In Focus: The Ferrite Bead

 

A ferrite bead is a passive electric component that suppresses high frequency noise in electronic circuits. It is a specific type of electronic choke. Ferrite beads employ the dissipation of high frequency currents in a ferrite ceramic to build high frequency noise suppression devices. Ferrite beads may also be called blocks, cores, rings, EMI filters, or chokes

Large ferrite beads are commonly seen on external cabling. Ferrite beads are one of the simplest and least expensive types of interference filters to install on pre-existing electronic cabling. For a simple ferrite ring, the wire is simply wrapped around the core through the centre. The introduction of the ferrite core around the wire increases the wire’s self-inductance, and thus still absorbs energy from noise in the wire.

Ferrite beads prevent interference in two directions: from a device or to a device meaning that the energy is either reflected back up the cable, or dissipated as low level heat.

The Ideal ‘Route’ for your Wires and Cables

Wire and cable routing is a significant point of product design and specification and one that is often overlooked. Choosing the right route for your wires and cables not only improves the aesthetic appeal of the product but also improves system performance and product maintenance.

Good routing allows for a longer product shelf-life, ease of assembly solutions and provides an improved solution to repairing and maintaining routes for access around cables.

Most products connect a variety of components together to make the complete product. Connecting a PCB, switches, relays, motors, and other components together often includes a number of cables that must be positioned to allow for final assembly at a minimum for the product to work and be visually appealing.

Choosing Express Assemblies Ltd: The ‘Ideal Route’

At Express Assemblies Ltd, we are often asked to help customers with the routing of their wires and cables. With a number of ‘routing’ measures, the company ensures to meet all project demands and offers a number of solutions, to what for some can cause a real headache and lead to complete project redesigns.

Why not consider:

• Wire or Cable Loom/Harness: A wiring loom or cable harness is a very useful solution to help with the routing of wires and cables. Harnesses and looms can be created in a number of ways from using off the shelf components to strategic placement of cable ties or electrical tape. The advantage of a proper cable harness is that all of the wires and cables share a common path through the product that can be easier to secure and protect the wires from damage, vibrations, and the environment. Also using a single-routing path is often a better use of space, the risk of wires shorting is reduced, and installation becomes simpler.
• Cable Identification Methods: Using Express’ cable-identification methods such as single-character wire markers or heat-shrinkable labels offers an ideal way to trace and identify any wires and cables.
• Wire and Cable Cut and Strip Length: As a wire cut and strip business, Express is very knowledgeable of the fact that the less wire you use [i.e. the length of wire] in your wiring routes, it offers a significant cost saving but also reduces opportunity for RF and EMI noise to get in and disrupt electronic pulses and signals.
• Wire and Cable Types: With Express Assemblies stocking a wide variety of wire and cable types, we can also advise what types of wire and cable would be the best choice for your routing enquiries. The current a wire will carry as well as the voltage of the signal are two of the key wire selection factors that must be taken in to account.
• Routing Channels: Express Assemblies offers a number of ‘routing channels’ that offer a flexible and adaptable approach for any wire and cable routing problem. Using tubing and sleeving, as well as a large range of cable management techniques, we can approve and apply our designs to most applications.
• Fasteners and Fixings: With our extensive inventory of fasteners and fixings, we can provide an easy and quick installation approach to secure and fasten any wire or cable route.

 

Man v. Machine

So as reported in this month’s Assembly Magazine,” a new generation of robots are redefining man-machine interaction and rewriting the way that automation can be used in manufacturing environments. Collaborative robots can perform a variety of repetitive assembly tasks—all while safely and intelligently working next to people without the need for traditional safety barriers; soon there will be no need for humans on the manufacturing line”.

http://www.assemblymag.com/articles/91862-human-robot-collaboration-comes-of-age

This is an interesting point. Can OEM’s operate without direct human interaction and can manufacturing processes simply be left to robotic machines and automated techniques.

Since robots first started appearing in factories 50 years ago, research suggests that robots have been put in place to deliver 100% perfection and eliminate human error. All very well in theory, but in practice, a working relationship is built on communication face to face with a customer and supplier.

No matter how sophisticated the machine we are talking about, there will always be a need for the human touch in manufacturing plants and assembly factories. I understand the benefits of using autonomous measures: cost effectiveness in the future, improvements in accuracy and efficiency and a more thorough and detailed analysis of work procedure, but if the assembly process becomes entirely ‘robotic’ then working practice becomes flawed.

What if the machines break down, how do they repair if there is no need for human contact?

With the machines now commercially available, it seems the only reason that a company would use these robots is purely technology-driven. Robotics will definitely have a massive part in our lives in the future, but I cannot help thinking what a sad day it will be when man gets replaced with machine!

‘GAUGING THE RIGHT WIRE’

When considering various engineering projects and electrical applications, it is safe to say that you are going to be using some sort of electrical wire.  When choosing your wire of choice, it is therefore important to know how to determine the size of wire you require.

But where to begin? When choosing wire all sizes are determined by the American Wire Gauge scale or AWG for short. This defines a wire size based on a set of wire cross-sectional areas. The different gauges are used to determine the amount of current available to pass through the wire.

The important thing to remember is that the larger the diameter of the wire, the more current the wire can handle, but the lower the gauge size.

Choosing the correct electrical wire gauge is critical because using underrated wire creates a fire hazard and can cause repetitive and annoying circuit breaker trips

At Express Assemblies Ltd we generally handle standard wire gauges ranging from 2AWG to 24AWG, but can cut cable up to 30AWG. This clearly shows that we are very flexible in our manufacturing process and adapt to a diverse range of requirements.

WIRE SIZE	WIRE GAUGE [AWG]
0.25mm	24
0.5mm	22
0.75mm	20
1.0mm	18
1.5mm	16
2.5mm	14
4.0mm	12
6.0mm	10
10.0mm	8
16.0mm	6
25.0mm	4
35.0mm	2-3

THE IMPORTANCE OF QUALITY CRIMPING

Used as a means to improve connection between a terminal and a wire or cable, crimping technologies have revolutionised the wire and cable manufacturing market, with many companies opting to include this procedure in their daily business.

Where connecting and joining wires used to be simply soldered terminations, it is now perceived that crimping methods are the correct technique to use when terminating wires or cables.

Using both automatic and manual processes, and using both insulated and uninsulated components; the importance of quality crimping is vital to ensure that a product does not ‘short’ or fault during electrical installation.

So why is crimping the best choice?

• EFFICIENT: It is a time-saving exercise; instead of painstakingly terminating all wires by hand, the use of automated crimping methods is a much improved method of efficiency and also with the correct set-up ensures that all wires/cables are produced to the same quality.
• CHEAP: Terminals are often very cheap to buy and also if there happens to be a problem with some of the crimps, they are very easy to repair or replace.
• CONVENIENT: Crimps and crimping materials are extremely easy to get hold of. There are literally thousands of places to source crimps and crimping equipment.
• PERFORMANCE: Crimps are put through rigorous testing process before you [the customer] receives them, meaning that you can rely on their performance for final installation.

I hope this post has been helpful, and don’t forget we want to hear your views and comments, so please get in touch.

 

RESISTORS – EXPLAINING COLOUR CODES

One of the most common components used in electrical circuits is that of the resistor. Resistors come in many shapes and sizes, but understanding resistance and the purpose of resistors is critical to ensure the success of your final product.

 

 

Resistors have something called ‘values’ and this is determined by the coloured rings or ‘codes’ that appear on the body of the resistor. Being able to read a resistor means that you can factor the amount of resistance your product needs quicker and much easier.

There are three types of common resistors:

1. 4-band colour with 1 tolerance colour band
2. 5 band colour with 1 tolerance band
3. 5 band colour with 1 tolerance and 1 reliability band

Courtesy of http://www.instructables.com/id/How-to-read-color-codes-from-resistors-1/  

As you can see in the picture the first three bands in the picture are ‘DIGITS’.  The first two being brown and the third being black. That means the resistor has a value of 1,1,0. The fourth band which is a ‘MULTIPLIER’ is red, meaning you need to multiply the previous three digits by 100. 1,1,0 x 100 [using the three 000’s] means the resistor has a value of 11,000 ohms.

HOPE THAT’S CLEAR

WIRE AND CABLE TYPES!

Wires and cables are big business. Part of our everyday existence, they have transformed and revolutionised the way that we live. Without them, there would be no mobile phones, computers, televisions, microwaves or kettles [to name a few], the importance of them often goes overlooked, but simply put how would society function in a world without wires or cables?

With the wire and cable manufacturing market estimated to grow to $200 billion by 2015, it is not only an exciting market but an extremely lucrative industry to be involved in.

• FACT: Did you know that there are over 5000 types of wire or cable available to consumers. But with so many different ones to choose from, how do you decide which is the one for you

This post aims to simplify that process and identify a few common wire and cable types and their everyday uses

• EQUIPMENT/HOOK-UP WIRE: Hook-up wire is small-to-medium gauge, solid or stranded, insulated wire, used for making internal connections inside electrical or electronic devices
• TRI-RATED WIRE:  Its a high temperature, flame-retardant electrical cable designed for use in panel building
• MAINS CABLE: A power cord, line cord, or mains cable is a cable that temporarily connects an appliance to the mains electricity supply via a wall socket or extension cord
• SPEAKER CABLE: Speaker wire is used to make the electrical connection between loudspeakers and audio amplifiers. Modern speaker wire consists of two or more electrical conductors individually insulated by plastic or, less commonly, rubber.
• SWITCHGEAR WIRE: A switchgear cable is a flexible electrical cable,  designed to isolate electrical equipment.
• AUTOMOTIVE WIRE: Wire used in general automotive projects, ranging from cars to trucks, tractors etc
• WELDING WIRE AND CABLE: A welding electrode fed into the handset from a reel
• TELECOMMUNICATIONS CABLE: Telecommunication cables are a type of guided transmission mediums. Cables are usually known to transmit electric energy but in telecommunications fields, cables are used to transmit electromagnetic waves, they are called electromagnetic wave guides
• SIGNAL CABLE: A signal cable is an electrical cable of one or more insulated conductors enclosed by a common conductive layer. The shield may be composed of braided strands of copper, a non-braided spiral winding of copper tape, or a layer of conducting polymer
• FIRE CABLE: used as heat resistance cables. They are mainly used in fire alarms and emergency lighting circuits
• FIBRE OPTIC CABLE: a cable made of optical fibres that can transmit large amounts of information at the speed of light
• CATEGORY 5E AND 6: Category 5 cable (Cat 5) is a twisted pair cable for carrying signals. This type of cable is used in structured cabling for computer networks
• COAXIAL CABLE: Coaxial cable, or coax, is a type of cable that has an inner conductor surrounded by a tubular insulating layer, surrounded by a tubular conducting shield
• KYNAR/TEFZEL WIRE: special plastic material in the fluoropolymer family; it is used generally in applications requiring the highest purity, strength, and resistance to solvents, acids, bases and heat and low smoke generation during a fire event. 
• PVC WIRE: PVC is commonly used as the insulation on electrical cables; PVC  acts as the source of the wires’ fire retardance.
• LSZH WIRE AND CABLE: LSZH cable jacketing emits limited smoke and no halogen when exposed to high sources of heat. Protects people and equipment from toxic and corrosive gases. 
• RIBBON CABLE: The purpose of ribbon cable is that it transmits numerous signals or electrical pulses whilst adjacent to each other, offering a space saving and efficient alternative to large amounts of connected wires and cables
• BRAIDED CABLES: A flat cable made from bare woven wire. Similar to stranded wires, braided wires are better conductors than solid wires. Braided wires do not break easily when flexed. Braided wires are often suitable as an electromagnetic shield in noise-reduction cables
• SILICONE WIRE: Used for typical industrial applications including food processing, packaging, refrigeration, furnaces and lighting.
• SOLID CORE WIRE: Solid wire is cheaper to manufacture than stranded wire and is used where there is little need for flexibility in the wire. Solid wire also provides mechanical ruggedness; and, because it has relatively less surface area which is exposed to attack by corrosives, protection against the environment
• STRANDED WIRE: Stranded wire is composed of a number of small gauge wire bundled or wrapped together to form a larger conductor. Stranded wire is more flexible than solid wire of the same total cross-sectional area. Stranded wire tends to be a better conductor than solid wire because the individual wires collectively comprise a greater surface area. Stranded wire is used when higher resistance is required
• PTFE WIRE: In industrial applications, owing to its low friction, PTFE is used for applications where sliding action of parts is needed: bearings, gears, slide plates, etc. Also hydrophobic, this makes it suitable for use as an insulator in cable assemblies
• POWER CABLE: A power cable is an assembly of two or more electrical conductors, usually held together with an overall sheath. The assembly is used for transmission of electrical power. Power cables may be installed as permanent wiring within buildings, buried in the ground, run overhead, or exposed. Flexible power cables are used for portable devices, mobile tools and machinery

 

EXPRESS GOES GREEN

 

 

All through our history, mankind has pillaged, pawned and plundered Planet Earth. Until fairly recently, most businesses didn’t give the environment a second thought; even 20 years ago, it fell off the corporate radar and was generally regarded as ‘hype’.

Much has changed. It’s become increasingly apparent that so-called ‘global development’ cannot continue unchecked, indefinitely. Issues of sustainability have moved up the political and economic agenda and they can no longer be ignored.

Pro-Activists

Today, the pressure on businesses to ‘be green’ has never been greater. As consumer awareness of environmental issues increases, so have consumer expectations. Thankfully, eco-friendly practices are becoming the norm, and green credentials are something by which we measure performance, value and success.

Now, when it comes to the environment, there’s no way that businesses can vouch ignorance. Whatever they do, be it good or bad, it will be noticed; it goes without saying that everyone wants to be noticed for the right reasons.

There’s been a distinct shift in investors’ preference for companies that intentionally ‘do more good’ rather than just ‘do no harm.’ It’s no longer enough to not be bad and avoid mass pollution and all the shocking, headline-grabbing crimes. Now, businesses are expected to be proactive and intelligent in their efforts to make the world a better place.

Good All Round

What’s good for the environment is ultimately good for business. No company can hope to have a good image without green credentials. A strong, innovative and thoughtful environmental policy gives companies a well-earned reputation for being credible, ethical and responsible.

Consumers are starting to really care about this sort of thing, and they’re more discerning than ever. The demand for environmentally-friendly products and services is strong and growing, with many willing to pay more and demonstrating loyalty and goodwill towards companies with good green credentials. You’ll also find they can open the door to greater community involvement and real engagement with the locals.

Being green is a real competitive advantage on the international playfield. Having all the right green credentials and qualifications satisfies stakeholders, reassures investors, builds stronger community relationships and provides access to new partnerships and business opportunities. It also helps businesses to attract the best employees, as many of today’s best young employees report that they’re more inclined to work for companies that are known to be environmentally-friendly.

Saving Money- and Face

Being green can save businesses a fortune. The small upfront investment required is made up for many times over by the cost savings. Being environmentally-friendly involves scrutinising every single business process in order to reduce waste and fuel consumption. Green means lean, and maximising operational efficiency will ultimately bolster the bottom line.

Finally, being green mitigates risk and saves face. New environmental legislation is being set out all the time. Organizations that are leading the way, rather than dragging behind, can be confident that they won’t land a fine, face the hassle and embarrassment of prosecution or have to fork out for higher insurance premium.

All businesses, whatever their size, culture or industry, will really benefit from being green. Those that choose not to prioritise the environment will end up green with envy at the success of their competitors

LET’S GET THIS STARTED: EXPRESS HITS THE BLOGOSPHERE

Welcome to our official company blog. Providing company news, industry trends and subject opinion we aim to be the blog that makes all the right connections.

Focusing on wires and cables, we aim to cover any topic and answer any question you may have.

We would love to hear your comments and hope you enjoy reading our posts