being used for said connections is dependable ranks fairly high for operations ‘musts’. Some of these issues include but are not limited to monitoring efficient use of power, as well as the impact of supplying poor to average power to equipment can have on overall operating expenditures.
But what exactly goes into lead wire assembly on the manufacturing side? For company leaders looking to get the most out of the physical capital in their facilities, ALL things related to lead wire assembly are of consequence. Here is a basic guide for understanding lead wire assemblies:
Establishing Specs — Some specs worth noting include determining wire gauge, overall length, crimping style on ends, terminator style, and labeling.
Testing — Lead wire assemblies are a connection between two components. This means that there may be tension present. If the lead wire assembly cannot handle the stress of this tension, the connection will be broken. Manufacturers of note adhere to UL 486 pull test standards to make sure they deliver a quality product.
Lead Time & Delivery — Delivery can further complicate a specific timeline if the manufacturer does not have a strategic facility close at hand that’s capable of producing quality materials closer to clients, thereby reducing wait time compared to competitors.
Most importantly, the best lead wire assemblies are made by the best manufacturers. This means finding the right manufacturing partner, a task unto itself. Still, it might be as simple as looking for manufacturers that can actually meet industry standards. This means having the right credentials to meet multiple standards across industries & possibly needing the credentials provide overseas support. It is important that they understand the application through & through. This way, there are as many opportunities to make usable & detail-oriented changes during design & prototyping phases.
Not surprisingly, the most important part of a lead wire assembly project has to do with establishing budget at the beginning of the project. Whomever is in charge of ordering new materials for your company will be interacting with a handful of prospective manufacturing partners. What is NOT needed is a sales pitch. A detailed breakdown of where a project stands, what items are needed, and the best way to get there BASED on a client’s available budget are what is most important.
The right manufacturing partner allows companies to order a lead wire assembly while providing valuable feedback throughout the process. This can come in the form of choosing budget-friendly (though not lesser quality) materials for the build. It can also mean working on a better design based on the application & the immediate environment in which the lead wire assembly is found.
LoDan Electronics, Inc. of Chicago has understood what it means to keep the client at center of things since 1967. Our design & engineering teams are well-equipped to understand your needs, make assessments, and determine the best course of action for both your current project AND possible needs in the future Touch base with us here at LoDan Electronics, Inc. today.