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Circular Cable Assemblies

Circular cable assemblies are mainly used in applications that require multiple cables or cable connectors packaged into a wide variety of shapes. This could include circular, conical, rectangular or other complex shapes. This form of cable assembly is highly advantageous for applications that require fast installation, high-flexibility and resistance to shocks or vibrations. Examples of applications using circular cable assemblies could include three-phase AC systems, power grid systems, automotive systems, medical machinery and automated industrial machines.

Principle of Operation

The basic principle behind the working of a circular cable assembly is to bundle multiple wires or cables into a desired shape. First, the individual cables are cut to the desired length and the ends are stripped to expose the conductor strands inside the cables. The ends of the cables are then joined together by soldering or wire-wrapping techniques, forming a new cable bundle. This bundle is then shielded with a flexible metallic shield, which acts as a protective cover for the cables. This shield is then covered with a second layer of insulation to protect the shield from any external damage. The shield and the insulation protect the internal cables from any physical and electrical damage and help maintain the desired shape of the cable assembly.

Advantages

One of the major advantages of using a circular cable assembly is that it enables the user to customize the shape of the assembly according to the requirement. This allows for efficient routing and ensures a more compact design, as compared to other cable assemblies. Additionally, circular cable assemblies offer several levels of protection to the cables within, as the bundle is covered with multiple layers of insulation and a protective metallic shield. This helps protect the cable assembly from external damage or environmental conditions such as moisture, dust or vibration. Circular cable assemblies are also easy to install, repair and maintain, as any problems can easily be detected and remedied.

Disadvantages

Despite its many advantages, the use of circular cable assemblies is not without its drawbacks. The main disadvantage is the cost associated with creating the desired shape of the cable assembly. The procedures involved in creating the assembly, such as cutting, stripping, soldering or wrapping of individual cables, can be costly and time-consuming. Additionally, the materials used in the assembly, such as the insulation and shield, can be expensive. Therefore, it is important to consider all factors before deciding to use a circular cable assembly.

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