SYSTEM SOLUTIONS

Cable confection and cable assemblies

Assembled cables have a wide range of applications, both in the private and professional sectors. Assembled cables must meet special requirements, particularly in industrial processes. For this reason, customer-specific assembled cables with a high degree of variability are primarily used. The areas of application range from automation technology and mechanical engineering to medical technology.
Thanks to our many years of experience in the field of cable assembly, we are also equipped to meet the special requirements of various industries and assemble individual cables on request. We offer a wide range of products – from large series (e.g., servo cables) to small series and customer-specific cable assemblies.

The production of assembled cables often varies, as cables and cable assemblies must meet individual requirements and functions depending on the type of application. Initially, certain geometric and electronic specifications are followed. The cross-section of the assembled cable is determined and the cables for which the cable will be used are specified. It is important to calculate the maximum bending radius in order to prevent cable breaks and ensure high quality. Production must therefore be very precise but also simple so that the cable can be replaced as quickly as possible in the event of damage.

When assembling cables, it is important to comply with the prescribed DIN standard in the manufacturing process. Among other things, the environmental conditions, shielding, material, configuration of the conductors and cables, and the shape of the connector must be taken into account. All of this has a major influence on cable assembly. Ultimately, it is the functionality of the product that counts, which is why it must be thoroughly tested before sale.

Cable assembly at LQ involves four important steps: printing the order, cutting to length, stripping, and assembly. In the first step after printing, the required cables are cut to the desired length. Each cable has a so-called sheath, which is removed with special pliers. This process is called “stripping.” Stripping is followed by assembly. This involves stripping the individual strands, crimping, and assembling the connectors. Stripping involves removing the insulation from the individual strands without cutting or damaging them. This is followed by crimping the ferrules. Crimping comes from the English word “to crimp,” which means “to press” or “to squeeze.” Here, the metal sleeves are pressed individually onto the strands. These sleeves create a connection between the cable and the connectors. Finally, the connectors are assembled and subjected to an electrical test. 
In addition to manual assembly, some cables are manufactured and overmolded by machine. For this purpose, the cables are fitted with different plugs and contacts, which are manufactured in a molding machine. There are various mold inserts that can be used and replaced repeatedly, depending on the type of plug.

We use various connectors in our cable assemblies. Different plugs and connectors are used depending on the area of application and specific requirements. When you place an order for a cable assembly with LQ, we will advise you individually in advance on the options available and find the optimal solution for your requirements.

The following connectors are used in assembly at LQ, among others:

• Round connectors
• Rectangular connectors
• SUB-D connectors
• Data connectors 
• PCB connectors
• Coaxial connectors
• AV connectors
• Power connectors
• Signal connectors
• Data connectors

Depending on the application, cables with end fittings on one or both ends may also be necessary. End fittings can be:

• Wire end ferrules
• Ring/pin/fork cable lugs
• Crimp contacts
• Flat plug sleeves

Furthermore, one or both cable ends could also be prepared:

• Cut smoothly
• Stripped to the desired length with or without shrink wrapping
• The wires partially stripped
• Individual or multiple wires insulated
• Shield exposure at the cable end or also cut to size in the middle of the cable