Depending on the situation, you may be required to design a custom electrical connector or interconnecting cable assembly. When designing a cable assembly, take a moment to consider these tips regarding major design aspects. By following this outline, you'll be well on your way to designing your newest cable assembly.

1. Electrical Requirements

Most importantly, be sure to review the electrical requirements, such as the operating voltage (AC or DC), operating current, number of contacts, shielding of cable (or lack of shielding), and corona/partial discharge requirements. Understanding your electrical requirements will help you source the correct materials for your cable assembly.

2. Cable Type

Consider what sort of cable will best suit your application. There are countless options available when looking at custom cable, so be sure to ask yourself the right questions. Does the cable need to be shielded, dual extruded or triple extruded? Should it be round or flat? How many conductors are required?

3. Operating Environment

The next consideration is where your equipment will be used. Will your cable assembly be exposure to damaging chemicals or oils? What temperatures can you expect it experience? Will the cable be subject to bending, pulling or repeated movement?

4. Coupling Mechanism

The coupling mechanism is also an important factor that bears examination. Will you be using a threaded, bayonet or push-together coupling mechanism? Each has its pros and cons, such as the threaded coupling connector providing a secure mated condition while the push-together is very quick to mate and un-mate but is not as rugged. Consider which will be work best in your application.

5. Termination

Finally, determine which type of termination you will be using. The are many factors to consider. For example, the use of factory terminated connectors, molded or potted to their high voltage cable, ensure the highest quality and dependability. Field termination or non-factory termination kits are available from many suppliers.