Cable Assembly Design

Factors to Consider When Designing A Cable Assembly

  • When it comes to cable assembly design, a number of factors need to be considered such as, work load, abrasion, cycle life, and flexibility, environment, cost, safety.
  • The larger the cable diameter, the greater the work load capacity. For most applications, use a 5 to 1 safety factor when designing an assembly.  For critical safety or shock load applications an 8 or 10 to 1 safety factor is needed.
  • The larger the diameter of cable, the less flexible it will be.  Example:  1/8” 7 X 19 cable is more flexible than 1/8” 7 X 7 cable, but the 7 X 7 construction is more abrasion resistant.
  • Stainless steel cable is more corrosion resistant than galvanized but has a slightly less tensile strength.
  • Coated cable can greatly extend the life of the assembly in most applications. If using coated cable, the coating must be stripped off when swaging to achieve the maximum strength.
  • The tighter the tolerance of your cable harness assembly, the higher the cost of the cable.

Be sure to also check out our conduit cable offerings.

If you require any assistance with cable harness assembly, wire rope tether or anything else, feel free to call!