What is Thermocouple Wire? Types, and Uses, an Overview

What Is Thermocouple Wire? Thermocouple wire or cable is used within a thermocouple that senses temperature using the point of cold junction compensation. Thermocouple wire is used to control instrumentation and for building the sensing point in a thermocouple and is made out of two dissimilar metals. Overmolded Thermocouple cable Usable Lengths of Thermocouple Wire There are many factors that impact the usable length of a thermocouple. The two main factors that affect the usable length of thermocouple wire are total loop resistance and electrical noise. Thermocouple wires are made of different conductor materials. Because of this, the total loop resistance varies from based on the type as well as the wire diameter and length. However, the main goal for a usable length of thermocouple wire is to keep the loop resistance under 100 ohms. With the other factor, the longer the wire, the higher the possibilities of it getting influenced by electrical/radiated noise. This long length of the wire will then affect the performance of the wire. As such the usable length of thermocouple wire is recommended not to run or exceed a minimum of 10 feet. And in case the wire is extended it is recommended to use a shield to reduce the noise interference to an acceptable level. For this purpose, a metal over brad or twisted shielded wire can be used. At the same time avoid running wires closer to sensitive areas like motors and power wires. All in all, the recommended goal for a usable wire length is to keep the wire reduced to less than 100 feet with 20 AWG or thicker wire in an area free of electromagnetic interference. Now with the recommended lengths defined, let’s get into the types of thermocouple wires available and how they differ....

One of the most significant elements of an electronic or electrical system is the cable assembly. But still, it is one of the last components that is addressed or given importance to. In fact, an over or under designed cable assembly will have a tremendous negative consequence in the performance of the electronic system. What is A Cable Assembly? Cable assembly is a group of wires or cables that are organized and integrated into a single unit. Cable assembly is primarily used to transmit power, signals, and information to the designated application and to provide cables protection. Cable assembly also makes an application easy to use, repair and maintain. A cable assembly is also known as wiring looms or cable harness. You will be able to find cable assemblies of various sizes, colors, lengths, and sizes depending on the application. Anyway to give you a more detailed view on this topic I have an interesting flow of subheadings below. How It Works As we might know electronic devices and applications deal with many cables that are often overwhelming to maintain. Think of an instance where the cables are tangled and the pain to untangle them. This can even cause disruptions in the flow of signals and power. So what a cable assembly does is bring the different cable components in an application or device to a single unit in a neat and well-organized manner. This will prevent the cables from getting all over the place and make it easier to use and maintain. In addition, rough usage of cables and other unpredictable weather conditions can easily damage cables and disrupt their functioning. So under a cable assembly, all the cables are neatly bundled in an extremely durable sheet of material of exterior covering. This will thereby...

Electrical Wire Harness Design Basics, Steps, Common Mistakes, Advice Electrical wire harness designing is possibly one of the significant steps which allow any electrical device to work, especially helping a vehicle to work the way it is meant to. In fact, the success of an application and its relationship with wires and the overall flow of current is all anchored to how well a wiring harness is designed. What is a wire harness? A set Wire harness is the assembly of wires or electrical cables to transmit signals or electric power. The wires are bound by a durable material such as nylon tie in the assembly process. It’s the wire harness that ensures the reliability of effective energy and information transmission in an application. So there’s plenty more we can tell you about wire harnesses, but in the article, we’re going to give you a basic overview, the steps to guide you on design and construction. Where Wire Harness Assemblies Are Used Wire harness assemblies are used in a multitude of different environments. The motor industry, aerospace, military applications, consumer products, and even for home projects. Many of these applications will contain multiple wire assembly harness installations and many are integral to enable the machine, vehicle or product to work effectively. When Wire Harness Assemblies Should Be Installed Wire harness assemblies are used in a multitude of projects that contain and rely on a variety of wires and cables that function to complete different tasks. The challenge for most cable installations is that the cables and wires themselves are difficult to organize and keep straight and neat. A wire harness assembly can keep things better organized and help the project and installation install more easily and for the whole unit to...

Cables are definitely one of the most confusing and complicating things to understand. Especially when it comes to choosing a cable that better suits applications. In recent times molded cables have become an attraction among many users. In fact, it’s now becoming one of the comfortable cable options for users. What Is Molded Cable? Molded cables are created by injecting heated molten material into a mold cavity. The mold mechanically attaches the connectors to the cables making it a single part. This gives the cable the ability to withstand vibration, shock, and flexibility along with good exposure to a harsher environment. Molded cables have become extremely important among many users. But many users rarely notice they use a molded cable. This applies to everyday objects; you perhaps didn’t know your phone charger had a molded cable. So let’s give you a clear guide on these types of cable. How a Cable is Molded? The molding process takes a great deal of pressure in forcing material into a mold cavity. It all starts by installing molding materials into the heated barrel of the molding machine. When heated, the material melts and turns into a resin. Any desired colorants can be mixed at this point. The resin mixed with the colorant is then forced into the mold cavities. After cooling, it will then take the appearance of the mold including any trade names, logos and so on. Pretty useful right? Now let’s see the types of molded cables you can come across. Cable Inner Pre molding In Mold 2 cavities After Over molding Types Of Molded Cables There are many types of molded cables that are offered by different brands in the cable industry. However, they all more or less narrow down to the following types of molded cables. Standardized Molded Cables...

Low pressure Molding, What Is It, How It's Used and Where, the Process Low pressure molding is a technique we all see and encounter in our everyday lives, even though you may not realize it, low pressure molding is integral in many of the appliances and equipment you may use daily. It silently goes about its business and you probably don’t give it a second thought. Here at QL-Custom we have many years of experience with low pressure molding, so we thought we’d share some of the main points about this process with you in this article. Here’s a quick take away answer for you, then we’ll dive deeper into the process and benefits of low pressure molding, not only for applications but for the environment too. So What is Low Pressure Molding? Low Pressure Molding is a technique for protecting and encapsulating components prone to damage, moisture, or other external influences. Typical in applications such as wiring and printed circuit boards. Using materials known as hot-melts, polymers are used to seal around components using specialist machinery. Dimer acid based Polyamide materials often referred to as ‘hot-melts’, are thermoplastics that, when heated to specific temperatures become pliable and malleable for use around precious connectors and connections. Why it’s called Low Pressure Molding Low pressure molding, (or LPM) in particular, is as the name suggests, the use of lower pressure processes and techniques used where components may suffer from the normal pressure or extreme heat otherwise used in more industry standard pressure molding applications. To reiterate, there are two main reasons an application may require the use of Low Pressure Molding. Malleability One major factor is the need for the applied thermoplastics to be more viscose. Viscosity allows the injected material to be applied...

How to Find Suppliers in China and deal with them

1) How to Find Suppliers in China and deal with them ? In recent years, China has seen an enormous surge in interest from foreign businesses. This is all thanks to the country’s low manufacturing and labor costs as well as the huge market potential it has to offer. Still, even with all the hype, finding the right supplier is not as easy as it seems. When looking for a supplier in China, it is not a matter of finding one as there are hundreds, probably even thousands who are able to produce your product. Your goal is to find a reputable manufacturer. What Should I consider when dealing with China supplier ? Understand your Product Requirements Before you begin searching for a manufacturer in China, it is crucial that you know the most important features of your product. Create a list of product specifications and requirements based on your buyer’s needs or your end goals to help you choose the most suitable manufacturer. Source for Manufacturers Starting out with nothing when you are trying to establish a business relationship can be daunting. However, it is not impossible. While an internet search is convenient and cost-effective, we highly recommend looking into manufacturers that have already been inspected by a third party like Thomas or CBP (Customer and Border Protection). Build a list of at least ten potential suppliers that you can easily and promptly communicate with directly. Building an extensive list is crucial as it reduces the feeling of scarcity in your search for a dependable manufacturer. Verify Reliability As with any new business partnership, it is crucial that you perform due diligence before signing any agreements or making payments. One great way to verify a manufacturer’s reliability is by conducting a supplier audit. The audit should cover; A...

What is Injection Moulding ? Injection molding is a manufacturing process used by Steel Mold Tool , the melt plastic been pour into the mold cavities after instant cooling and output the same shape parts. Injection moulding is mostly used when creating a large number of identical products in a short lead time(current 3weeks). The process can be performed with variousPlastic Materials including polymer, elastomers, thermosetting resins. Injection Molding including Horizontal Plastic Molding and Vertical Injection Molding, plastic molding tool is much larger than the vertical injection molding tool. Currently plastic part molding by a large mold like light cover, containers, bottle caps, home appliances, plastic parts, electronic box, screen frame, toys and so on. Vertical injection molding often to be used in encapsulation on cables assemblies and components. Horizontal molding machine Vertical injection machine Today a big percentage of manufacturers are using injection moulding to create products in an accurate and faster way. You will find that all the parts are computerized in the injection moulding machine something that means all the work will run independently like a clock and the outcome that you will get will be accurate. A good example of an industry that utilizes injection moulding a lot is the car manufacturing companies. Some of the things that are made using the technology is the lid of a car’s radiator. There are so many cars that are made every year all over the globe and this sort of process is used to ensure there is high accuracy and speed. How much does injection molding cost ? Currently vertical injection molding tool is far cheap than a plastic part mold tool. It determined by the steel you selected, high expensive steel cost you hundreds or thousand of U.S. dollars for steel itself. Since designing a molding tool...

Low pressure molding Low Pressure Molding History 1972 :France IBM first time. 1987 :Eruope automotive start to molding for electronics 1993 :Use for France automotive wiring harness industry 1995 :Wide use for automotive and extended to electronic 2000 :Use for PCB, Sensoring Device and connectors. After2000: Wide range use for worldwide inudstries. What is Low Temperature molding The low pressure injection molding process is a packaging process that uses a very low injection pressure to inject the encapsulating aterial into the mold and quickly solidation. In order to achieve insulation, temperature resistance, impact resistance, reduce moisture, waterproof, dust, chemical resistance. Applies to: circuit boards, electronic connectors, wiring harnesses, batteries, switches, LED lights, coils, etc.. Advantages Short injection cycle Resin Materials environmental protection The compound does not have to be mixed Thermoplastics do not require solidation time High reliability Simple mold design Advantage of Overmolded parts Waterproof Insulation Impact resistance Temperature resistance Chemical resistance Scrap No harm to the environment Charactors of the PA PA materials elements Plastic Resin Elements Dimer acid based polyamidoamines are the result of Dimer acid based polyamidoamines are the result of polycondensation between diamines and dibasic acids. Where the low pressure plastic resin come from? Dimer acid extracted from common agricultural products Castor oil Corn oil Linseed oil Peanut oil Vegetable oil Tall oil What is the color of Low Pressure materials The material is granular Generally black or amberCan be made into other colors Our provide materials including Inejction Pressure1-200psi(0~60kg) Molding temperature160° C~230° C Protect the property of IC and components Charactor PA/PO/PET/PUR QL-Custom sufficient stock QL-Custom Professional advice Envirmetal Good insulation properties, flame retardant properties and corrosion resistance How to select the materials of low pressure molding ? ...

How to Strip the cable metal braids ? Why need to use flash stripping machine ? A lot of cable factory have a big question that how to cut the cable braiding and Foil tapes, today we are talking about how to strip the cable metal braids quickly and look beautiful. Some of the braiding under the shealth or out of the cable jacket , first position only application for shielding for transmission signal ,keep the cable transfer the signal normally. But the out of braid not only for signal shielding ,the most important function for abrasion proof. While the factory handle the cutting during mass production course it is current a head-hurt problem and can’t keep up the pace of delivery time. As the development of this industry , some people create a machine named Flash Stripping ,using the short-time high voltage and high electrical current to melt the braids. It would break a little of the jackets ,but didn’t breakdown the cable jackets at all. And the fronts are easy to pull off. This way proved our efficiency very quickly. Just one second speed to peeling off. You can take off the braids easy now How to set the parameter on the machine ? 1\ Set the time use about 1 second , or 2~3 seconds if the thickness is too much, 2\ Set the Voltage and current on fuse blade. Instant high current will fuse break the metal mesh 3\ Test again the fuse temperature verifying the cable jacket has some break, if so, turn down the temperature set. See our video to learn strip cable braid off 1 second only What it looks like after stripping & What service we can serve? After instant stripping the cable braids and shieldings, you...

Overview of custom cable process Are you a major stakeholder in aerospace, telecommunications, satellite, broadcast or transport industry looking for bespoke custom cable services? Is your project in need of custom cables that exceed “industry level” standards? Well, look no further. We’ve got you covered. Say hello to precision engineering We distinguish ourselves as the best in cable solutions. With many years’ experience to boot, excellent services, product innovation and reliability, we guarantee you high quality, durable and bespoke cables. As a company with unrivalled dedication to precision enginering, we will design custom cables that blend effortless into your application. This is the ideal solution you are looking for. Quality is guaranteed. Gives us a drawing-print and watch as it comes to life Here is a breakdown of the process – from design right to application. First, draft a drawing (blueprint) of the cables and send it to us. Our team of experts will analyze the blueprint and quote a price for you. Note that if you do have a sample from which you want us to replicate in mass production then you should send it to us. If you are OK with our quotation, we will build a prototype with the same labels, terminals and circuitry. Feel free to request for a redo otherwise a nod should do for completion of the project. You can never go wrong with the decision to choose us as your custom cable solution. We have established ourselves as the partner of choice for other entities just like you. Our excellent track record, satisfied clients and engineering prowess speaks for itself. Contact us now for a bespoke solution. Whether it is coaxial cables, multicore cables, power cables, multipair cables, ribbon cables, RJ45 patch lead cables or...