Reverse Engineering: Why you need it and when.

Do you need a wire or cable and have no idea what it is? You are not alone, it happens more times than not especially for equipment repairs, obsolete parts and failure analysis. When do you need to have a cable reversed engineered? You may like a particular cable’s performance or you have a piece of cable that you or your customer may want more of but don’t know what it is or who manufactured it. Then reverse engineering is the answer. Who performs this service? Most custom wire and cable manufacturers can assist you.

Reverse engineering wire or cable is commonly performed to determine:

• Conductor stranding and material.
• Cable construction
• Insulation and jacket materials

Custom wire and cable manufacturers routinely reverse engineer wire and cable to identify the materials used and the cable construction. It is best to provide a sample between 1 to 2 feet if possible and keep in mind it will be dissected in the process.

Outer jacket
Reverse engineering wire and cable begins with measuring the outside diameter (OD) of the wire or cable. The longer the piece the better it is to obtain the nominal OD. The outer jacket is carefully removed to expose the core. Normally, cross sections are taken of the outer jacket to measure wall thickness. Jacket material is tested to identify the type of material used.

Braid, shield or tape
If there is a braid or shield the construction will be examined. The pitch, number of ends, material and coverage can be determined at this point. If there is a tape wrap present, the overlap,  type of material and size will be examined.

Core construction
The next step is to examine the cabling construction. Once the shield and/or tape is removed the following can be determined: Cable lay or twists per inch, filler material used, the use of strength members, number of conductors and conductor color code.

Conductors
The conductor material, plating used (if any), gauge and conductor strand count and construction are checked. A cross section of the conductor will identify the wall thickness of the insulation and OD. At this point the insulation material will be identified.

Insulation and jacket materials
There are several ways to identify the materials used for insulation and jackets.  The obvious is the look and feel of the insulation or cable jacket. Computer analysis and burn testing are also used. Plastics and rubber each have distinct characteristics when placed on a flame. Experienced engineers can determine the type of insulation material by whether it burns, melts, or self extinguishes. The odors produced when burned also are distinct to each type of material. Burn testing should only be done by experienced individuals in a controlled environment, gases can be toxic as well as the risk of fire is present.

Failure analysis
Failure analysis is another reason for reverse engineering wire and cable. When a cable fails, determining the cause can many times be done  with reverse engineering to pinpoint the problem. Common problems with handheld devices with poor strain relief is damage to conductors or conductor stranding due to excessive bending. Shielding material can over time damage conductor insulation. Dissecting the cable at the problem area can expose the problem. Custom wire and cable manufacturers can make material suggestions such as the use of higher conductor stranding or alloys, insulation materials or cable construction design alterations based on the findings of reverse engineering.

Medical cables do differ from cables used in other industries

While concerning about medical grade wire, the standard thing is the top most priority. These wires that are created are useful for saving lives and the result that meets the very best standards of quality. No matter whatever the wire is, medical cable and wire needs to be the best how much it can. There’s sure a basic thing that goes with each kind of wire, matching up these basics to your requirements will surely make sure that you make the right choice. Right from the shape to material, there are several to look for.

For starters, it’ll be able to match up the form which you need to the wire available at the time. Whereas coming back to the most commercial or residential wire it is the essential round shape, while the medical grade custom is different. In several cases, round wires as well as flat wire are very common, but you may also require a standard wire that has an open center or with stronger form that is designed for various types of application and machines utilized in today’s date medical industry. Once you wish for a specified wire shaped, you may go for medical shaped wire to get the type of wire that you need for your equipment.

The material that a wire is made up of will typically have a big impact on the amount of things like resistance, conductivity, etc. Whereas talking about copper alloys, stainless steel or any other advanced coating like anodized wire or electroplated wire, there are plenty of options available in the market to choose from There are wires which are made from gold, silver and platinum. No matter what the material type is, you will be ready to find out the one which matches your wants.

Coating or insulation is also an important issue to consider protecting the parts of the machine and ensure that their performance is at highest level. If you’re able to match up with all the basic elements that helps to make a good medical grade wire, like the materials used, shape, coating, insulation as well as overall quality that you need, you may also be able to find the best wire for your medical equipment or for any other use. The quality of the cable very matters a lot to you and to the people who very rely on it. That’s the reason for which you choose the best cable as well as wire for all your wants. For further information visit http://www.calmont.com/medical-wire-cable.php

Standard medical cables and wires for medical equipments

While concerning about medical grade wire, the standard thing is the top most priority. These wires that are created are useful for saving lives and the result that meets the very best standards of quality. No matter whatever the wire is, medical cable and wire needs to be the best how much it can. There’s sure a basic thing that goes with each kind of wire, matching up these basics to your requirements will surely make sure that you make the right choice. Right from the shape to material, there are several to look for.

For starters, it’ll be able to match up the form which you need to the wire available at the time. Whereas coming back to the most commercial or residential wire it is the essential round shape, while the medical grade custom is different. In several cases, round wires as well as flat wire are very common, but you may also require a standard wire that has an open center or with stronger form that is designed for various types of application and machines utilized in today’s date medical industry. Once you wish for a specified wire shaped, you may go for medical shaped wire to get the type of wire that you need for your equipment.

The material that a wire is made up of will typically have a big impact on the amount of things like resistance, conductivity, etc. Whereas talking about copper alloys, stainless steel or any other advanced coating like anodized wire or electroplated wire, there are plenty of options available in the market to choose from There are wires which are made from gold, silver and platinum. No matter what the material type is, you will be ready to find out the one which matches your wants.

Coating or insulation is also an important issue to consider protecting the parts of the machine and ensure that their performance is at highest level. If you’re able to match up with all the basic elements that helps to make a good medical grade wire, like the materials used, shape, coating, insulation as well as overall quality that you need, you may also be able to find the best wire for your medical equipment or for any other use. The quality of the cable very matters a lot to you and to the people who very rely on it. That’s the reason for which you choose the best cable as well as wire for all your wants. For further information visit http://www.calmont.com/medical-wire-cable.php

Ultraflexible wires for SuperFlex plastic materials

What exactly is colorful, totally malleable, dirt, trendy and cheap? It is of course, plastic. Plastic materials are easily available material that can be turned into anything you want. In general, plastic materials are known for more durable than any metal and can be infinitely difficult to carry around. Typically, Ultraflexible wires plastic materials are synthetic substances available in amorphous solid material form. Manufacturers of plastic industry sometimes add up other substances to improve overall quality and try to bring down the cost. Well, plastics are of two types: Thermoset and Thermoplastic. The initial one includes things like glasses, plates and circuit boards, which retains the shape unless they are burnt and destroyed. On the other hand, Thermoplastics, melt soon when exposed to heat. This may include things like piano keys, grocery bags and some of the motor parts.

Normally, plastics are not restricted to one category. Some of the common kinds of Ultraflexible wires of plastics include: Teflon, Acrylic, PVC and PFA.  Since ever plastic was invented, it is just giving a metal counterparts a tough competition. It can be said that some of the machined plastic materials are considered to be reliable than any metal item. Plastics can be molded into any desired size and shape as per the requirement. Plastic materials for machining, is however not a child play and more complicated than metal machining. You need to go for the exports for any machine plastics for a right and meaningful way. Many factors like shapes, qualities and close tolerances that are needed to be produced are considered. 

Machined Ultraflexible wires materials are used in variety of industries which includes medicine, aerospace, space, electronics and hydraulics. You need to note that machining is totally different from molding. It can be easy for machine tighter substances as well as machined plastics that don’t need a secondary operation. Along with these plastic materials, generally there is no quality variance on orders and molders usually have an attrition rate. Typically, based on design, quality, tolerance as well as material, plastic materials for machinery offers competitive pricing on the production that runs.

 Highly trained engineers are generally needed for Ultraflexible wire plastic materials to be machined. That’s why it is not just one to take up the task. Exports in this field are famous for cutting edge precision for plastic machining technology.  With the evolution of new equipment that they offer for machining generally possess CNC turning and CNC Swiss screw machining. When going for machining plastic materials for aerospace, medicine, and hydraulics you must trust only the best.visit http://www.calmont.com/flexible-wire-cable.php for more details

High Voltage Cables Going Flexible

Transmission of high-voltage power requires an HV or high voltage cable, which come in different varieties and lengths. Shorter cables are used for devices and equipment. Large plants, ships, and establishments have very long and extensive network of cables. High-voltage cables are ubiquitous. Manufacturers have developed these wires so that they become less bulky and more flexible. There is a growing need for the high-voltage flexible cable, which is easier to work with.

High-voltage wires now don’t have to come too stiff. For instance, silicone cables now come with high flexibility and excellent insulation, yet still capable of transmitting high-voltage power.

High-voltage wires are generally thick. Thick wires have low resistance and thus are able to pass electric current without accumulating significant heat. The insulation must be made of tough material to avoid fatal electrocution upon contact. Although these cables are imbedded inside insulation walls, there will be times when people will come in contact with them. Electrical technicians doing cable installations, inspections, and repairs will intentionally come in contact with these cables.

High-voltage wires are susceptible to the damaging effects of corona discharge. Thus, their insulation should be so designed as to be more resistant to corona discharge. Reducing such damage is possible through designing the cables appropriately. A known method involves covering the conductor in semi-conductive casing, a procedure that increases the conductor’s thickness and eliminates the gap between the insulation casing and the conductor.

High-voltage wires come in different designs to meet different applications. Many companies make customized cables that fit the unique needs of the client. Manufacturers usually provide high-voltage wires for other companies, such building companies, laboratories, and hospitals.

Customers need to discuss their specific with the manufacturer so that they get the right cable, because cables used for laboratories have different specifications from those used for movie sets and concerts. In latter cases, cables that are used need to be really flexible so they can be easily removed from a location and reinstalled in the next location. Hence, a super flex wire is the likely option.

Apart from being flexible, cables must be friction-resistant. The insulating casing will always come in contact with smooth or rough surfaces, which will gradually cause wear. People always drag, move, and step on wires. Wires with poor casing can easily get torn. Worn wires are a hazard. Makers of high voltage cable wires encase conductors in polyurethane material, which doesn’t easily get worn, thus giving the wires a higher degree of safety and longevity. Tough encasing is also necessary to resist high-voltage stress, which also cause gradual wear of the insulation.visit http://www.calmont.com/types-of-conductors.php for more details

High Voltage Cables Going Flexible

Transmission of high-voltage power requires an HV or high voltage cable, which come in different varieties and lengths. Shorter cables are used for devices and equipment. Large plants, ships, and establishments have very long and extensive network of cables. High-voltage cables are ubiquitous. Manufacturers have developed these wires so that they become less bulky and more flexible. There is a growing need for the high-voltage flexible cable, which is easier to work with.

High-voltage wires now don’t have to come too stiff. For instance, silicone cables now come with high flexibility and excellent insulation, yet still capable of transmitting high-voltage power.

High-voltage wires are generally thick. Thick wires have low resistance and thus are able to pass electric current without accumulating significant heat. The insulation must be made of tough material to avoid fatal electrocution upon contact. Although these cables are imbedded inside insulation walls, there will be times when people will come in contact with them. Electrical technicians doing cable installations, inspections, and repairs will intentionally come in contact with these cables.

High-voltage wires are susceptible to the damaging effects of corona discharge. Thus, their insulation should be so designed as to be more resistant to corona discharge. Reducing such damage is possible through designing the cables appropriately. A known method involves covering the conductor in semi-conductive casing, a procedure that increases the conductor’s thickness and eliminates the gap between the insulation casing and the conductor.

High-voltage wires come in different designs to meet different applications. Many companies make customized cables that fit the unique needs of the client. Manufacturers usually provide high-voltage wires for other companies, such building companies, laboratories, and hospitals.

Customers need to discuss their specific with the manufacturer so that they get the right cable, because cables used for laboratories have different specifications from those used for movie sets and concerts. In latter cases, cables that are used need to be really flexible so they can be easily removed from a location and reinstalled in the next location. Hence, a super flex wire is the likely option.

Apart from being flexible, cables must be friction-resistant. The insulating casing will always come in contact with smooth or rough surfaces, which will gradually cause wear. People always drag, move, and step on wires. Wires with poor casing can easily get torn. Worn wires are a hazard. Makers of high voltage cable wires encase conductors in polyurethane material, which doesn’t easily get worn, thus giving the wires a higher degree of safety and longevity. Tough encasing is also necessary to resist high-voltage stress, which also cause gradual wear of the insulation.

Applications for Flexible Wire and Cable

Flexible wire can be used for a wide variety of applications in a wide variety of industries. Medical device, aerospace and automation manufacturers often require flexible cables for several of their products. Sometimes a simple description such as, “the wire needs to be as limp as a wet noodle” is enough to understand your needs.  The choice of type of conductor and insulation can greatly influence the flexibility of the cable performance. Understanding what the flexibility requirements are will help to determine the materials and construction for the flexibility of the wire or cable.

When specifying a flexible cable you need tell your cable manufacturer what the intended use will be.  Being as specific as possible when it comes to the requirements of the application will help the engineers design the cable to meet these specifications.

• Do you need to route it through equipment or a tight space?
• Will it be subject to continuous flexing?
• Do you need the cable to flexible during use?

There are several characteristics of flexible wire that make it unique, such as:

• Conductor stranding
• Shield types
• Cable lay 
• Insulation materials. 

In conductor stranding, the more strands a conductor has the more flexible the cable will be.  “Off the shelf” wire and cable is stranded in 7 or 19 strand configurations, which is not flexible enough for most applications requiring flexible or high flex cycles. The general rule is the higher the strand count of the conductor, the more flexible the wire is. Stranded conductors are composed of un-insulated “strands” of wire twisted together. The advantages of stranded conductor over a single strand are increased flexibility and flex-fatigue life. When you see 22AWG (19/34) for example, what the description means is that there are 19 strands of 34 AWG making up the 22 AWG conductor. Other common options for a 22 AWG is a single strand (solid) up to 168/44 strands. The construction of the conductor also plays a role in the cable’s flexibility, for example a rope stranding is the most flexible.  For repetitive flexing applications, the use of high strand alloy material is recommended.
Choosing the right insulation can also add to the cable’s flexibility. Silicone is one the most flexible of the compounds used in wire and cable.  Silicone wire is used to meet a variety of demands such as extreme high and low temperature requirements, flame resistance, flexibility, strength and purity. The application of the cable and the environment that it will be exposed to also plays a role when choosing the right jacket material. Harsh environments, chemicals, and abrasion will narrow down your insulation and jacket options.  Discussing your flexible wire application with an experienced cable manufacturer can help you choose the right materials for the performance and longevity of your product.
To learn more about the applications of flexible wire and other custom cable solutions, please visit: http://www.calmont.com/robotics.php

Why Custom Wire And Cable Can Help You And Your Network

Thinking about your need for custom wire and cable? Each application of wire requires a unique design in order to maximize its efficiency.  Flexible wire has hundreds of important uses around the house and in business. Depending on what kind of wire you need, you could be looking at many different options.

However, if you don’t know anything about wire or cable in specific, it can be difficult to untangle all of these different options.  So, it is a good idea to take a good general look at wires and cables and how they differ, what they do, and how they do it. Here is a quick introduction to this often overlooked world.

Many people believe that “wires” and “cables” are interchangeable, but this is not actually the case. To make a long story short, cables consist of a bundle of wires, each one made to very particular specifications, and bundled together in a certain way. The thing that makes a cable a cable is the way the wires work together and how they are shielded from the outside world using the rubber outer housing. For this reason, just to give an example, an extension “cord” is not usually a cord at all, but a cable, while each individual wire is properly called a wire.

Everything that you do with computers communicating over a distance depends upon these cables. Although you could choose to use wireless services, these are notoriously unreliable when you need to achieve a very high level of trust. If you are in a building with thick walls and heavy construction, you definitely need to consider the trustworthiness of customized cabling rather than wireless. Customized cables can be made to very heavy duty specifications so that you are never in danger of having low performance because of factors like distance, interference, and the relative impedance of your walls and floors.

When it comes to cables, wires are the heart and soul. They must be made of the right kind of metal and they must be bound together in precisely the right way. The tiniest distances between the individual wires impact how well they work and for what purpose they are suitable. While copper wiring was the most common for decades, it is now possible to use several other materials that offer excellent quality of service, although typically at a premium price. A good understanding of your needs will help you to know what price point you should go to in order to get the service you need.visit www.calmont.com for more details

Customer Wires: The Solution to Your Cable Headaches

Are you having a hard time finding one cable that would be able to connect all your entertainment devices and get them to work? Are you looking for a wire that could solve all your electrical device headaches? The problem is not just finding one that is compatible with all the devices that need certain connections but also finding a wire or cable that has the correct length and the right jacks.

For problems such as those, one of the best solutions would be to use a custom cable assembly or a custom wire assembly. A cable assembly is an arrangement by which wires or cables are grouped using ordinary tape or a sleeve. Grouping wires together helps make it neat and more importantly, protects them from being damaged. An assembly can come in any length that is convenient for you and the best part is that it can be used for all sorts of appliances or electrical devices.

Cable assemblies are commonly used in the electrical wiring in vehicles. Offices that use many computers also need cable assemblies. There are different connectors that may be used. A Molex connector is one of the most commonly used cable assemblies for computers. D-Subminiature and SDL connectors are what are used for connecting computer parts to the CPU. USB connectors have been widely used nowadays for cellphone chargers or other appliances since most people work around the computer. There are also JST connectors, which come in various types and can accommodate many cables or wires with different jacks. There are so many kinds of cable assemblies to choose from and are convenient for different uses. For home appliances, the most commonly used cables are HDMI and SVGA. These are used for people with high definition television sets or play station units that have sophisticated graphic features.

Custom wire and cable is available in hardware stores. It is likely that you can find what you need from a hardware store even though it may be a little too specific or sophisticated. The employees in the hardware store are also familiar with these kinds of cables; let them know what you are looking for so they can help you find the right one for your appliances. Some electrical hardware stores also offer special services where they create a special one that will suit your needs and are specifically made to be compatible with your devices.

When it comes to finding custom made cable assemblies, it might be best to consult with an electrician first so that he may be able to guide you in looking for connectors that should be used and the material that is suitable for your devices.

Custom Cable Solutions Offer Plenty of Support

There are a lot of cables and wires out there in the world already today. Of course, even though they're mostly universal, a lot of these cables aren't really going to help people. For that reason, there are companies that also offer custom cable solutions for those who need them. Custom wiring and cabling solutions are perfect for people who are looking for something more unique and who need a little extra help than they can find in a box of cords that they buy at the electronics store.

Companies that specialize in custom cable solutions are designed to give people the information and insight that they need as they work, as well. They understand the latest innovations in technology and how to get the most out of wiring and cabling so that they can give you everything that you need. Plus, they're always there to help you when you need it along the way. There's so much to appreciate that it just makes sense to check out custom solutions before you do anything else.

Whether you are looking for a certain type of electronics cable or even silicone wire that is customized to your needs, there are so many different ways to get what you want. Of course, if you shop online with a reputable custom wire store, it will be easy for you to find what you need. Plus, you'll get better selection and much lower prices, giving you even more to love about getting customized cable solutions for your business or your home, no matter what you have in mind.

The world of consumer technology is changing drastically in the coming years and it has already done so a couple of times. When you have the upper hand in items like custom cabling and wires, you will be able to get more out of your business or entertainment. Make sure that you take the time to read up on these services and see how much you can find that you can benefit from with custom cords and cables because there is truly something for just about everyone.

Custom cables are all about your needs. If you take the time to do your homework and talk to professionals about your cabling needs, it will be easy for you to get everything that you need from this investment. Just remember to check out your options and find the cables that fit your needs.