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Value-added Services: Wire and Cable Modifications

Wire and cable do not generally come with all the modifications needed for a specific application. For example, your application could call for wire with ink-jet printing for easy identification during installation and usage. Similarly, you may want your wires dyed various colors for prompt circuit identification. This is where value-added manufacturers take over.

Several manufacturers supply distributors, wire harness manufacturers, and OEMs with value-added services for wire and cable products. A value-added service indicates a customization on an order that goes beyond a basic or core service. In other words, it benefits the end user by “adding value” to the standard service offered.

In the electrical wire and cable industry, value-added services include braiding, cut and strip, printing, bar-coding, dyeing, custom put ups, striping, and more.  These services can be broken down into four main categories – Identification Solutions, Installation Solutions, Labeling Solutions, and Packaging Solutions.

Identification Solutions:  Striping, Dyeing, and Printing

Striping and Dyeing

Manufacturers and distributors of electrical wire often add stripes or dye a base wire another color. These processes are multifunctional as they add value to the product, differentiate the wire for circuit identification and help control inventory volumes of stocked material.

In order to dye a wire, a specially-built machine feeds the wire product through a system of pulleys. First, the wire passes through a “wiper,” a foam circle that encompasses the entire cable. The jacket of the wire absorbs a formulated dye that is present in the foam. After passing through the wiper, the wire goes into a heat tower to cure and dry.

Striping, which many manufacturers offer for extruded wire, is performed in the same machine as dyeing. However, for striping, the wire does not pass through a foam wiper. Instead, the wire passes through a striper head that spins around the wire before it goes into the dryer tower.

The produced stripes are either longitudinal or spiral. Post-production striping usually generates a spiral stripe, like that on a candy cane.  Longitudinal stripes, which run along the side of a wire, are also available post-production, but are not as common as the spiral type.  Contrasting stripes are generally used when more than ten circuits have to be identified.

Almost all insulations are able to be striped, including PVC, rubber, silicone, and PTFE. Similar to striping, most PVC compounds can be dyed to individual specifications without encountering any problems. However, some compounds that are CV-cured or irradiated are not able to be dyed because they were originally designed to repel both petroleum- and alkaline-based chemicals. The color will not soak into the insulation and is prone to flaking.

Printing

In addition to common striping and dyeing methods, there are other ways of marking wire for identification. Many OEMs and harness manufacturers prefer using printed wire in their assembled products. Printed wire not only helps in the assembly of products, but also benefits installers and users of the finished product.

One way of marking wire is with ink-jet printing. Using a dot matrix printer, a series of “dots” create characters on a wire. For example, in the automotive industry, a harness may be manufactured for turn signals. In this case, the specific wire would be ink-jet printed “left front turn signal” or “tail lights.” Each wire would be color coded in the harness and ink-jet printed, making it user-friendly and easily identifiable.

Another way of marking wire is hot stamping, which entails a process similar to that of a typewriter. A character-shaped “head” strikes a colored tape, causing the chosen character(s) to appear on the wire.

Installation Solutions:  Twisting, Braiding, and Cut & Strip

Twisting

Many OEMs need paired wire in the manufacturing process. Grouping single- or multi-conductor cables into various configurations can cut installation time dramatically.  It allows wires to lie together, which in turn makes working with them easier.

In order to create paired wire, a process known as twisting must occur. Twisting entwines multiple wires and arranges them tightly next to each other. Two, three, and even up to eight wires can be twisted together.

The process of putting wire ends into a drill and twisting the wire is one home-grown twisting method that’s still practiced on the production floor. It will get the job done to some extent, but it will not remove the natural twist in each wire. This means that if the wire is cut into small lengths, it will not stay twisted together.

Another problem with this method is the wire acquires dirt and grit on the production floor. The dirt could transfer to the finished product, which could then pose major problems. Twisting using a dedicated wire twisting machine is the only way to get a good lay to the wires.

Braiding

One process that helps add protection against abrasion in harsh environments is braiding.

Braiding is a process in which small strands are woven together on top of a wire or cable for added protection. At the start of the process, numerous spools, also called “Bobbins,” of very small gauge wire (32-36 AWG) are inserted into a wire braiding machine.

The bobbins are each placed in a precise location within the machine and the ends of each bobbin are pulled to the top of the braiding machine. Next, the bobbins are subjected to a spinning or circular weaving motion, while a wire or cable is pulled up through the center of the bobbins. As the synchronized process commences, a weave or braid is manufactured over the cable. Finally, the finished product is drawn out of the braid machine onto a larger spool or payoff.

Cut & Strip

Having your wire cut and stripped saves time and money and prevents excessive waste. Let’s say you need 1000 four-inch pieces of wire to install in printers that you manufacture. For each piece, you need .5 inches of wire exposed on the ends. Instead of having your factory workers manually cut each piece off the reel and then remove the insulation from the ends, have your value-added manufacturer complete the process for you.

The cut and strip process starts at one end of a cut and strip machine where a reel is held in what is called a “payoff.” The machine operator enters the overall length and desired cut and strip measurements for the pieces. Next, the wire is fed through a set of pressure-sensitive wheels that hold the wire tautly.

Then the wire is passed through a pair of blades that strip the insulation, as it can sense where the bare wire begins. The wire is then pulled to the end to make the length cut. Finally, it is pulled backward slightly in order to make the final ‘strip’ cut. The pieces of insulation cut for the strip can be left on the end of the wire to prevent the strands from fraying. This detached piece of insulation is called the slug.

The final cut and stripped wire is dropped into a bin.  The machine will finish the process for the total amount of wire length the machine operator entered at the beginning.

Labeling Solutions:  UL/CSA Labels, RFID, Custom Labels, Bar-Coding

UL & CSA Labels

Wire and cable products can be sent pre-labeled with UL and CSA tags.  Use of these tags ensures that products will arrive at the delivery-point already marked to meet internal classifications, aiding in proper identification and distribution upon receipt.

RFID & Government Labels

RFID (Radio Frequency Identification) is another Value-Added option to pre-label products for ease of receipt.  These labels are encoded with a radio frequency that can be “read” by a transponder.  RFID labels provide more than the basic information offered by a standard print label or even a bar-code, and can be read at long distances.

Value-added manufacturers will also produce Government labels.  These specify any government-level classifications of Mil-Spec wires and cables, and can aid in tracking and inventory.

Custom Shipping Labels

Custom shipping labels include the specific information a company requires to meet their standards right on the package.  The types of information likely to be found on a custom shipping label, aside from the shipping address, include Part Number, Supplier Part Number, PO Number, Lot Number, and Date.

Bar-Coding

This service will print the needed information right on the shipping label in the bar-code standard the company uses.  There are two general types of bar-codes:  linear, which is used more often, and matrix, which holds more data.  Common linear formats are UPC, generally used in retail, and MSI, generally used in warehouse inventory.

Packaging Solutions:  Special Packaging/Reel Sizes

Wire is heavy, consumes space, and is hard to keep in inventory. In addition, OEMs worry about the costs in set-up and handling of preprocessed and post-processed wire. Many OEMs that regularly use wire have gotten special reels or spools in order to efficiently use storage area, maintain an accurate inventory, and keep costs to a minimum.

Wire and cable distributors that cater to OEMs and harness houses have developed unique ways to store wire. One such way is to use large bulk Drum “reels.” Drums are commonly constructed of cardboard or pressed paper (with a center core of the same material) and metal rings around the top and bottom. When wire is ready to be stored, it is laid into the Drum using a circular motion that allows for easy removal. Storage capacity in any given Drum can be thousands of feet, depending on the gauge of the wire. However, if the Drum is rolled or damaged, the wire may become almost impossible to remove.

Reels and spools come in many different sizes and configurations for use with varying wire types. For example, large 6 to 8 foot tall wooden slatted reels hold large gauge power cable.  Many wire manufacturers use 2,500 ft to 5,000 ft spools for hook-up wire.

Small gauge wire may be spooled on a 10-inch plastic spool that has a center core length of 5 to 6 inches and holds up to 10,000 ft.  Certain factors determine the spool size you will need; one important factor is how the wire will be used in the manufacturing process.

If the manufacturer usually cuts their wire by automated machine, the spool size or Drum size may be critical. For example, using an automated machine, a large Drum of wire can be gone in as little as 30 minutes, depending on the length of the cut. Cost is another factor. As an added benefit for a large reel size or Drum Packs, many distributors offer discounts on bulk reels.

With all of their unique abilities, value-added services conveniently customize while offering solutions for precise wire and cable specifications. As an additional advantage, purchasing wire and cable from a value-added manufacturer proves to be cost-effective because everything you need can be completed in a single location by one vendor.

Electrical wire and cable distributors have the tools to prepare wire for the buyer’s convenience. Whatever the service, the value-added distributor offers the ability to custom-order inventory to fit individual process and storage needs. This translates into better usage of time and space, and that further translates into profit.

Tim Flynn is the President of Allied Wire and Cable, a leading value-added distributor of electrical wire, cable, tubing, connectors, and accessories, headquartered in Collegeville, PA. Tim, a graduate of Drexel University, has been President of AWC for its entire 20+ years in business, and he has guided the rapid growth of the customer-focused, relationship-based company. For more about AWC, please visit: Allied Wire and Cable, Inc.

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Residential Wiring Diagrams – Who Needs Them?

You will benefit from using residential wiring diagrams if you plan on completing electrical wiring projects in your home. An electrical wiring diagram can be as simple as a diagram showing how to install a new switch in your hallway, or as complex as the complete electrical blueprint for your new home.Although household electricity is nothing to play around with, in many ways, wiring is simpler than other repair and remodeling skills such as carpentry. Once you’ve learned some basic skills such as installing boxes, running cable, and splicing, you just need to determine which wire goes where. This is why a good wiring diagram is important for wiring your home safely. Keep your diagrams near-by. You’ll want to refer to them often as you work on your project.Wire Colors:Electrical wiring diagrams that are in color have an advantage over ones that are black and white only. The wires will be colored the same as the actual wires you will be using. Commonly, the green wire is ground, white or off-white is neutral, and black, red or other colors indicate the hot wire. In some instances, such as some switch legs, the function of the wires will be indicated by colored electrical tape.Symbols:When looking at any residential wiring diagram, start by familiarizing yourself with the symbols that are being used. The electrical symbols will not only show where something is to be installed, but what type of device is being installed. Make sure you understand the symbols on your diagram before beginning your project. There should be a chart on your diagram showing the different symbols being used, much like a legend on a map.For example, a surface ceiling light will be shown by one symbol, a recessed ceiling light will have a different symbol, and a surface fluorescent light will have another symbol. Each type of switch will have a different symbol and so will the various outlets. You’ll even find symbols showing the location of smoke detectors, your doorbell chime, and the thermostat.Switches:When it comes to household electricity, there’s a lot more to consider than simply turning a switch On and Off. Some of the most common questions electricians receive involve switches. Once you understand the different types of switches and follow a good wiring diagram, you should be able to install a new switch in your home.Here are some of the more common switching configurations:A Single-Pole Switch provides switching from one location only. “Single-Pole” may sound simple, but there are different ways to wire a Single-Pole Switch and a set of electrical wiring diagrams will explain each of them to you clearly.3-Way Switches are used to control one or more fixtures from two locations. This is a common configuration in hallways and staircases. There are many ways to wire a 3-Way Switch. The power can start at a fixture or either of the two switches. Without a wiring diagram it can be very easy to make a serious mistake.A wiring diagram will even take the mystery out of wiring a 3-Way Dimmer Switch. What a great way to enjoy softer light and a reduced energy bill!One of the most complicated wiring configurations is a 4-Way Switch. These switches enable you to control one or more fixtures from three or more locations. It would be almost impossible to write the instructions in a way that you could simply read them and complete your project. However, a good wiring diagram will make it possible for you to successfully and safely tackle wiring 4-Way Switches.As important as electrical wiring diagrams are to the successful completion of your wiring project, safety and respect for electricity are essential. Never work on live circuits. Before you begin your project, identify the circuit you’re working on and then turn off power to that circuit at the main panel. Then confirm that the power is off with a voltage tester. If at any time you feel unsure about what you’re doing, please call a licensed electrical contractor.

More information on residential wiring diagrams and diagrams for all of these switches can be found in the Residential Wiring Diagrams section of my website: Ask-The-Electrician.com.


Dave Rongey is a Licensed Electrical Contractor with over 35 years of experience. He is also an avid Do It Yourselfer. Through the years Dave has seen too many DIY projects that are serious fire and safety hazards. Visit Dave at Ask-The-Electrician.com for electrical project guides, complete with photographs, which will enable you to enhance the beauty and value of your home safely.

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★★★★ 2001 volkswagen passat wiring diagram

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2001 Volkswagen Passat Wiring DiagramThis wiring diagram applies for 2001 Volkswagen Passat series. Here you will find complete schematic electrical wiring diagram of 2001 Volkswagen Passat. Consist of 106 pages of pdf/ filetype document, this wiring diagram manual include Automatic Air Conditioning Circuit Diagram, Anti-Lock Brake Circuit, Anti-Theft Circuit, Engine Performance Circuit, Computer Data Lines Diagram, Cooing Fan Circuit, Cruise Control Circuit, Defogger Circuit, Headlight Circuit Diagram, etc. Download the 2001 Volkswagen Passat Wiring Diagram here (pass: wiringdiagrams21.com)

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★★★★ 1967 ford truck f 100 wiring diagrams

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1967 Ford Truck F-100 Wiring DiagramsThis wiring diagrams applied for 1967 Ford Truck F-100 series. Here you will find 13 diagrams depicting the 1967 Ford Truck F-100 wiring installation including truck auxiliary tank diagram, truck courtesy light wiring, exterior lights and turn signals, truck horns diagram, ignition, charging, starting and gauging diagrams, instrument panel diagram, interior lights, instrument lights and cigar lights, truck overdrive series diagram, overdrive diagram, roof and platform marker lights diagrams, transmission system diagram, windshield wiper and wiper diagram. Please download the 1967 Ford Truck F-100 Wiring Diagrams here (pass: wiringdiagrams21.com)

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Auto Audio Questions & Answers

200 dollar/ Car speakers/ With the best point?
Hey sup guys I just get my first car, and the nouns system is terrible I be thinking about getting speakers and a sub woofer but immediately knowing how much everything is now a days I granted I am just going to go and get speakers, does…

2000 Ford Escort…?
Want to know if a factory CD player exists for this considerate of car, ive found ones near cd changer controld but i want to know if their is one that has a cd player within the dash for this vehicle, thanks within advance!

2000 Ford Mustang speaker size interview….?
I have a dais model of a 2000 ford mustang with the orgional speakers that I preference to upgrade. My only put somebody through the mill is whats the standard size for this car model, and would other sizes would fit contained by the front…

2000 Montero Sport Speaker size?
I need to find out the size of the factory speakers surrounded by my montero sport… its not in the owners booklet and I couldnt find that info online…does anyone here has or have the same open-handed of car? I really requirement to replace my speakers… Thanks

2000 watt amp?
ive brought a 2000 wat amp im just unsure what electrics kit i would have need of and does it even make a difference

2001 Eclipse radio code?
I need the code for my radio. replaced the clutch they pulled the mobile radio # MR 337276 Ser# 0×208280 might have a C on the ending. Thanks,

2001 Ford Escape XLT 6 dics disc changer?
I have a 2001 Ford Escape xlt and the 6 disc cd changer is no longer working. Part number YL2F-18C815-BE. I’m trying to find a used replacement for this section but am not sure what will work in my vehicle. Can I bring back one from any…

2001 Ford Taurus Factory compact disc Player?
is there anyway to purloin out the factory cd player out of a 2001 taurus ses and put in a store bought cd player (pioneer, sony etc.) if so, what loving of kit would i want and approximately how much would it cost to install?

2001 Ford Taurus Radio?
I just bought a used 01 Taurus SES it have a tape deck contained by it but on the side it has a button for a cd and I’m not sure where on earth or if it has a cd changer. I read the article for…

2001 maximum after i installed unmarked stereo the subwoofer don’t work?
i replaced my bose unit near clarion VRX765VD. I got the special harness beside RCA jacks coz the speaker wires go directly to a amp everything go well except after i installed the unsullied system my subwoofer(stock bose) stoped working any one have any perception why??…

2001 pontiac sunfire wireing diagram what color cable manner what?
im installing a new radio surrounded by my sunfire and the colors of the wires dont match up and i cnat numeral it ou

2001 V6 mustang audio.?
Ok so i have a mustang with everything stock audio. I hold not messed w/ anything in it yet because when i play cd or video its pretty nice for a stock. Now i’m thinking of adding a sub maybe but I hold no idea where…

2002 pioneer deh 6300 series v.s 2007 pioneer 6900 series cd player?
who thinks they can bring up to date these two apart, and also, which one do you find to be nicer, or easier to use, or just wantt o comment on any of the two, I own both.

2002 Pontiac Grand Am MP3 hook up press.?
I’ve got an ’02 Grand Am that I am interested in hooking up an MP3 player to the origional radio deck. The soul before me had a satellite radio contained by it but I don’t know how she went about hooking it up. She’s…

2003 BMW 325i radio removal (yes, I own the car)?
In the course of wishing to “enhance” my car, I’ve purchased a Grom audio component for the BMW. However, I’m having a bit of problem finding any documentation giving concrete answers on how to remove the radio from the car. It’s a 2003 BMW 325i, and…

2003 Chevy Silverado aftermarket stereo won’t turn on. Why?
I hooked up all the speaker wires. The pallid wire. The black (ground) telecommunication. They told me that the 12 volt positive lead be not on the factory wire harness on this truck. They told me I have to wire it into the fuse box….

2003 Honda Accord:radio panel go black(radio and compact disc still work). Does anybody know what’s wrong beside it?
Can I fix it instead of taking it to Honda dealer? Thanks

2003 Jeep TJ subwoofer does not play at adjectives?
Hey Guy’s, I have an 03 Jeep TJ Sport with the opitional 7 speaker system next to a subwoofer, It was working fine and all of a sudden soon it just stopped playing. I remember driving over a bump when it happened, that be roughly a…

2003 nissan murano, six disc changer, skips when it cold, what to do?
Wife’s car. When she get in it within the morning. The cd player skips till the vehicle is warmed up. Trying to numeral a way to maintain this from happening. To hold wife happy. Any planning, other than warm the car up back using the cd…

2003 pontiac august am near a monsoon stock nouns system. I want to make a payment subs, but I want to hold my cd player?
I have a 2003 pontiac splendid am with a stock monsoon nouns system. I have two 10″ subs and a 460 watt amp that I want to attach but I don’t know if I can run it all near my stock monsoon cd player. How do…

2004 Corolla S In-dash disc Player install?
Ok bear w/ me, I’m surrounded by no way “sports car savvy”. I am getting a 2004 Corolla Sport in January. I want to win a better CD player than a short time ago the stock one like one beside an aux jack for my…

2004 mazda 3 speaker cross-question?
i have a 2004 mazda 3 sedan and am looking to replace my factory door speakers. crutchfield tells me to use 6×8 or approaching 51/4 in the doors. im not sure which size to go beside. i also have a 12 inch sub in the trunk…

2004 Nissan Xterra CD Player (Best Answer?)?
I have a friend with a 2004 Nissan Xterra It have the stock manufactured AM/FM and CD player double din She put a CD in it, it worked for a while, and now it won’t come out Where can I find the reset button or…

2005 Chevy Malibu Head-unit flex code??
A friend of mine Tryed to put in his own after market cd player and cut the factory telecommunication harness. And he wants to wire the after souk cd player to the cars wire’s if any one no’s what each of the car’s wire’s do please…

2005 F150 Radio Wire Harness?
Do they make wire harness for a 2005 F150 nonetheless?

2005 Pontiac G6 compact disc Changer Error?
My 6 disc cd changer keeps giveing me a error mesage of “cd changer error” Pontiac give me a quote of $350 to install a new radio….and my warranty is up. Please Help

2006 ford f-250 super duty series……..saloon stereo??
is it my disc or can it just not play my mp3 disc??

2006 Mustang – iPod hookup?
I have a 2006 Mustang and I be wondering how I could hook my iPod up to the stereo without using the radio attachment. I hold the Shaker 500 Stereo System. PLEASE HELP! Thanks.

2006 Pontiac GTO (Sunroof and XM radio Integration)?
I think I am going to buy a 2006 Pontiac GTO, but it does not hold a sunroof or XM satellite radio, dose anyone know if I can put a sunroof in an 06 GTO? What is the best style to integrate satellite radio into a GTO…

2006-2007 mx5 miata door panel removal?
would anyone know the process for removing these door panels? ive tried near no sucess! the reason is that im trying to put up to date speakers in. Thank you within advance!

More Auto audio questions please visit : YesImAuto.com

YesImAuto.com

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★★★★ general motors radio wire harness color diagram

♔♔♔ general motor radio wiring diagram The following wire harness applies for General Motors Radio. Herein you will find detail information about the color diagram of GM radio wire harness e.g. Pin A for right rear speaker has a light blue color for typical GM factory in Dash Wire Color while it is purple with black stripe for typical new radio equivalent wire color. Another example, Pin B for left rear speaker is yellow for typical GM factory in Dash Wire Color, while it is green with black stripe for typical new radio equivalent wire color. (Source: installdr.com)

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★★★★ 1996 yamaha tdm850 wiring diagram and electrical system

♔♔♔ yamaha tdm850 wiring diagram The Yamaha TDM850 is a Dual Sports or Adventure Sports motorcycle produced by Yamaha Motor Company of Japan, that first came out in 1991. The following wiring diagram and electrical system troubleshooting manual actually part of 1996 Yamaha TDM850 service manual. Herein you will find detail information regarding electrical system troubleshooting guideline and wiring diagram harness schematic of TDM850 which covers discussion on electrical components, switch inspection , ignition system circuit diagram and troubleshooting, electric starter system, starter motor, charging system, lighting system check, signal system wiring diagram, throttle position sensor self diagnosis.

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★★★★ 2006 yamaha wr250f electrical system and wiring diagram

♔♔♔ yamaha-wr250f-electrical-system-and-wiring-diagramThe following electrical system and wiring diagram manual applies for 2006 Yamaha WR250F. Herein you will find brief and detail information about electrical components, cable routing and wiring diagrams of Yamaha WR250F series. The electrical component discussed in this material covers headlights, multi-function display, engine stop watch, clutch switch, diode, starter relay diode, throttle position sensor, starter relay, fuse, CDI unit, etc.

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★★★★ 2001 toyota rava electrical wiring diagramhtml

♔♔♔ toyota-rava-electrical-wiring-diagramThe following wiring diagram applies for 2001 Toyota RAVA series. Herein you will find brief description and illustration on Toyota RAVA electrical system which includes Anti-Brake System Circuit, Air Conditioner System, Cigarette Lighter, Door Lock Control, Headlight, Horn, Remote Control Mirror, SRS and etc. Find the details illustration of 2001 Toyota RAVA Electrical Wiring Diagram here (58 pages of pdf file docs. PASS: wiringdiagrams21.com)

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★★★★ 2001 toyota rav4 car wiring diagram

♔♔♔ toyota RAV4 wiring diagramsThe following car wiring diagram applies for 2001 Toyota RAV4 models. Herein you will find detail description and illustration of the electrical system, parts and components, and wiring diagram of the vehicles. This manual is divided into sections which are relay locations, electrical wiring routing, overall electrical wiring diagram, connector joining wire harness and connector list. Following are parts discussed in this article: anti-lock brakes system, air conditioner, back-up light, charging, cigarette lighter, door lock control, horn, power heater, radio and player, remote control mirror, seat belt mirror, stop light taillight, wireless door lock control, etc.

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