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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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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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★★★★ honda acura integra connector and wiring harness location 98 01html

♔♔♔ Acura Integra Wire Harness and Diagram Following connectors and wiring harness location apply for Honda Acura Integra (98 – 01) model years. Here you will find brief instruction and procedures of how to identify the connectors and wiring harness of the vehicle. This manual covers starter cables, battery ground cable, engine ground cable, engine wire harness, A/C wire harness, engine compartment wire harness, main and rear wire harness, dashboard and door’s harness, hatch wire harness, etc.

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★★★★ fordlincolnmercury radio wire harness

♔♔♔ Ford Lincoln Mercury Radio Wire Harness The following wire harness applies for Ford Lincoln and Mercury Radio. Here you will find information regarding standard wire harness connectors and common ground wiring of the vehicles. Most major auto makers use the same wire colors yea after year. However, Ford does not consistently use the same wire colors. Two identical vehicles can have different wire colors depending upon the year of the vehicle where different models may have completely different wire colors from all other Ford vehicles. Ford uses 3 wiring configurations which makes it difficult to accurately show correct radio wire configurations and wire colors. (Source: installdr.com)

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★★★★ toyota prado wire harness 2000

♔♔♔ Toyota prado wire harness The following wire harness applies for Toyota Prado 2000 model year. Here you will find brief illustration of the electrical system and wire harness diagram of the vehicle. This article covers topics on air conditioner system, central differential lock diagram, charging circuit, combination meter system, condenser fan diagram, cruise control circuit, engine control wire harness, engine immobilizer system, starting system, SRS circuit, fuel heater diagram, connector list, etc.

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★★★★ honda civic radio installation guide and the wire harness

♔♔♔ Honda Civic Radio Installation Guide and the Wire Harness The following article describes radio replacement and installation guide, also wire harness and schematic of Honda Civic 1996 – 1998 model year. Here you will find detail overview of civic radio Installation procedures, parts needed for the radio installation, tools, and supplemental information (including basic DC electronics for automotive applications, wire splicing, testing wire and wire harness), etc.

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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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★★★★ honda prelude wiring harness routing and ground location 88

♔♔♔ The following diagram and schematics shows 1988 Honda Prelude Wiring Harness Routing and Ground Location of engine compartment (including engine ground wire, engine wire harness, battery wire harness, engine compartment wire harness, radio condenser ground wire, defogger wire harness), floor, trunk, door, roof and dashboard.

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★★★★ car stereo wiring harness catalog

♔♔♔ Car Stereo Wiring Harness The following file (PDF type) contains detail information about Car Stereo Wire Harness. The wire harness include Sony XR-4220, Pioneer KEH-2900RDS, Pioneer KEH-1300, Pioneer DEH-P545R, Sony XR-340, Sony  CDX-340, Sony XR-U220, SVCKS-FX220, Chrysler 2001, Toyota, Daihatsu, Plymouth, Dodge, Mitsubishi, Kenwood, Honda Passport, Car Stereo Set, Car Connector Line, etc.

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Cheap Car Alarms, Practicality at Its Finest

Car alarms are essential these days die to the growing number of car thefts. If you are looking for practical means to afford one, there are inexpensive car alarms sold in the market already. Make sure that even if it’s the cheapest car alarm, it is still of good quality.Body: Car alarms are electronic devices that are installed in a car or any vehicle in order to discourage thieves from stealing a car or a vehicle and its contents. Car alarms emit a high-volume sound when someone triggers the alarm. The sound of car alarms are usually like a klaxon, a siren, verbal warning, the own horn of the vehicle or a combination everything mentioned.
Listed below are some tips on how to buy an affordable car alarm with good quality. The tips will help you spot a good car alarm from the bad one. This will also help you find the best way to find an installer for your car alarm so as to avoid any problems from occurring.
• Most people search on the World Wide Web in order to look for a cheap car alarm. The internet is full of websites that sell car alarm accessories and car alarms. The internet is also the best place to find cheap car alarms. The newest model of car alarms are those that page the owner via its remote that can work even at a maximum of 3000 ft whenever there is an intrusion. There is also a model that is called a “GSM based car alarm”. This so-called GSM based car alarm will call the owner on its cellular phone if there is a possible intrusion to the car. This can even allow the owner to listen to the activity inside the car. With this new innovation, the owner can now shut down the engine and talk to the robber with just a push of a button from the owner’s cellular phone. Advancements in car alarms include the GPS feature where in the owner can track the car’s or vehicle’s whereabouts via cellular phone.
• Some people buy either directly from a dealer, purchase from a shop or via internet transactions. There are many kinds of alarms for your car and different brand names as well. In order to differentiate which car alarm is of good quality, check its wiring harness. The thicker the wire, the better. This is due to the fact that it can withstand the electrical current. Low quality car alarms use very thin wiring.
• Look at the diagram of the wiring. Most good quality car alarms use the same color coding. This is while car alarms of low quality use a different one. The idea of a universal color system makes an experienced installer install a car alarm in no time. If the color coding is different, the installer can have a hard and long time installing the car alarm. This can also waste precious time and money if ever the installer charges his services by the hour.
Below is a list of how the wiring must be coded.
The “RED” wire is equal to 12+ Positive
The “BLACK” wire is equal to Negative Ground
The “WHITE” wire is equal to Parking Lights
The “BROWN” wire is equal to Siren
The “BLUE” wire is equal to Shock Sensor or Sensor Input
The “ORANGE” wire is equal to Negative when Armed
The “VIOLET” wire is equal to Door Lock
The “PURPLE” wire is equal to Door Lock
The codes listed above are basically the wire connections on the car alarm’s main harness. Alarm systems have lots of wires but the ones listed above are most important ones that any customer must look for.
• When choosing a car alarm, buy the one that comes with or without the integrated immobilizer. In the United Kingdom, choose the Non Tatcham or Tatcham approved car alarms. Most cheap car alarms are easy to install or can be a DIY (Do It Yourself) type. The Tatcham approved alarms should be installed by a qualified and experienced installer.
• The cheapest car alarm that is of good quality is the Non Tatcham alarms that have no immobilizer. This car alarm is available via a do it yourself installation. The only thing that the owner will do is to connect the courtesy light, sensors, central locking and power supply. If the owner arms the car alarm, the “central locking technique” will allow the cars to lock as well as close the windows because of its automatic window closure technique.
• Most cheap car alarms cost only 100 dollars but their quality is superb! Listed here are two cheap car alarms:
1. Wrap Steering Wheel Lock: This car alarm is cheap and has a four-star rating. This kind of alarm covers the vehicle’s steering wheel so that the airbags will not be stolen. This steering wheel has a dual function since it works as a car alarm and a steering wheel lock. These are practically provided in one simple package. This is the reason why this car alarm has a high rating. The buyers of this product loved its results.
2. The so-called Crime Stopper: The “Crime Stopper” or the “CS2011DPII Deluxe Vehicle Security Alarm/Remote Start Combo” contains a siren that has up to 6 different tones. The tones of this car alarm is being projected at a high decibel level meaning no one will be able to ignore this alarm once it has been triggered. The “Crime Stopper has about 4 outputs where in 2 are programmable and the other 2 outputs are fixed. This car alarm also has about 30 diverse programmable options.

For more information on Cheap Car Alarms please visit our website

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