5 Types of Cable Assemblies You May Need - Rapport, Inc.

Shopping around for cable assemblies can be challenging. You’re typically looking for something completely custom to handle a unique problem just for your business. To make sure you are getting exactly the assembly you need, we’ve compiled 5 of the most common cable assembly types and the type of applications you may need them for.

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Military Grade Cable Assemblies

When you think of things that are military grade, you may imagine something rugged, simple, and fine with being dropped off a helicopter. You’re mostly right – military grade cable assemblies are typically used for tactical and marine applications. There are a number of strict requirements for cable assemblies marked as military grade, and a separate set of requirements for the connectors on your cables and the wires used in the assembly. Additionally, the use of the cable assembly is taken into account; the requirements for cable assemblies that will be used in underwater environments are totally different than those used on planes. Military grade cable assemblies are often required for field communication links, airborne systems, remote weapons control, marine systems, military ground equipment, and inter-shelter communications.

RF/EMI Cable Assemblies

We live in an incredibly noisy world – and each of your cables is probably adding to that noise. RFI is radio frequency interference that occurs on the radio frequency spectrum. EMI references electromagnetic interference. “Both man-made and natural sources generate changing electrical currents and voltages that can cause EMI: ignition systems, cellular network of mobile phones, lightning, solar flares, and auroras Northern/Southern Lights.” (Wikipedia.org). “The disturbance may degrade the performance of the circuit or even stop it from functioning. In the case of a data path, these effects can range from an increase in error rate to a total loss of the data.” There are applications where you may want to leverage these signals, and times when you may not want them. You’ll want to work with your cable assembly creator to figure out what is best for you.

Molded Cable Assemblies

You probably have seen a number of molded cable assemblies in your non-work life. HDMI cables are typically molded cable assemblies. Below you can find an image of an HDMI cable underneath the molded shell. Molded assemblies are typically used in applications where a more durable and finished appearance is desired so if those are your requirements, a molded cable assembly may be the way to go.

Shells can be made of plastic or metal, can be shielded or unshielded, and can be used in a wide variety of applications.

Assembled Coaxial Round

Coaxial cables or “coax” cables have been around for a very long time – they work really well. Additionally, you almost certainly have one or more coax cables in your house already – they are the stabby usually black cables you plug into your TV to get cable (or hide behind a piece of furniture because no one has cable anymore).

A Coaxial cable “is a type of electrical cable that has an inner conductor surrounded by a tubular insulating layer, surrounded by a tubular conducting shield. Many coaxial cables also have an insulating outer sheath or jacket. The term coaxial comes from the inner conductor and the outer shield sharing a geometric axis.” Some of the uses for coax cables include cable internet, and applications in vehicles, aircraft, medical equipment, and radios.

Flat Ribbon Cable Assemblies

Flat Ribbon cables look really cool. Rather than the wires being bundled together within a sheath, the wires are nicely organized in a flat ribbon. If you’ve ever opened up a really old computer you may have seen a ribbon cable – they are mostly no longer used in computers as they are large and hard to fit in a tiny case but they are just as effective as round cables, and have applications where a flat cable assembly may be more advantageous than a round one. With a ribbon cable, you can color code each wire to know what they do, as well as see each wire individually. “The main point of ribbon cables is to allow mass termination to specially designed IDC connectors in which the ribbon cable is forced onto a row of sharp forked contacts.” Ribbon cable assemblies may be more durable than their round cable counterparts, and are great for usages where the width of the cable is important.

What are circular electrical connectors?

Electrical connectors are essential components in a wide range of electronic and electrical systems, enabling the transfer of power and signals between different devices. By providing a reliable means of joining circuits, they enable communication and functionality across applications ranging from consumer electronics to industrial machinery.

Among the many types of electrical connectors, circular connectors stand out for their robust design and user-friendly features. These connectors, including options like the 12-pin configuration, are specifically designed to deliver secure and efficient connections in space-constrained environments while offering protection against environmental factors such as moisture and dust.

The adaptability of electrical connectors makes them indispensable for applications requiring reliable and durable connections. Circular electrical connectors are available in various designs and pin configurations, tailored to accommodate diverse power and data transmission requirements. Thanks to their ability to maintain electrical integrity even in challenging conditions, they are a preferred choice for professionals seeking optimal performance and reliability in their systems.

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Overmoulded Cable Connectors

These connectors are fully encapsulated in a protective moulding, offering superior strain relief and excellent protection against environmental factors. Known for their durability, they withstand harsh conditions and deliver reliable, consistent performance over time. Another advantage is that they are ready for immediate use and can be connected directly without the need for complex assembly.

Use Case: Suitable for heavy-duty industrial applications or environments subject to frequent mechanical stress.

• Connecting cordsets (cable-to-cable connector): Designed to connect two cable ends, these connectors allow for quick extension or joining of cables. They provide flexibility in wiring systems that may need to be adapted or extended over time.
  Use Case: Applications requiring cable extensions or connections across long distances.
• Single ended cordsets: With a connector on one end and open wires on the other, single-ended cordsets simplify direct device connections to power or control systems. Their pre-configured design ensures quick installation and reliable performance, making them ideal for industrial and automation applications.
  Use Case: Ideal for direct device connections where quick and dependable wiring is required.

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2. Number of Contacts

The number of contacts in a connector indicates how many circuits it can support. It is essential to ensure that the connector has an adequate number of contacts to handle both the power and data signals required by your application.

• Low-Contact Connectors (2 to 4 contacts) are suitable for simple applications that only require power transmission or basic signal flow, such as in lighting, basic sensors, or low-power motor control. However, they can still transmit high data volumes, which can occurs via Ethernet protocols rather than purely digital signals.
• Medium-Contact Connectors (5 to 12 contacts) are common in industrial environments where both power and data need to be transferred, such as in automation systems, sensors, or industrial machinery. These provide more flexibility for signal and power segregation.
• High-Contact Connectors (13+ contacts) are used in complex systems like communication networks, multi-channel data acquisition, or high-performance computing systems. They enable transmission of a large volume of data and power through a single interface, supporting advanced control, monitoring, and communication protocols.

Important: The number of contacts also impacts the voltage and current that can be transmitted through the connector. A higher number of contacts results in smaller distances between the pins, allowing only lower voltages to be safely transmitted to avoid the risk of short circuits. Therefore, it is not always straightforward to classify connectors solely based on the number of contacts as either simple or complex. Factors such as transmission protocols, current and voltage requirements, and specific application conditions also play a crucial role. More info below.

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3. Gender (Pin/Socket)

Connectors consist of two components: a male element (pin) and a female element (socket). These can either be permanently installed or attached to the end of a cable. In practice, pins and sockets are always used together once the connection is established, making it challenging to classify their usage by application. However, there are certain tendencies: device connectors (panel mounts or flange parts) often feature a socket, while cables typically use a plug. Once the device is connected, both plug and socket are integral to the connection, e.g., a plug in the device and a socket on the cable.

• Male connectors typically have exposed pins, which can allow for easier contact during mating and faster signal transmission. Male connectors are often used in stationary or fixed components such as control panels, where they will not be exposed to damage from frequent handling.
• The sockets of female connectors offer protection for the internal contacts, reducing the risk of electrical shorts or accidental contact. In applications where accidental exposure to live parts could pose a risk such as high-voltage systems or areas where connectors might be touched), female connectors are safer because their sockets shield the live pins.

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6. Rated Voltage

The rated voltage indicates the maximum voltage that a connector can safely withstand. This is one of the most critical specifications to consider when selecting a connector, as it determines the electrical insulation and breakdown voltage the connector can handle without failure.

Voltage ratings can be specified for AC (Alternating Current) or DC (Direct Current) systems. Our product range spans from 24V to V. It is essential to ensure that the connector's rated voltage aligns with the voltage requirements of your application.

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7. Environmental and Temperature Range

It is essential to assess the IP rating (Ingress Protection) of the connector, which indicates its level of protection against dust and water, along with its ability to withstand temperature and other environmental factors. For connectors used in extreme conditions, such as high temperatures or heavy vibrations, ensure that the connector has an appropriate IP rating and environmental sealing features.

In harsh environments, such as medical or food processing applications, it is particularly important to select connectors with robust and hygienically safe seals to prevent breakage, contamination, or exposure to harmful substances.

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9. Wire Size / Wire Gauge

Ensure that the connector is compatible with the wire size or gauge that aligns with the current rating, especially when operating close to the maximum capacity for the connector type. This is a crucial consideration when selecting a circular electrical connector, as it directly impacts the connector's ability to handle current, voltage, and overall performance in the application.

Choosing the correct wire size is vital to prevent issues such as overheating, voltage drops, and other inefficiencies that could jeopardise both safety and functionality. Wire sizes are typically measured using the standard American Wire Gauge (AWG) system.

• Smaller gauge numbers indicate thicker wires capable of carrying more current. This usually applies to power connectors used in industrial machinery that require lower gauge (thicker) wires, such as 10 AWG or 16 AWG.
• Larger gauge numbers represent thinner wires that are suited for lower current applications. For signal transmission or data lines, such as in sensors, telecommunications, or medical devices, higher gauge (thinner) wires like 24 AWG or 26 AWG are often used.

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