Cable assembly

Cable assembly

Cable production | Rapid and reliable

Since 1975, CiS has manufactured customer-specific cable assemblys, modules and electromechanical components with 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 Germany, Czech Republic, Romania and Asia. This guarantees the economical production of the cable assemblies. CiS is your competent partner for cable assemblies and is at your disposal with individual solutions exactly adapted to your requirements. Get in touch with us now.

Cable assembly: robust and flexible solutions

An assembled cable, cable set or cable assembly consists of either a simple A-B connection or a complex wire harness. A wire harness is made up of several strands and/or conductors. Large wire harnesses can have several hundreds, sometimes even thousands, of contact points. As a rule, a cable assembly is an elementary component of electrical power and data transmission in many technical devices and systems. Every cable system must function for years, sometimes under adverse conditions, so that the customer’s electrical system works reliably. The cable assembly from CiS fulfills the highest quality standards and will provide you with long-lasting loyal service.

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. Please do not hesitate to contact our consultants in this regard! Cable assemblies differ in a number of ways. Fast data transmissions are susceptible to interference, which is why the cables and connectors used are shielded against interference. In power transmission, the focus is on safety, electromagnetic compatibility and the reduction of losses. The different requirements each have an influence on the selection of stranded wires, cables and connectors.

What are the advantages of custom cables?

Custom cables offer a number of benefits, including:
  • Accuracy of fit: custom cables are designed to meet the exact requirements of a specific application, which means they fit perfectly and perform better than standard cables.
  • Reliability: Custom cables are designed to meet specific requirements, which means they perform better and are more reliable than standard cables.
  • Flexibility: Custom cables meet the requirements of a specific application. This means they can be used in a variety of environments.

Overview of cable types

The following list summarises the common cables types: 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)
  • Overmoulding
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:
  • Voltages / currents of the application, as well as the electromagnetic compatibility.
  • Interference, fastening, insulation of the cable, as well as length and weight
  • protection against humidity, shocks and temperatures (heat and/or cold)
  • mechanical stress and bending radius of the cables

Why is cable assembly construction important?

Cable assembly is important because it provides the ability to create custom cables that meet the requirements of a specific application. These custom cables are more powerful and reliable than standard cables because they are made specifically for a particular application. This ensures safe, reliable and effective transmission of data and power between different components. Here are some reasons why cable assembly design is important:
  1. avoidance of power failures A badly constructed cable harness can lead to power failures, which can cause significant damage to electronic equipment. A well-constructed cable harness minimizes the risk of power failures and thus increases the reliability of the equipment.
  2. Better data transmission A well-constructed cable assembly ensures better transmission of data between different components. This is especially important for devices that require fast and reliable data transmission.
  3. Efficiency A well-constructed cable assembly can help improve the efficiency of electronic devices by optimizing the transmission of power and data. This can lead to longer device life and help reduce operating costs.
  4. Safety A well constructed cable assembly also ensures the safety of electronic equipment. Faulty cable assembly can lead to short circuits, overheating and even fires, which can be a significant hazard. A well-constructed cable assembly minimizes the risk of safety problems.

What should be considered in the construction of a cable assembly?

When constructing a cable assembly, several factors must be considered to ensure that it is safe, reliable, and effective. Below are some important factors that should be considered when designing a cable assembly:
  1. Materials The choice of materials for cable assembly is of great importance. Materials should be used that meet the requirements of the particular application and have a long service life. The materials should also be resistant to chemicals and moisture to ensure high reliability and durability.
  2. Wiring and connection Wiring and connection of cables should be done carefully to ensure optimum transmission of power and data. Proper connection and shielding also minimizes noise and interference.
  3. Strain relief The cable assembly should have adequate strain relief to ensure that the cables are not damaged and that the connection remains secure. The strain relief should also have sufficient stability and flexibility to withstand possible loads.
  4. Coding Cable assemblies should be coded to allow easy identification and connection of components. Proper coding can also facilitate troubleshooting and minimize the risk of connection errors.
  5. Testing and quality control A cable assembly should also be subjected to careful testing and quality control to ensure that it meets requirements. Testing and quality control also ensure that cable assembly is safe, reliable and effective.
The CiS development-team will be happy to support you as early as the design stage of a cable assembly, the selection of the right materials and the optimization of your design with regard to an economically and technically sensible solution.

Get cables assembled: customized solutions for different areas

Quality cable assembly is essential in numerous industries and sectors to ensure smooth operation and optimal performance. In the automotive industry, for example, it is crucial for the reliability of vehicles, as it enables a secure and efficient connection between the various electronic components. In the field of telecommunications and information technology, precisely assembled cables are of great importance to ensure fast and reliable data transmission. Likewise, cable assembly plays an important role in the medical technology industry, where it supports life-saving devices and systems. The power, automation, aerospace and industrial electronics industries also rely on reliable cable systems to ensure the functionality and safety of their applications. You see: In a wide variety of industrial sectors, quality cable assembly offers the assurance that connection technology meets the highest standards and meets the increasing demands of our modern world.

Why should you purchase cable assemblies from CiS? -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

Choosing the right cable assembler

Choosing the right cable assembly service provider is critical to ensuring that you receive high-quality, reliable custom cables. Here are some factors you should consider when choosing a cable assembly service provider:
  1. experience: Experience in custom cable design and manufacturing is especially important to customize cable assembly to meet the needs of your specific industry. With over 45 years of experience and know-how, we can implement any kind of customized requirements in your industry. We can bring the experience of diverse industries to your product and optimize it with total cost in mind.
  2. quality: Verify that the service provider uses high quality components and carefully performs the cable assembly process to ensure that the cable will function smoothly. CiS stands for the highest quality without exception. Our cable assemblies go into life support.
  3. Customer support: For customer-specific solutions, good customer support is crucial in order to find a targeted solution and respond quickly to your requirements.
As one of the most experienced cable assemblers on the market, CiS has also perfected these factors over the years. Quality, reliability and customer service go hand in hand for us and have the highest priority. We offer an uncomplicated and smooth process so that you can focus entirely on your core processes. CiS solves tasks. Are you looking for a competent and experienced partner in cable assembly? Then please contact our technical advisors. We are also there for you when it comes to other products – such as electromechanical components and input systems. We look forward to your enquiry!