APPLICATIONS OF CUSTOM CABLE ASSEMBLIES

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Medical Industries
Healthcare operations and hospitals have very detailed requirements for cables and wiring. Conditions such as high temperatures or large amount of moisture used for sterilization of medical instruments, make the cables deteriorate and disintegrate at a much faster rate. Thus, the medical industry needs custom cables that are able to sustain this repeated exposure day in and day out.
Telecommunications
Custom cables are manufactured for the digital age and broadcasting using fiber optic technology. Whether we are using our Smartphone, laptop, computer, tablet or anything that requires a network these cables help in the quick transfer of data. For cable technicians, custom fiber optic cables are excellent for meeting critical network needs when standard patch cables can’t do the job.
Military
From powering overseas military bases to securing confidential communication, to the units on the field, the military uses custom cabling and wiring for many of its branches. Also, cables used in military operations, need to endure harsh environmental conditions and perform under intense exposure, especially when on missions, so custom cables are a good choice to meet these critical requirements.
Aerospace
With the advancement of technology there is a continuous increase in the list of products needed by the aerospace industry. All digital instruments and workspaces need to have quality cables for optimum performance of any aircraft. From the hard wiring in the cockpits to the receiving units at the base, precision cables are integral to the success of the flight.
Automotive
The automotive industry is one of the largest industries that requires mass usage of cable assembly services. Proper cable assembly from the dashboard to the engine are critical for the efficient working of any vehicle.
Electronics
There’s much more that goes into electronic gadgets than just their look and style. Behind the user interface a lot of custom cables are at work to ensure that the product functions well and delivers what it’s meant to do, while at the same time being compact and user-friendly.
Utility Industry
Public utility companies serve many functions from powering homes to streetlight timings and other applications, all of which need custom cables to transmit power.
Industrial Controls
Massive machinery and hydraulics that are needed in any production line, require cables not just to transmit power but signals as well.
Sensors and Scanners
Custom cables are used widely in different devices and equipment which could be point-of-sale(POS) scanners, terminals of instruments, and automated kiosks.
Testing and Measuring Equipment
Testing and measuring devices, used in continuity testing for example, are critical in verifying whether a particular equipment, model, gadget or appliance meets required specifications.  These instruments might need simple wiring all the way to complex custom assemblies for high quality and precise testing results.

TOP 21 BENEFITS AND APPLICATIONS OF CUSTOM CABLE ASSEMBLIES

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complex application and standard cable seems to be falling short, custom cable assemblies might be the way to go.
As a cable technician, you know that purchasing the right cables are essential to any application requiring cable assemblies, whether it’s for setting up a home theater system that requires a special power cable, or an industrial application that needs a custom coax.
Poor wiring, or using standard cable just to make do, can lead to improper set up and technical issues. In the case of mission-critical applications for industrial use, a glitch can result in a temporary shutdown which can spell disaster.
Sure, standard cables may work in many instances, but custom cables come with their own set of advantages that off-the-shelf cables can simply not provide.
LET’S DISCUSS THE TOP 21 BENEFITS AND APPLICATIONS OF CUSTOM CABLE ASSEMBLIES THAT YOU SHOULD KNOW.
BENEFITS OF CUSTOM CABLE ASSEMBLIES
Accuracy
Custom cables are manufactured as per the specifications in the design. This makes their application extremely precise to fit into the tolerance level detailed for the assembly.
Quantity
An exact amount of cables can be ordered tailored to the needs of the application. There is no wastage, nor are any excessive cables left after the assembly is completed. The exact count for conductor, size and stranding can be optimized during the design of the assembly.
Flexibility
The length of each cable can be manufactured exactly as per the requirement of the project. This makes the set up clean without any need to hide additional cables and wires.
Accountability
The person working with the custom cable assembly will have a closer association with the cable manufacturer. The manufacturer therefore is accountable for the quality and standard of the cables that have been ordered, as well as ensures that the set up is functional as desired.
Material Requirement
Materials used for construction of the cable such as shield, insulation, jacketing material can all be specified to suit the application. Control on the material sources and manufacturing process can also be detailed in case of critical applications such as the medical industry.
Quality Assurance
Applicable test data such as electrical parameters, tolerances, temperature performance and resistance to chemical exposure can all be supplied by the custom cable manufacturer to ensure that the cable is tested for the given parameters before assembly.
Saves Time
Custom cables save many hours which would have otherwise been spent struggling with making standard cables fit the needs of the application. Hurdles like cable length, connector ends, resistance of cables, faulty cables and mismatch of specification can all be eliminated by just ordering custom cables.
Higher Performance
Due to the fact that custom cables undergo a stringent manufacturing process and are extensively tested, they may offer higher performance as compared to their standard, bulk or store ordered counterparts. With a longer lasting life span, custom cables save money in the long run.
Multiple Functions
For specialized applications such as security and surveillance, custom cables can be manufactured to incorporate multiple functions such as power, signal, optical fiber, coax, video, cable shielding and more, all into one cable. This specialized solution takes us minimal space and is built for unmatched performance.
Additional Services
Many a times custom cable manufacturers offer additional services such as laser marking and even design support for choosing the best custom cables for your application, which could serve as a big cost saving factor.
Professional Branding
Specifications for aesthetics such as color matching, look and feel, as well as texture of the cable can be detailed to the cable manufacturer when you order your custom cable. You can even add labels for easy identification. This gives a clean, neat and tidy finish to the project making it look like the hard work of a professional.

WANT TO ACHIEVE OPTIMAL FIBER INSTALLATION RESULTS?

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If you’re a fiber optics cable installer or technician you know how important precision and comfort is due to the repetitious nature of the installation job. Although no special tools are required for fiber termination, a fiber installation termination kit is worth thinking about as it comes with all the specialized tools you need to prepare the fiber correctly, while also providing a stable work surface so that you get the best installation results possible.
Although fiber optic strands are 10X stronger than steel, the strands are about 2.5 times the thickness of a single human hair making fiber termination a somewhat delicate operation! Especially when compared to let’s say a single copper conductor on a CAT6 cable, which is relatively easy to terminate, right?
Well, the good news is that since fiber optic technology was introduced in the late 1970s, many new connector styles have been developed and each design is meant to offer better, faster performance and cheaper termination.
The latest Fiber FX Brilliance Universal Connectors by Belden feature a no-epoxy, no-polish, no-crimp design making fiber optic termination quicker, easier and cost-effective.
Using these connectors for LC, ST, SC adapters becomes even easier when you get a full array of termination tools, instructions and a comfortable, spacious pouch to carry your gear to any fiber termination site you need to go to. That’s where the FX Brilliance Universal Installation Kit by Belden comes in.
You can let go of the perception that fiber-optic cabling is too cumbersome to install or too expensive. Many people today from homeowners to network managers to technicians and system engineers are discovering that fiber optic cabling and technology are actually quite feasible, and with the right tools in hand, the job gets that much easier.

WHAT IS FIBER-TO-THE-x (FTTx)?

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FTTx is a generic term used to refer to various types of broadband networks making use of fiber optic cables to deliver communications signals to subscribers at high speeds. These fiber optic cables are able to deliver more data across greater distances than traditional copper wires. Below, we’ll delve into some of the most common types of FTTx:
Fiber-to-the-home
Fiber-to-the-home (FTTH) involves the use of optical fiber to deliver a signal from operator’s equipment to an individual home or unit, greatly increasing connection speeds for broadband networks. Single-Family Units (SFUs), MDUs, and businesses can all benefit from FTTH, as internet, voice, and video services are able to operate with much higher speeds and efficiency.
Fiber-to-the-building
FTTB (fiber-to-the-building or basement) uses fiber cable to deliver communications signals to a central area in shared working or living properties. Other types of cabling, such as twisted pair, wireless, or coaxial, are then used to convey the signal to the individual SFUs, offices, or other spaces within the shared property.
Fiber-to-the-premises
The term FTTP (fiber-to-the-premises) is used as a general way to refer to high-speed connectivity optical fiber run into a subscriber’s home from a central location. FTTP can be used to reference either FTTH or FTTB fiber optic connections.
Fiber-to-the-node
FTTN (fiber-to-the-node or neighborhood) makes use of a fiber cable carrying a shared connection to a common network box, or cabinet, in order to serve an entire neighborhood. This may be used to reach hundreds of different customers, usually within a mile radius, who then individually connect to the cabinet with other types of cabling, such as twisted pair wiring.
Fiber-to-the-curb
FTTC (fiber-to-the-curb or cabinet) refers to the process in which an optical fiber cable is installed directly at the “curb” — a general term that can be used to refer to any common platform, such as a communications shed — to reach multiple subscribers. The signal generally stops within 1,000 feet of each individual customer. FTTC provides faster broadband speeds than telephone lines can.
Fiber-to-the-telecom enclosure
FTTE (fiber-to-the-telecom enclosure), sometimes called fiber-to-the-zone (FTTZ), is a standards-compliant, extremely cost-effective cabling method used in common spaces; long link lengths of fiber cable are extended from main equipment rooms (ER) to telecommunications rooms (TR) without the need for splices.
Fiber-to-the-distribution point
Similar to FTTC and FTTN, FTTdp (fiber-to-the-distribution point) delivers fiber to a distribution point in a specified area and then uses existing copper connections to serve individual units without actually entering them. This allows for a much more cost-efficient solution than FTTP methods.
Fiber-to-the-antenna
Describes the process of using fiber to feed wireless services, such as various cellular distribution devices. As wireless speeds increase, fiber is increasingly needed to provide the bandwidth necessary for these devices.

How Fiber Optics Are Made?

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Many people ask how fiber optics are made. You can’t just use “regular” glass. If you were to make optical fiber from ordinary window glass, the light that you shine through it would have a difficult time traveling more than a few kilometers, let alone the distances necessary for long distance transmission. That’s because ordinary glass contains distortions, discolorations and other impurities that would quickly absorb, reflect, or otherwise disperse light long before it could travel any great distance.

Read Corning’s Advantages of the Corning Process

In contrast, because optical fiber is actually made from very pure glass, the light traverses great distances largely unimpeded by impurities and distortions.

Fiber Optic Cable – Light How it Works

To transmit light effectively, fiber optic cable must contain glass of the highest purity. The process of making glass with this level of purity is very demanding, requiring careful control over the materials and processes involved. Yet, the fundamental concept is simple. Essentially, optical fiber is made from drawing molten fiber from a heated glass blank or “preform.” The following provides a more detailed explanation of the three basic steps involved in making optical fiber.

Step #1

Create the Fiber Optic Preform

A preform is a cylindrical glass blank that provides the source material from which the glass fiber will be drawn in a single, continuous strand.

Making a preform involves a chemical process known as Modified Chemical Vapor Deposition (MCVD). This process involves bubbling oxygen through various chemical solutions including germanium chloride (GeC14) and silicon chloride (SiC14).

The bubbling chemicals produce gas that is directed into a hollow, rotating tube made of synthetic silica or quartz.  A torch is moved up and down the rotating tube, resulting in very high temperatures that cause the gas to react with oxygen to form silicon dioxide (Si02) and germanium dioxide (Ge02). These two chemicals adhere to the inside of the rotating tube where they fuse together to form extremely pure glass.

Creating the preform takes several hours, after which additional time is required for the glass blank to cool.  Once cooled, the glass is tested to ensure that it meets quality standards, especially in terms of index of refraction.

Step #2

Draw Optical Fiber from the Preform In this step, the finished glass preform is installed at the top of a tower which supports various devices used in the fiber drawing process.

The process begins by lowering one end of the preform into an in-line furnace that produces heat in a range of 3,400 to 4,000 degrees Fahrenheit. As the lower end of the preform begins to melt, it forms a molten glob that is pulled downward by gravity.  Trailing behind the glob is a thin strand of glass that cools and solidifies quickly.

The equipment operator threads this glass strand through the remainder of the devices on the tower, which include a number of buffer coating applicators and ultraviolet curing ovens. Finally, the operator connects the fiber to a tractor mechanism.

The tractor device pulls the glass strand from the preform at a rate of 33 to 66 feet per second.  The actual speed at which the tractor pulls the strand is dependent upon the feedback information the device receives from a laser micrometer that continually measures the fiber’s diameter.

At the end of the run, the completed fiber is wound onto a spool.

Step # 3

Test the Fiber Optics

The completed optical fiber must undergo a number of tests to determine the quality of the finished product.  The following are a few of the assessments involved:

• Refractive index profile
• Fiber geometry inspection, including core, cladding and coating
• Tensile strength
• Bandwidth capacity
• Attenuation at different wavelengths
• Chromatic dispersion
• Operating temperature and humidity range

Quality Control in Optical Fiber Production

Various factors influence the quality and purity of the optical fiber produced.  These include:

Chemical Composition – Achieving optimal ratios of the various chemicals used to create the preform is important for achieving glass purity.  This mixture of chemicals also determines the optical properties of the fiber that will be produced from the preform, including coefficient of expansion, index of refraction, and so forth.

Gas Monitoring – It is crucial that the gas composition and rate of flow be monitored throughout the process of creating the preform.  It is also important that any valves, tubes and pipes that come into contact with the gas be made of corrosion-resistant materials.

Heat and Rotation – The hollow cylinder that is used to create the preform must be heated at the proper temperature and continually rotated to enable the chemicals to be deposited evenly.

Fiber Optic Cleaving – Key to Quality Connectors and Splices

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To prepare a fiber end for a connector or splice, the end of the fiber must be cleaved to a 90 degree flat end. This is needed because when a fiber end is inserted into a connector or splice, it is going to butt up against another fiber which is usually perfectly 90 degrees flat. If the inserted fiber has been cut with a razor or standard knife the end of the core/cladding combination will have an irregular face which won’t allow the light energy to pass from the fiber strand into the connector or splice.

For technicians the problem is that the end of the fiber strand is so small that it is impossible to tell with the naked eye whether the strand has a flat end – it’s just too small to see. So it’s important to use the proper tool with good technique to consistently achieve a 90 degree flat end. If you don’t achieve the proper flat end, you won’t know until you test the connector or splice and find out that it’s no good.  And then you will have to start the whole process over.

Whatever vendor or type of fiber optic cleaver you use, they all perform basically the same function. To achieve the 90 degree flat end, the fiber is scored or scratched at a specific length. The cleaver doesn’t cut the fiber; if you cut the fiber with the cleaver, you will need to redo the operation. After the fiber has been scored, operation of the cleaver by the technician will either bend or pull the fiber end, stressing the fiber. This stress will cause the fiber to break at the score mark, leaving a 90 degree flat end if all goes well. So the cleaver doesn’t cut the fiber; it breaks the fiber at a specific length.

There are two broad categories of fiber optic cleavers, cheap ones and precision cleavers. While both types perform the functions above, the difference between the two categories of cleavers is the percentage yield of good cleaves. An experienced fiber optic technician will achieve approximately 90% good cleaves with a cheap cleaver, while the precision cleaver will produce 99% good cleaves. The difference doesn’t seem like much but since you cannot see whether a cleave is good or not, it is best to invest in the precision cleaver. The time saved in redoing bad connectors made with cheap cleavers will quickly make the precision cleaver a better investment.

Before cleaving the fiber it is very important to clean the stripped fiber end using a fresh alcohol pad. This cleaning is necessary to remove any microscopic debris left on the side of the fiber from the stripping process. When cleaning the fiber technicians should squeeze the fiber end with the alcohol pad with some pressure. This will stress the fiber before the cleaving process. In the event that the fiber core/cladding was inadvertently nicked during the stripping process, squeezing the fiber with the alcohol pad and pulling it through will cause it to break in the pad. If the fiber has been nicked we want it to break now, before we do the cleaving and connector/splice installation. It’s quite possible that a nicked fiber that isn’t stressed with the cleaning pad before installation will break at some inopportune time in the future.

Once the fiber is cleaned, the strand is placed into the cleaver so that a specific length of stripped fiber extends from the remaining 900 micron jacket to the cleaved end and the cleave process is performed.