Custom Cable Assemblies / Harnesses

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Custom Designs (OEM/ODM)

YCABLE ELECTRONICS offer many kinds customized or OEM cables and wires in different fields.

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Our Capabilities

ENGINEERING TEAM:

Our engineering team consists of production engineer, electronic engineer and mechanical engineer. Each engineer is very professional and dedicated.

New product design and development:

YCABLE ELECTRONICS can design different products for you according to your needs in different fields. Our current design productions includes:
1. Cable Assemblies and Wire Harnesses(Kiosk wire harness for parking lot automation/Automotive cables/Deutsch 9P and 6P to HD26P/OBDII to Atari 14P/Waterproofed USB cable/Audio cables/New energy vehicles cable...)
2. Ultrasonic welding products(PCBA Assembly/Ultrasonic welding/ Assembly cover/PCBA assembly molding...).

REVERSE ENGINEER:

Step 1 Get samples.
Step 2 Material analysis.
Step 3 Electrical/physical performance analysis
Step 2 Drawing the 2D & 3D drawing sheet according to the samples
Step 4 Make quotations
Step 5 Sample producing

2D&3D DESIGN:

We provide two types of drawings, 2D and 3D, to determine the specification details of the product and provide a more intuitive understanding of the product structure, which is helpful for product development and specification confirmation.

Design and development of molds:

After confirming the specifications, we will design molds for the injection molding part, After the preliminary mold is made, we will make a preliminary attempt and conduct testing after completing a sample. We will make electrical performance tests on internal connections, waterproof tests on overall components, and visual inspections and so on.

E-LAB:

1. PCB mock up
2. Signal Generator
3. Bridge Test
4. Oscilloscope
5. Frequency Meter
6. Quadratic Element Analysis

Reliability Test:

Electric: Insulation Test; Current Resistance Test; CIRRIS Tester; CT-8681 Tester; CT-8751 NAC Tester
Mechanical: Bending Test; Plug & Pull Force Test; Plug & Play Test (durability test); 360°Rotation Test; Drop Ball Test; Torsion Test; Vehicle Standard Bend Test; Vehicle Standard Bend Test to SR with 5 Pounds Weight
Environment: High & Low Temp Test; High Temp Aging Test; Brine Spray Test; Ultraviolet Accelerated Aging Test

Case Analysis of Wire Harness&Cable Assembly Process Flow

Ycable Electronics is the leader in supplying high-quality wire harness and cable assembly.

CASE A

The manufacturing process of this wire harness is:

  1. Cutting electrical wires to 310mm (computer cutting machine cuts electronic wires and peels both ends)
  2. Twisting (P2 end core wire twisting)
  3. Terminal punching (P1 end riveting terminal)
  4. Inspection (finished product inspection
  5. Packing

CASE B

The manufacturing process of this cable assembly is:

  1. Cut the CABLE length to 1524mm (manually cut with a cutter).
  2. Cutting the tube(Cutting by casing machine).
  3. Stripping the jacket both end of the cable.
  4. Stripping the insulation of the core wires and tinned(P2).
  5. Add the terminal (P2 end core wire riveted waterproof terminal).
  6. Terminal inspection.
  7. Threading through the tube (threading D and E casing from P1 end).
  8. Add the TELEPHONE JACK by hand, and fix it.
  9. Dismantle the waterproof terminal of item G.
  10. Thread the waterproof terminal (insert the P2 terminal into the waterproof terminal).
  11. Assemble the waterproof terminal (reassemble the previously disassembled components).
  12. Test the waterproof terminal assembly.
  13. Remove the waterproof head and apply glue.
  14. MOLDING the inner mold(P2).
  15. P2 end waterproof terminal immersion and air blowing inspection.
  16. Cable assembly continuity test
  17. MOLDING the outside mold(P2).
  18. IP67 immersion waterproofing test.
  19. Heating the tube.
  20. Dust cover (P1 end TELEPHONE JACK dust cover protection).
  21. Finished product inspection.
  22. Labeling
  23. Packing

Custom Case