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Circular cable assemblies, or CCA, are standardized plugs and cables used in a wide variety of electrical applications. Typical applications of circular cable assemblies include telecommunications, automotive, medical, audio/video, and more. CCAs are available in a wide variety of configurations, including multi-conductor, single-conductor, shielded and unshielded, and multiple-contact.

The term “circular cable assembly” comes from the round shape of the connector used to attach the cable to its related equipment. CCA connectors come in both metric and imperial sizes, each with its own design features, such as pin configurations, pin and cable insulation types, and cable end terminations. The most popular sizes are DE, DB, DIN and DMC.

CCAs are designed to meet specific current and voltage ratings, depending on the specific application. The pins of a circular connector typically have a copper alloy with gold plating, which offers superior electrical performance. The outer shell of the connector is typically made of a plastic polymer hybrid material, with the cable secured inside the connector by a compression-fit ferrule.

An important factor to consider when using a circular cable assembly is the contact resistance. Contact resistance, measured in Ohms, describes the resistance of an assembly’s pins to current flow and is affected by the type of material used in the pin construction, the number of contacts, and the assembly’s configuration. Low contact resistance is necessary to ensure the long-term performance of the CCA.

When put into operation, a circular cable assembly usually operates between two or more devices. It is commonly used in both power and signal applications. The power applications use the conductors of the CCA to carry higher currents and dangerous voltages, whereas in the signal-based applications, the CCA is used to transfer digital and analog signals from one device to another.

The CCA is mainly composed of a plug-in part and a detachable part. It has a lot of advantages, such as quick disassembly and assembly, a wide range of applications, convenient installation, low design cost, high performance, simple construction, good shielding effect, and small space required. It is widely used in electronic equipment, audio and video equipment, interior decoration, communication equipment, computer systems, industrial automation systems, etc.

There are many types of CCAs on the market, such as receptacles, molding, splices, extenders, tension-locks, and more. Receptacles are typically used as the cable portion of a CCA, as they provide insulation, heat resistance, and wiring protection between the outermost cables and the electrical terminals. Molding, or “molded overmolding”, forms an insulation barrier around the base of the CCA. It is typically used to protect the pins from extreme temperatures and corrosion.

Splices are used to join two CCA cables together, providing a secure connection between the end-points. Extenders connect two CCAs together, extending their length and versatility across applications. Finally, tension-locks are threaded connections that secure the cables and pins in place.

The design and engineering of CCAs is critical to protect against electrical hazards, provide mechanical strength, and ensure the proper performance of the equipment. It is important to consider the environment in which the CCA will be operating and to verify that the connection is capable of withstanding the mechanical, electrical, and environmental conditions.

In conclusion, CCA’s are a widely used type of connector in a variety of applications. They provide a secure, reliable connection and offer superior electrical performance. With the wide range of sizes and configurations available, engineers are able to select the optimal CCA for their specific application.

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