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CABLE (HARNESS) ASSEMBLY

Home Services CABLE (HARNESS) ASSEMBLY

We are providing cable harness assembly and wire harness manufacturing services to various industries for all applications. Jayshree Instruments feels pride by satisfying custom cable or wiring requirements of different needs. Decades of experience helping us to shine better than other manufacturers by providing cutting edge solutions of modern difficulties.


To know more about our services

Custom cable and custom wiring harness assembly highlights

  • Decades of experience in cabling & wire harness solutions
  • Industry specific quality systems and regulatory certifications
  • Rapid NPI (New Product Introduction) to full scale production
  • World-class quality and training systems/processes
  • Integral Supply Chain partnerships
  • Competitive cost advantages and lower logistics

Engineering highlights:

  • Engineering design recommendations aimed at Quality, Cost and Delivery efficiencies

         Technology upgrades

         Documentation validation

         Component cross referencing and alternative sourcing options

  • Reverse engineering specialty cable and custom cable assemblies
  • Quick turn prototypes
  • Concurrent Engineering

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    What is cable assembly?

    Cable assemblies are a set of cables covered by an intensive exterior product. Usually they are made of heavy duty materials like thermoplastic rubber, shrink-wrapped thermoplastic or vinyl. Cable harness assembly is designed to transmit electrical power or signals.

     

    Jayshree Instruments offers a full range of cable and wire-loom assembly services. We build custom cable harness solutions to customer specifications servicing a wide range of industries including Defense, Automotive, Medical, Mining, Telecommunications and General Electronics etc. Using the latest manufacturing equipment we provide ‘End to End’ solutions including integration of Wiring, PCB Assemblies, Box Build and Testing. We can supply in either Low or High volume with quick turnaround if required.

    Whether designed with specific customer requirements or for a special application, our custom cable assemblies can meet the challenge of required specifications.

     

    Jayshree Instruments has the design capability and practical experience to build cable assembly that require any number of connectors, styles of termination or types of cable. As one of the best wire harness manufacturing company in Gujarat, Jayshree Instruments helps manufacture custom wire harness. Our team is very qualified and experienced to satisfy all kinds of custom cable assembly and wire harness requirement.

    Cable Assembly Services

    Industries we serve

    CABLE ASSEMBLIES FOR MEDICAL INDUSTRY

    With years of experience, Jayshree Instruments makes custom cable assemblies for numerous medical devices and equipment’s. We offer all that you need, be it safety jacks, bio-sensitive connectors, cable connectors for medical applications and more. Our team has the experience and have the tools and a dedicated process to create the cable assemblies you require.

    CABLE ASSEMBLIES OF TELECOM

    Demand of wireless technology is consistently increasing and the telecom industry is quite wired. But Jayshree instruments provides all the capabilities to create the cable assemblies and connectors you require. Our design team will makes sure you get the cable assembly; be it cable for 10 conductors, a coaxial cable, over molds for USB’s and more.

    CABLE ASSEMBLIES FOR MILITARY APPLICATIONS

    Cable assemblies used in Military applications are generally used in harsh situations. Jayshree Instruments is experience in creating cable assemblies for military applications since a very long time and can help you create strain relief cables and over mold connectors to survive in tough conditions. We can help you make custom cable assemblies to satisfy your complicated requirements as well.

    CABLE ASSEMBLIES FOR INDUSTRIAL CONTROLS

    For all your industrial control needs, Jayshree Instruments will help you create cable assemblies with strain relief cables, cable stops and over molded connectors to confirm hermetic sealing.

    CUSTOM CABLE ASSEMBLY FEATURES

    Jayshree Instruments offer custom cable assembly design expertise. We have manufactured cable assemblies to fit a vast filed of flexural requirements. Our experience and abilities help us efficiently create custom cable assembly for variety of industries.

    CONDUCTOR SIZES

    We can eject conductors is different gauge sizes and also can combine different sized gauge to create a mixed gauge cable. The sizes are available ranging between 34 awg to 12 awg.

    CONDUCTOR COLORS

    Jayshree Instruments is a well-known cable assembly manufacturer and we can make cable with numerous conductors. Especially to keep a track of conductors we can make use to different colors, different stripes, text, dashes and more to make sure the right conductor is used for the right spot.

    STRANDING SIZES

    Conductors can be made with stranding which is as small as 0.0002 inches, which is great for hi-flex and supple cables. Stranding can be of different materials like care copper, tinned stranding, tinned conductor and more. They can also be make of metals like silver to get better conductivity

    CONDUCTOR INSULATION

    Conductor insulation is the first protection layer in any cable for which we use wide range of insulations from basic PVC, PE or PP. The stiffness and softness of each material may differ

    FILLERS

    To make a cable give the best results, it is important to include fillers in the electric cable. Materials like basic cotton, nylon and Kevlar are used usually. All materials are custom matched as per the requirement of the application to give the best outcome.

    WRAPS AND SHIELDS

    A cable’s conductor needs to be wrapped or shielded generally. High flex cables require a soft barrier between the conductors and outer jacket to avoid abrasion. Numerous electric cables require shielding to secure it from RFI or EMI interference. Materials like fleece, cotton and aluminized Mylar are used to help the cable match the operating environment. It is usually wrapped with spiral overwrap.

    JACKET MATERIALS

    The final barrier between the environment and the inside of the electric cable is usually its jacket. The final covering is used like an insulator, a shield and protective cover. To create a cable we can utilize materials live PVC or natural rubber, Teflon or Silicone.

    PROCESS OF CABLE ASSEMBLY

    The cable assembly process is tricky, time consuming and task oriented. Below is the process of cable harness assembly:

    Cable harness conducts power and transmits information in a uniform way. Engineers and designers must explain and overcome electrical issues regularly, especially during the electronic product research and development stage to bring a product to the market successfully.

     

    One of the most important part of this includes a challenge which has a custom design for each products electronic part and step by step cable harness manufacturing procedure to finish the assembly. In this step, designers select harness components and decide on other use specifications.

    Prototyping allow an engineer or designer to see the final product in real. This is to test the harness in the actual application before implementing the first production run, assuring the best performance.

    In wire harness manufacturing, design specification must be accomplished along with high quality standards. Cable harness manufacturing process still does rely on manual assembly even after the global expansion of automated manufacturing. Hand manufacturing of harness and cable assemblies is necessary because of the minute and time consuming steps which help to complete the process. Though needful automation can be incorporated in the process.

     

    One more reason behind the manual production of wire harness and cable assemblies is that it needs to be customized for each application. It has particular components designed for specific larger parts. This step includes of wire cutting, stripping and connecting and then ends at assembly.

     

    Wire cutting is to be done in the right length which can be executed by a wire-cutting machine. The next step needs the wire ends to be stripped for the cores to be exposed. This step is initiated to attach terminals or connector housings or modules. And then lastly the wire are gathered in a harness using an assembly board to fulfil the design specifications.

    After the process of production, each wire harness compulsorily have to undergo electrical safety testing for any kind of specifications it be face in real. This is an important step to ensure the final product performance to be 100% secure.

    For more information about the cable assembly, we offer at Jayshree Instruments, call us today at +91 79 2657 8740 / +91 84609 59733 or fill out our quote form.

    WHAT IS A WIRE HARNESS?

    A wire harness is a set of wires or cables which uses low cost elements to keep the components together in an organized and efficient manner. A wire harness usually uses a sheath material similar to thermoplastic which protects the internal wires and cables. But in most of the cases these components already have their individual protective sheathing, reducing the requirement of additional protective measures.

     

    Wiring harness resolves 2 main issues within an electrical system which are geometric limitations and electrical requirements. Wire harness are used in numerous applications for airplane engines as well as commercial and residential electrical wiring

    Different TYPES OF WIRE HARNESS TERMINALS

    Wire Terminals are available in variety of shapes and sizes. This depends on the size of wire and screw. Here several types of terminals used for Wire Harness Manufacturing.

    RING TERMINALS

    A ring terminal has a round-end helping a screw or stud to be attached. They are also commonly known as ring connectors which are available in various sizes. It is necessary that the ring terminal is compatible with the wire gauge and the size of stud. They are usually soldered or crimped to the wire and are available in insulated or non-insulated.

    SPADE TERMINALS

    Due to the shape of the terminal, Spade terminals are also commonly known as spade connectors or fork terminals. It is available in various sizes depending on the gauge of the wire and size of the stud. For efficient attachment and screw removal, the open-ended spade terminal is very useful and more importantly for wire harness projects where the space is a concern for installation. Spade terminals are available in insulated as well as non-insulated.

    HOOK TERMINALS

    Hook terminals are similar to spade terminals which are convenient to use with an open end. They are available in insulated as well as non-insulated. They provide a simple yet durable connection for different kind of projects.

    QUICK-DISCONNECT TERMINALS

    A quick-disconnect terminal offers an easy connect and disconnect with two wires along with convenient and reliable usage. They are usually used in consumer products, auto products and other industrial products. The products using quick-disconnect can be insulated and as well non-insulated. This terminal assures stable and durable connection.

    BULLET TERMINALS

    Bullet terminals assure and easy, secure and reliable connection. It is easy to disconnect as well. They also connect to the open-ended female connectors as well as male connectors providing a high-quality connection. Which is why connection with bullet terminals helps avoiding corrosion and other harmful materials to get in the wire harness.

    BUTT TERMINALS

    A Butt Terminals terminates or connects single or multiple wires. They help avoid abrasion and cutting. They offer extra protection to keep the moisture, corrosion and other negative elements away. You just need to install each wire on the open end of the connector, and then crimp the terminal from both the ends to secure the connection.

    FERRULE TERMINALS

    Ferrule terminals are utilized in numerous applications for fastening, sealing, joining or reinforcing wires to each other.

    FLAGGED TERMINALS

    Flagged terminals is also known as Flag connectors assuring secure and convenient connection. They work well in tight spaces and also when a quick-disconnect is too large. Flagged terminals assure easy connection and disconnection

     

    Wires are available in different types as well like stranded, flexible ground braid, ribbon cable – Gray, THHN – solid, THHN – stranded. These wires are used as per certain specifications

    Testing of Harness

    cable harness

    Looking for Wire Harness Testing Equipment manufacturers? Jayshree Instruments is the one stop solution for everything related to electronic manufacturing services. We have been manufacturing variety of Wire Harness Testing Equipment’s from latest technology as we believe in quality manufacturing for our clients.

     

    One of our main methods for Harness testing is Automatic Test Equipment. An ATE is a simple digital multimeter controlled by computer containing dozens of complicated test instruments which is capable of automatically testing and finding faults in sophisticated electronic packaged parts or on wafer testing which includes system on chips and integrated circuits.

    DIFFERENCE BETWEEN CABLE ASSEMBLY AND WIRE HARNESS ASSEMBLY

    DIFFERENCE BETWEEN A WIRE AND A CABLE

    A wire is a materialistic strand that conducts electricity. For example, aluminum and copper. And a cable has a group of wires that run together. They are usually bonded or braided together which is why they appear like bunches or intertwined wires.

    WHAT IS A WIRE HARNESS?

    A wire harness is a set of wires or cables which uses low cost elements to keep the components together in an organized and efficient manner. A wire harness usually uses a sheath material similar to thermoplastic which protects the internal wires and cables. But in most of the cases these components already have their individual protective sheathing, reducing the requirement of additional protective measures.

     

    Wiring harness resolves 2 main issues within an electrical system which are geometric limitations and electrical requirements. Wire harness are used in numerous applications for airplane engines as well as commercial and residential electrical wiring.

    WHAT IS A CABLE ASSEMBLY?

    Cable assembly are a group of cables or wires which are covered by an intensive exterior product. They are usually made of heavy materials. Their functionality is similar to wire harnesses, including keeping cables and wires in place. But they are designed for entirely different environments. They specially designed for certain environmental factors which include the size of the area where it’s being used and also the environmental situations it might have to encounter. And so cable assemblies are available in numerous sizes and shapes and are made to shield the internal wires and cables from friction, moisture, heat, compression, abrasion, and other problems.

     

    So the difference between wire harnesses and cable assemblies is that they are used in different environments. Wire harness provide a cost-efficient solution for keeping the wires organized whereas the cable assemblies keep all the products secure in the extreme environments as well.

    FAQ'S

    Cable harness conducts power and transmits information in a uniform way. Engineers and designers must explain and overcome electrical issues regularly, especially during the electronic product research and development stage to bring a product to the market successfully.

     

    One of the most important part of this includes a challenge which has a custom design for each products electronic part and step by step cable harness manufacturing procedure to finish the assembly. In this step, designers select harness components and decide on other use specifications.

    Cable Assemblies are used with almost every other electrical system. Jayshree Instruments focuses on manufacturing high-quality cable assembly components in different industries like medical, telecommunications, industrial, military and others. The design capabilities are different depending in the kind of industry.

     

    We can help you the design the perfect set-up for any application as per your requirement. Our experienced and skilled engineers make sure to satisfy the all complicated requirements of the clients with products which can be utilized for long term. Jayshree Instruments also serve customized design.

    Cable assemblies consist of filters which can be easily overlooked for their simplicity. But actually filters provide numerous important support functions to the cable assembly.

     

    Generally custom cable assembly need using wires with variety of diameters. Filters play a major role, by helping them maintain the round shape of the cable. It helps to keep uniform appearance and offers support as well.

    Jayshree Instruments offers quality in house prototype PCB assembly services, so that your product can be tested before you commit to manufacturing it. Our core expertise is to provide advanced and reliable electronic manufacturing services.

     

    We understand the value of prototyping services. As an electronic contract manufacturing company, we know the challenges met at the prototyping step. Our mission is to bring you a full electronic manufacturing solution and make your product ready for the market.

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