A variety of industries utilize cable assemblies for their products. Sometimes, reliable, high-voltage versions are needed. During the product’s design stage, it is good to become educated about what options are available. The basic components of any assembly are the cables, accessories, and connectors. By designing a product to compliment the attributes of the cable assemblies, money can be saved in the end, because the design is smart and efficient. It is also closer to being ready for production, since the assembly order is already outlined.

High voltage cable assemblies are used for numerous applications. The manufacturing, security, medical, and research industries use them in a variety of ways, such as with x-ray technology. The military operates many systems that require high voltage, such as sonars, weaponry, communication systems, and radars. Industrial systems have seeming endless needs for accelerating voltages, and most are unique and highly customized.

Options for high voltage cables
The cable is obviously the most important feature to review when designing cable assemblies. By knowing the attributes of a few options, the right one can be chosen for the job. When reviewing cables, pay attention to the gage of wire and the material used to insulate it. The gage will dictate how much operating current it can handle, while the insulating material indicates how high of an operating voltage can be used with the wire.

There are a few types of wire that are best suited for high voltage uses, namely single, double, and triple extruded wires. Extrusion is a manufacturing process by which one material is forced into a particular shape by a dye. As the name indicates, a single extruded cable is one conducting wire covered by an insulating layer. A double extruded wire is a single center conductor, with a semi-conductive material extruded over it, and all encased in an insulating layer. Triple extruded wire is a double extruded wire covered in a second layer of semi-conductive material, thereby creating three conducting layers and one insulating one.

Depending on the application, the cable assemblies may need to be shielded or have a protective jacketing added. These options add a layer of safety to the final product. High voltage is already a concern, but environmental influences should also be considered, such as heat, cold, water, and stress.

Accessories to consider
As with any new product, there are an infinite number of accessories that might be necessary for it to work. A few usual suspects are used most often, in order to maintain the integrity of the unit. A cable clamp is helpful because it keeps the cable from bending or moving inside the connector. In order to reduce mechanical stress on the cable assemblies, a strain relief adapter could be used. Also, straps and devices can be added to ground high voltage cables.

Connectors to know about
Different shell styles are available for connectors. One may suit the product’s needs better than another. They include bulkhead receptacle, right angle, inline receptacle, and inline plug. After the type of connector is selected, the size can be determined by looking at the size constraints and operating current and voltage of the conducting wire being used.

Safety is always the first concern when constructing cable assemblies. High voltage options require an extra level of attention. Coupling mechanisms offer safety when putting together and taking apart the assembly. They can be in a few varieties, such as push-pull, bayonet, and screw. A silicone rubber insert is also a typical option, to increase performance and reliability.

Anywhere throughout the design stages, it could be wise to consult professionals about specialized options that could be specifically created for the product at hand. Through ingenuity and experience, a custom cable manufacturer can help design cable assemblies to meet the end product’s needs.

If you would like to learn more about cable assemblies, visit LoDan Electronics, Inc.