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In today’s era of highly integrated electronics, the PCB Cable Assembly acts as the “nervous system” connecting different components, highlighting its crucial importance. However, complex circuit designs, varied cable types, and strict performance standards often pose significant challenges for engineers and procurement specialists during the design and manufacturing of PCB Cable Assemblies. Are you facing similar difficulties? Don’t worry—we offer a comprehensive solution, covering everything from PCB cable design to assembly, to help you tackle connection challenges with ease.
Selecting the appropriate connectors and cable types is the first step in designing a PCB Cable Assembly. The choice of connectors (such as USB, HDMI, or RJ45) and cable specifications (including cross-sectional area, shielding, insulation materials, etc.) plays a critical role in ensuring stable and reliable signal transmission.
For instance, 3M’s 7700 series controlled impedance cables are capable of supporting data transfer rates up to 20 Gbps, making them ideal for high-speed applications. Meanwhile, miniature coaxial cables are engineered for high-frequency signals, delivering minimal signal loss and superior integrity, which makes them perfect for high-frequency, multi-channel setups. In high-current scenarios, using cables with a larger cross-sectional area helps reduce resistance and lower heat generation.
The way of wiring plays a key role in improving anti-interference capability. When arranging cables, try to avoid crossing with high-current or high-voltage cables and stay away from the influence of strong electromagnetic fields. Arranging cables in areas with less electromagnetic interference helps to guarantee the stability of signal transmission. In addition, the routing and fixing of the cables need to be carefully planned to ensure that no loosening or damage occurs during the operation of the equipment.
When designing a customized PCB Cable Assembly, you first need to define the application scenario and specific requirements. For example, what kind of environment will the device operate in? Does it need to be resistant to vibration, high temperature, humidity or chemical corrosion? Is there a need for high-frequency signaling, high-speed data transmission or low-power design? Also identify the space constraints, weight requirements or cable length limitations of the equipment.
Selecting the right material and technology for the application is key to designing a customized PCB Cable Assembly. For example:
Before starting the assembly, we will make sure that all tools are complete and checked to avoid any delay in the work due to tool problems. Required tools include scale, allen wrench, tap, board file, hand saw, razor blade, electrician’s knife, special metal scissors, hammer, emery cloth, sharp-nosed pliers, water-jawed pliers, spinning pliers, screwdriver, copper brush, and special assembly tools.
1.Disassembly of connectors: Disassemble the connectors in order to ensure that the parts are disassembled in a standardized manner.
2.Cable end fixing: Fix the cable end on the axle plate, extend 200-300mm, adjust the angle to 30-45° to avoid bending.
3.Stripping the cable sheath: use a hand saw or electrician’s knife to strip the sheath by about 45 mm, make sure the edges are flat and avoid damaging the internal components.
4.Sealant application and connector assembly: Apply sealant evenly at the point of contact between the sheath and the outer conductor.
5.Install the rear end caps, gaskets, and seals in sequence and rotate the connector sleeve to ensure a tight connection.
6.Cleaning cable heads: Remove sheath powder and copper shavings with a copper brush to keep ends neat.
7.Dispose of copper tube outer conductor:Cut off the excess wrinkled copper pipe outer conductor (about 2 mm from the end face of the connection sleeve). Extend the outer conductor with sharp-nosed pliers and tap until flat and rounded. Remove burrs and sharp corners: Clean cable end burrs and sharp corners with nozzle pliers, file and emery cloth.
8.Inner conductor processing and tapping:
9.Connect inner conductor assembly:
10.Component assembly and fastening: Connect the inner conductor fixing parts, inner conductor assembly, and housing in turn, and fasten them with a screwdriver.
11.Installation of seals and back cover: Install seals, gaskets and back cover, tighten with a wrench to ensure sealing.
12.Snap plug installation: Insert the snap plug into the inner conductor assembly to ensure firmness.
13.Inflatable Handling & Testing:Inflate dry through the inflation nozzle and maintain air pressure at 0.05-0.2 MPa.Check air pressure after 24 hours to ensure sealing and pressure resistance (air pressure maintained at 90% or more).
Choosing an experienced manufacturer is key to ensuring product quality. Here are some suggestions for choosing a manufacturer:
PCB Cable Assemblies are manufactured to meet industry standards and certification requirements. By talking to the manufacturer, you can find out if they have the relevant certifications.
Reducing costs without compromising product quality or delivery schedules is a top priority for both procurement teams and engineers. Here’s how you can achieve this:
1.Streamline Your Supply Chain Management
A well-run supply chain is essential for cost control. Building long-term relationships with trusted suppliers ensures a steady supply of materials at competitive prices.
2.Choose Materials Wisely
When it comes to cable selection, we don’t necessarily need to go with the high end. fastlink can provide many types of cables for your board project, including AV cables, flat ribbon cables, molded case cables, and EMI or RF cables. By gaining an in-depth understanding of your project needs, we can recommend the most appropriate cable type and assembly process to ensure both product performance and cost control.
3.Optimizing Production Process
We continuously optimize our processes to ensure effective cost control while ensuring high quality and stable delivery. Take the crimp terminals commonly used in electrical connectors as an example, we utilize advanced automatic crimping machines to complete the process of metal sheet bending and precise clamping of bare wires, and operate in strict accordance with the IPC-620 standard to ensure the reliability of each metal contact point.
While in some applications requiring higher connection stability (such as medical, military and aerospace), we use terminals equipped with solder cups to firmly connect the stripped and tinned wires to the terminals by hand soldering by skilled technicians. In addition, we have automated production lines to ensure that each customized cable assembly meets predetermined AQL standards through a rigorous final inspection process that includes continuity checks, AOI, voltage testing, and critical dimensional measurements.
4.Mass ProductionReduces Costs
Through mass production, the cost per unit of product can be significantly reduced. Manufacturers often offer discounts based on the order quantity, and customers can reduce purchasing costs by increasing the order quantity. However, Fastlink does not have a minimum order quantity restriction, and even a sample can be produced to meet your flexible needs.
1.Clean the connector: Use a professional connector cleaning tool to clean the connector interface to avoid dust and dirt accumulation.
2.Inspect the cables: Check the cables regularly for cracks, fraying or other damages and replace the damaged parts in time.
3.Update firmware: If the PCB Cable Assembly contains programmable components, make sure its firmware is always updated to the latest version to optimize performance and compatibility.
Faulty, open or shorted cables can not only lead to degraded equipment performance, but can also pose a serious safety hazard. Here are some professional solutions to help you minimize the possibility of PCB cable assembly failure during the design and manufacturing process.
The prototyping and testing phase is one of the most effective ways to anticipate potential problems in the design and manufacturing of PCB cable assemblies. By building samples and conducting rigorous testing at an early stage, you can help identify weak points in a cable assembly and confirm that it meets all performance requirements.
Cables may be subjected to mechanical stresses such as pulling, bending or compression during manufacture and use. These operations may cause damage to the cable, which can lead to malfunctions or safety hazards. When cables are exposed to high mechanical stress, they can be wrapped in protective sleeves or sheaths. These kits are effective in minimizing mechanical damage to cables.
The material selection of the cable directly determines its performance and reliability. In different application scenarios, the performance needs of the material will vary. If the cable has to withstand high voltages (e.g. above 600V), it is recommended to choose materials with a high withstand voltage test capability, such as polyethylene (PVC) or polymer materials. These materials have better insulating properties at high voltages. At high or low temperatures, cables may fail due to reduced material properties. For example, in high temperature environments above 150°C, PTFE or silicone materials are preferred over PVC because of their higher temperature resistance.
IPC-620 is an important international standard for the circuit manufacturing industry that provides detailed guidelines for the design and manufacture of cables and connectors. Adherence to this standard can help us avoid problems with cable failures caused by improper assembly methods or processes.
Fastlink specializes in the design and assembly of PCB Cables, backed by 15 years of industry expertise and a team of skilled professionals. We offer the following services:
Our team of experts provides full-circle support, from initial design to final production. This includes material selection, where we recommend the right connectors (like USB, HDMI, or RJ45) and cable specs (such as cross-sectional area, shielding, and insulation materials) to ensure reliable signal transmission. We also offer custom design services to craft PCB Cable Assemblies that perfectly fit your application needs.
With extensive assembly experience and a rigorous quality control system, we ensure every product meets the highest standards. Using advanced welding and testing equipment, we guarantee precise assembly for every PCB Cable. Plus, we offer flexible delivery options and comprehensive after-sales support, whether you need small batches or large-scale production.
Leveraging strong supply chain management and cost control, we deliver highly competitive prices. By optimizing production processes and material selection, we reduce costs without compromising quality. At Fastlink, our mission is to help you save costs while maintaining high standards in your product.
Our PCB Cable Assembly solutions are extensively utilized across various industries, including:
By partnering with Fastlink, you’ll benefit from:
Reach out to us today for a free consultation and a personalized quote!