All You Should Know About Cables And Assemblies - Miracle Aerospace

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All You Should Know About Cables and Assemblies
- Miracle Aerospace
Cables are an integral part of all circuitry and
appliances that we use today. These cables can be
used individually in a small simple device, or
as a cable assembly comprising of multiple cables
grouped together to work in complex equipment. A
cable is a rod or coil of wires with many times
the diameter required for the finished product.
This rod or coil is drawn through a series of
dies that reduce the diameter by a set percentage
with each die, to bring to a size that is
required. However, with the diameter decreasing,
the length increases, thus keeping the volume of
the wire just the same.
Wires come in solid or stranded designs that are
generally circular in cross-section, with other
available options being square, rectangular, and
hexagonal. A solid wire is easy to manufacture,
but has a smaller cross-section and lesser
flexibility than a stranded wire. Stranded wires
are made up of multiple small wires bundled
together to form a large conductor. This gives
them greater surface area and makes them more
flexible, thus making them a better conductor as
compared to a solid wire. More the number of
wires, more flexible and break-resistant the
cable. The lowest number of wires used to produce
such cables is generally 7 with one in the
middle, and 6 surrounding that one.
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• There are many different types of strands that
  can be employed when manufacturing a stranded
  conductor. You can get all kinds of cables and
  cable assemblies at Miracle Aerospace, the
  leading cable assembly manufacturers in India,
  who is engaged in various Make In India projects
  like fighter jets, helicopters, cockpits, missile
  launchers, light transport vehicles, and more.
• Concentric strand This consists of a central
  wire surrounded by one or more layers of
  helically laid wires. Each layer has six more
  wires than the previous layer and each layer is
  applied in a direction opposite to the layer
  under it.
• Bunch strand This consists of a collection of
  strands twisted together in the same direction
  without regard to the geometric arrangement.
• Rope strand This consists of a collection of
  concentric stranded groups that are twisted
  together.
• Compact strand This consists of layers stranded
  in the same direction and rolled to a
  predetermined ideal shape. The final product is a
  conductor smaller in diameter, smoother on the
  surface, and containing no interstices or air
  spaces.
• When these cables are combined together, they
  form cable conductors that are supplied as both
  bare conductors with no coating, and with
  coatings. The most common materials used for
• coating include silver, tin, and nickel.
• Silver coating is used in high temperature
  environments and in high frequency applications.
• Tin coating is the most common coating used to
  improve corrosion resistance and solderability,
  and reduce friction between strands.
• Nickel coating is used in applications where
  temperature is over 200C however, along with
  higher electrical resistance, nickel exhibits
  poor solderability.
• However, different environments call for
  specialized compounds that can withstand high
  temperature applications, and allow high current
  carrying ability. In addition, conductors are
  also insulated with polymer or plastic to provide
  isolation from other conductors and the
  environment to prevent short circuits.