Cable assembly

Cable assembly
Cable assembly

Cable production | Rapid and reliable

Since 1975, CiS has manufactured customer-specific cable configurations, modules and systems technology with the highest quality. Experienced, competent and motivated employees together with state-of-the-art machinery ensure optimum commercial and technological solutions. Small, medium and large-scale series are produced with the highest quality and supported by effective supply chain management. Our production sites are located worldwide in the Czech Republic, Romania and in Asia. This guarantees the economical production of the cable assemblies.

An assembled cable, cable set or cable assembly consists of either a simple A-B connection or a complex wiring harness. In turn, the wiring harness consists of multiple wires and strands, resulting in over one thousand contact points. A cable set is a key component for electrical data transmission in almost all technical devices and systems.

Every type of cable assembly has to function for years, sometimes under adverse conditions, in order to ensure that the customer’s electrical system functions reliably.

What is cable assembly?

Cable assembly is a process for producing ready-to-connect cables with connectors. This is also referred to as cable packaging. In addition to cables, cable bundles, cable sets and even complete cable harnesses can also be produced via the cable assembly process. A complete cable assembly also includes the assembly of plugs, connectors, ferrules and contacts.

Ready-to-connect cables are used in industries and industrial processes which electronically transmit particles. Special cables and connectors must be selected for the cable assembly to match their specific purpose.  Cable assemblies are available either as standardised or customised products. We can also meet the needs of customers rely on precisely fitting cable assemblies.

Cable assemblies differ in a number of ways. These include the physical properties of a transmission, the quality of the wires, the structure of the cable and the complexity of its use.

Overview of cable types

The following list summarises the common cables types:

  • Copper cable fittings
  • Fibre optic or glass fibre assemblies
  • Round cables
  • Motor encoder cables
  • Ribbon cables
  • Flat ribbon cable
  • Cable harnesses (wire harness)
  • High-frequency cables or coaxial cables (coax cable)
  • Twinax cable (high-speed data transmission)
  • Signal cables or power cables
  • Ribbon cables

CiS has the expertise to handle all of the assembly processes for copper cables that meet the usage specifications for electrical engineering worldwide. We also offer optical cable assemblies on request and as required.

Cable assembly processes

  • Crimping
  • Soldering
  • Insulation displacement connectors (IDC)

When manufacturing standardised solutions, the cables are primarily assembled by machines. These cables are manufactured in large quantities. The machine automatically assembles the individual elements, i.e. cable connectors, contacts and ferrules. In some cases, the production of cables and connectors for customised cable assemblies and special applications is sometimes too unique and complex. This requires a manufacturing process that combines both semi-automated and manual production.

Construction of a cable assembly

The assemblies have to ensure that the cables and connectors are suitable for their intended purpose and function reliably. As such, both the development and the design of a cable assembly are highly important. Generally, complex cable assemblies are first drafted on the drawing board before they are produced. In the process, the various features can be tailored to suit the specific solutions during the planning stage itself. The following list contains the most important parameters of a cable. These application-specific requirements have to be taken into account during planning:

  • Length and weight of the cable
  • Insulation
  • Cable fastening
  • Sensitivity to heat or cold
  • Protection against moisture or impacts
  • Degree of bending of the cable
  • Stresses

Expertise gained from years of work and experience

The following processes are part of our core competence:

  • Support with developing connection technologies
  • Fully automated machines for processing stranded wires, single wires (cutting, stripping, crimping, tinning, printing)
  • Stockomat machines for stranded wires using insulation displacement technology (IDC)
  • Semi-automatic and fully automatic taping machines
  • Twisting stranded wire
  • Labelling systems (inkjet printing, laser printing, Tampoflex and hot stamping), label printing and automatic wrapping machines
  • Crimpers (single contacts, strip goods) and stripper-crimper machines with crimp force monitoring
  • Automatic spraying systems for spraying and overmoulding connectors, plugs, connectors, contacts and electronic assemblies or printed circuit boards, for the injection moulding grommets and manufacturing components and housings
  • Fine soldering, soldering
  • Printed circuit board assembly (in cooperation)
  • Mechatronic integrated devices (MID)(in cooperation)
  • Sensor manufacturing (capacitive, inductive, thermal)
  • Subassembly production, assembly of control cabinets and systems
  • Test adapters and primarily computerised test systems