Custom Cable Case Studies

Application

LED lighting systems for poultry and swine barns

Background

The customer had problems with the cable being difficult to work with, and the light fixtures were very hard to install.

Solution

We were able to create a cable with a slightly smaller diameter cable and a softer durometer jacket material to make installation easier. This custom cable will make installation time significantly shorter, and eliminate the need for a soap bath slipping agent, which will remove at least two steps in the installation process. The end result is a cable that is much easier to work with, lower material cost, and significant savings in labor costs.

Application

Digital displays installed over roadways to inform motorists of traffic delays, road hazards, driving times, etc.

Background

Off-the-shelf cables were limited in options, not cost-effective, and unable to meet the electrical requirements and temperature of the application. The conductor of this custom cable needed to be minimized so that during processing the cable would fit in terminals that had been specified.

Solution

By creating a custom cable, we were able to provide a twisted pair design to replace the current bonded pair design, resulting in a cable that was easier to process, and lead to a lower cost finished assembly. Also by working with Lapp Tannehill, our customer was able to reduce their lead time and soft cost savings to their supply chain.

Application

Paving equipment

Background

The customer needed a cable that would work with a specific cord grip since they weren't able to change the size of the cord grip. They were having problems with their current cable meeting their OD requirements. They needed a cable that would fill their needs for fit, form, and function The customer also wanted to outsource due to having internal, highly skilled individuals that were executing fairly mundane tasks building the assemblies.

Solution

By creating a custom cable, our customer was able to combine more than two cables into one, thus seeing a benefit in time savings. This also helped realign skilled employees to more challenging tasks, keeping them more engaged and heighten the likelihood of remaining with the company.

Application

This cable is being used to supply power and control to a telescoping crane in a high radiation area at a test facility. One cable reel will be mounted either to the bridge or the wall and will take in/pay out cable as the crane travels. A second cable reel will be mounted on the trolley and will take in/pay out cable to the trolley and hoist as the trolley runs back and forth.

Background

The customer was using multiple different gauge sizes, along with some shielded pairs. They wanted to group them all into a single cable as it would be going into one connector.

Goals

The main goal was to reduce the number of cables, preferably into one. The jacket and insulation also needed to be resistant to Gamma Radiation, along with OD constraints to be met, and specific bend radius.

Solution

We were able to engineer the cable to the exact specifications that the customer required. The conductors were arranged in a way that made the cable flexible enough to pass through the tight constraints. The insulation and jacket material will hold up to Gamma radiation for 10+ years of use. Printed custom markings were added to each of the inner conductors to differentiate conductors and simplify installation.