2 The Ideal Interconnect Cable Assembly For High Performance I/O ApplicationsFault Free: Form, Fit and Function100% Electrical ContinuityCorrosion-Resistant MaterialsMaximum Flexibility and DurabilityMinimum Size and WeightAbrasion-Proof CoveringsCrush-Proof ConduitHi-Rel Crimp Contact ConnectorsPrecision, Gold Plated ContactsHarsh Environmental ProtectionEMI Immunity
3 “Acceptable” Performance and Cost Dictate Design The Compromise“Acceptable” Performance and Cost Dictate DesignFit and forget vs. frequent mating cyclesExposed environmental vs. enclosed mountingCommercial vs. militaryHigh power vs. signal (or combined)Crimp vs. solderShielded vs. unshielded
4 Factors That Impact Cable Design and Construction: (1) Environmental and Mechanical Fluid ImmersionChemical ResistanceAbrasionClampingFlame/outgassingCorrosionImpact/crushShock and VibrationTemperature CyclingAltitudeFungusPressure ExtremesPull Forces/ElongationBend RadiusAgingStrain-Relief
5 Factors That Impact Cable Design and Construction: (2) Electrical Current ratingWire voltage ratingWire AWG and NumberWire material/finishInsulation/dielectricEMI/EMPImpedance requirement100 ohm pairs (Ethernet)90 ohm pairs (USB)75 ohm coax50 ohm coax
6 Size, Weight, Flexibility, Routing, Cable Management Factors That Impact Cable Design and Construction: (3) Usability and ErgonomicsSize, Weight, Flexibility, Routing, Cable Management
7 Interconnect Cable/Conduit Design, Materials and Construction
8 Connectorized System-to-System I/O Cabling From One Box to Another Box
9 For Non- or Partially-Connectorized Applications Feed-Thru CablingFor Non- or Partially-Connectorized Applications
10 (Non-Connector) Feed-Through Accessories Complete range of functional types: shield termination, strain-relief, environmental sealing etc.Split shells enable easy assembly and maintenance at any stage in the project.
11 Open Wire Bundle Cables Lightweight and Flexible Cable HarnessesAppropriate where no noise or crosstalk from adjacent wires is expectedPrevalent for data transfer with tightly twisted pairsShielded pairs might be inside of an unshielded cable assemblyGreat for routing
12 Open Wire Bundle Cables Used in Internal Box Wiringand Other Enclosed Non-Environmental SystemsLow cost compared to overmolded or jacketed solutionsField repairableNon-EnvironmentalNot particularly durable
13 Management of Open Wire Bundles Wraps/tapesCable tiesCable clipsSpiral WrapSplit tubingExpando braidBroom StitchOthers
14 Standard Jacketed/Shielded Cables Backshell Equipped for External Harsh EnvironmentsShields added to twisted pairs, or multi-conductor cables, to help prevent EMI (victim or source).Jacketing extruded, shrunk on or blown onTypes of jacketing based on environmental conditions such as immersion, chemical or caustic fluid exposure, corrosion potential, temperature or radiation exposure.Field maintainable, user installable backshells
15 Wide Range of Choices to Meet Every Need Jacketing StylesWide Range of Choices to Meet Every NeedExtruded jacketing is the best environmental sealing optionBlown on jacketing—soft rubber tubing is overfilled with compressed air, cable inserted, and tubing allowed to collapse for sealing fitBoth options offer a wide range of material types.Heat-shrink tubing is inexpensive, lightweight and ideal for short runs and prototypes
17 Environmental Sealing for Jacketed Cables Typical exploded view of cable sealing backshell
18 Shield Termination Options for Jacketed/Shielded Cables Dozens of different stylesConical ring backshellsTag ring backshellsCable Sealing Band in a Can BackshellsTinel-Lock BackshellsSealtite/Liquidtite Conduit BackshellsBand-It Clamping SystemConductive epoxy potting for EMI shielding and grounding in tight space applications
19 Jacketed/Sealed Cable Applications External Wiring RequirementsBattlefield electronicsUnder vehiclesLong cable runs connecting field equipmentSoldier systems
20 Overmolded Sealed Cables Ultimate Environmental ProtectionUse of encapsulating plastic medium to cover backshells, adapters and transitionsEffectively isolates conductors from contamination and protects from abrasionMold geometries for unique applicationsCan integrate mounting brackets and other hardware right on to the cable assemblyTamper resistant
21 The Advantage of Overmolding Outstanding environmental protection for harsh and caustic environments compared to unjacketed solutionsPolyurethane, Viton, EPDM, Polyamide and Glenair proprietary materials provide robust protection for connectors and cables in harsh/caustic environmentsInjection molding/transfer molding is a simple, reasonably priced solution to physical protectionDesign flexibility: from simple point to point, to complex multiple branch assemblies—even fiber-optic and hybrid electrical/optical designs
22 Top Ten Overmolding Bullet Points Superior, water-proof environmental sealingRobust mechanical protection of the connectorSuperior mechanical/strain-relief protection of wire/contact terminations.Superior resistance to chemical exposure damage.No induced cold flow stress to wire insulation or terminations compared to cable clampsSuperior electrical isolation and insulationReduced exposure of metal parts to wear damageFlexible routing/cable entry anglesSuperior performance compared to boots and backshellsTamper proof
25 Old School Overmold Tooling Manual injection tooling serves a broad range of standard connectors.Provides savings to customers and faster time to market.All classes of rectangular connectorsMil-Spec and commercial cylindrical
26 Production Overmold Systems Numerous other materials, besides Viton, are suitable for injection molded protection of connectors and terminations.Polyamide provides “good” levels of solvent resistant, abrasion resistance and temperature tolerance compared to VitonNew equipment and production system adds speed and reliability to catalog point-to-point or pigtail assemblies for the Series 80 “Mighty Mouse”.
27 Backshell Devices Used in Overmolding Banding backshells, used for shield termination and the attachment of heat shrink boots are also employed in Overmolding.The parts are blast abraded to facilitate overmold material bonding.Design shown at right incorporates a threaded section for easy repair and maintenance or terminations.
28 Overmolded Cable Applications Preferred technology for fuel cellsAdvanced F-18 E/F Fuel Cell Assembly with integral fiber optic mediaF-22 Overmolded Fuel Cell Assembly and Wheel Well AssembliesV-22 Fuel Cell Assembly
29 Cable Routing and Packaging Capabilities Essentially unlimited range of breakouts and layoutsStraight, 90 and 45 degree angular specifications.Existing tooling for many common molding adapters and connectors.Breakout, bulkhead and transition tooling for many configurations
30 Imbedding PCB’s with Overmolding A Unique Application of Injection Overmolding
31 Overbraid and Tubular Fabric Braid Strength Plus Chemical and Abrasion ResistanceFabric braid for improved cosmetics, wire management, tensile strength, chemical resistance, abrasion resistance, and flammability reduction
33 Low-End Tubular Fabric Braid Products Polyethylene -54°C to +121°C used for abrasion, cut through and overall protection also very flexible.Polyethylene is very standard and used extensively.Halar (E-CTFE) -73°C to +150°C provides higher temperature and better mechanical toughness.Materials are quite common and highly competitive with “Expando” braid type products.
34 Less Common Non-Metal Braid Products PEEK °C High temp, high performanceTeflon (FEP) °C chemical and fluid resistantKevlar Extremely toughDacron (Polyester) °CNomex
35 Overbraid and Tubular Fabric Braid For mechanical protection and EMI applicationsElectrical Continuity of a cable or EMI/RFI shielding is the primary purpose but strain relief, cable strengthening and armoring are also provided.Used for EMI/RFI shielding to prevent “conducted” signals from interfering with sensitive electronics; and to keep intended electrical signals and power from “radiating” and affecting adjacent cables or devices.Standard braiding materials include bare copper, tinplated copper-covered steel, copper plated with tin, nickel or silver; bronze, stainless steel, copper-covered steel, aluminum wire
36 Overbraid and Tubular Fabric Braid Mechanical Strength and EMI ProtectionMetal braiding physically protects cable conductors while adding tensile strength and integrity to the assembly.Metallic braids shield cable conductors from line-of-sight EMI penetration or escape, and by taking EMI to ground.Bulk braid size range from 1/32” to 2-1/2”Overbraids up to 3” diameterMore than 50 braiders
37 Ultra-Lightweigth Composite RFI/EMI Braided Shielding Nickel Plated AmberStrand Composite Shielding Offers Unique Solution to Electromagnetic CompatibilityExpandable, flexible, high-strength, conductive, elastic composite materialProvides abrasion resistance and EMI shielding at a fraction of the weight of metal braid
38 Lighter Weight and Less Costly Than Braid Foil Shield/Tape WrapLighter Weight and Less Costly Than BraidFoil shields: aluminum foil laminated to a Mylar, polyester or polypropylene film.Film gives the shield mechanical strength and added insulation.Provides 100% electrostatic shield protection.Can shield individual pairs of multi-pair cables to reduce crosstalk.
39 Lighter Weight and Less Costly Than Braid Foil Shield/Tape WrapLighter Weight and Less Costly Than BraidLighter weight, bulk and less costly than spiral or braid shields and are generally more effective than braid shields in RF ranges.Foil shields are often more flexible than braid but have a shorter flex life than spiral or braid.Drain wires often used with foil shields to make termination easier and to ground electrostatic discharges.
40 Multi-Conductor Cables Critical element of the harness assemblyCustomer defined:DimensionsCore TypeInsulationConductor, shielding and jacketingRoHS, UL or otherElectrical (Voltage, etc)Flame ratingTemperature rating
41 Common Choice for Telephone/Communication Cables Coil CablesCommon Choice for Telephone/Communication CablesSpecified by “working length,” and “Retracted Length.”Other design variables include:Hand pulled or machine pulledCoil “memory” strengthOrientation and length of straight ends
42 Summary: Application Checklist for Cable and Harness Specification
43 Application Checklist: Step One: Working Environment Required Information for Fast Design and DeliveryShipboardAircraftSecure CommunicationsGround SupportRail/Mass TransitSpaceMissile DefenseTelecommunicationsArmored Vehicle
44 Application Checklist: Step Two: Electrical/Optical Requirements Required Information for Fast Design and DeliveryApplication defined requirements for cable performance may include:Current ratingTest voltageInsulation resistanceDWVSignal leakageAttenuationVoltage dropCapacitance
45 Application Checklist: Step Three: EMI Shielding Requirements Required Information for Fast Design and DeliveryCustomer defined shielding specifications for the cable may include:Shielding effectiveness (dB)Frequency Range (Hertz)EMPTEMPEST
46 Application Checklist: Step Four: Key Environmental Requirements Required Information for Fast Design and DeliveryCustomer environmental requirements for the cable may include:Moisture/chemical ProtectionLow Smoke/Zero HalogenUL94-V0 FlammabilityNBC/CBRNE ResistanceUV ResistanceTemperature ResistanceControlling Specification
47 Application Checklist: Step Five: Key Mechanical Requirements Required Information for Fast Design and DeliveryCustomer mechanical specifications for the cable may include:Field ReparabilityCrush/Abrasion ResistancePull (Tensile) StrengthFlexibility/Flex CyclesMinimum bend radiusWorkmanship standardsStrain-relief
48 Application Checklist: Step Six: Packaging Required Information for Fast Design and DeliveryCustomer packaging/construction requirements for the cable may include:Critical dimensions/tolerancesRequired tooling, such as crimp dies, molds and test fixturesSpecific cable management and identification choicesApproved jacket, boot and dielectric materialsJacket finishSpecifications on length of lay in twisted pairs or other cable construction details
49 Glenair Cable Harness Design and Construction Services
50 ISO 9001:2008 and AS 9100:2009 Rev C Certified Cable Assembly Factories 100% Vertically IntegratedAll Key Processes Under Glenair ControlISO 9001:2000 CertifiedAS9100:2004 Rev. B CertifiedCertified soldering (NASA STD )Source inspection available
51 Testing Services 100% Testing all Cables Testing on Request Immersion Temperature cyclingPost-assembly filter performanceComponent verification (resistors, diodes, capacitors)X-ray for broken wires, loose strands, mold voidsReturn loss (back reflection)Interferometer measurement (fiber end face geometry)Contact resistanceWeight separationContact retentionContinuityHigh voltageInsertion loss (Fiber Optic Cable Assemblies)
52 Cable Harness Application Development The Bid ProcessDuring the bid process, Glenair will often add value with superior knowledge of wire and cable layout and assembly, especially in prototypes.
53 Turnkey cables as a standard catalog offering COTS Cable AssembliesTurnkey cables as a standard catalog offeringPoint-to-Point cordsets and pigtails available for all Series 80, Series 22, D38999 fiber optic and Micro-D connectorsHigh-speed data transfer cordsets for USB, Ethernet and more using Series 80 Mighty Mouse and other interconnectsStandardized part number developmentAccelerated lead times
54 Example Custom Cordset (High Speed 1000BASE-T Ethernet)
55 A Huge Arsenal of Factory Capabilities SummaryA Huge Arsenal of Factory CapabilitiesWring, connectors, accessories, braiding and sealing all availableCatalog standards and thousands of customsSoup-to-nuts cable design, assembly and testing rather than multiple vendor sourcingEngineering staff unparalleled in industryCan draw from a vast reservoir of cable experience