combining various electronics into your cable assembly

Manufacturing That Eliminates Risk & Improves Reliability

Combining Various Electronics

Into Your Cable Assembly

04.28.17


2

Agenda

Current Situation

Types Of Environments Cable Assemblies Can Be Used In

Techniques Employed To Protect Electronics

Examples Of Successful Electronics Incorporation

What Does The Future Hold?

“The performance of a cable assembly is based on its reliability, durability, and ability

to maintain signal integrity regardless of the mechanical, electrical, and environmental

stresses surrounding it.”


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Current Situation


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Current Situation

Usually The Last Component Considered When Designing Electronic System

Assemblies Are A Systems Lifeline

– Chain Is Only As Strong As Its Weakest Link

– If Assembly Fails Entire System Fails

Usually Designed With “Good Enough” Mentality

– Minimal Understanding Of Environmental Factors

– Minimal Concern For Performance

– Try To Use “Off-The-Shelf” Components

No Understanding Of Total Cost Of Ownership

No Understanding Of Electronics Involved


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Types of Environments

Cable Assemblies Can Be Used In


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Extreme Environmental Concerns

Shock And Vibration

Temperature Extremes

Temperature Cycles

Small As Possible

Light Weight

Space/Radiation Exposure

Fluids

– Water/Moisture/Petroleum/Chemicals

Particulates/Dust

Abrasion

Physical Impact

EMI/RFI

Extensive Flexing


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Techniques Employed to

Protect Electronics


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Use Over-Molding To Protect Electronics

Water-Proof Seal

Mechanical Protection Of Connector And Electronics

Strain Relief Protection Of Terminations

Resistance To Chemical Exposure

No Exposure To Metal Parts Causing Wear Damage

Tamper Proof

Far Superior To Boots/Backshells

Excellent Isolation Of Components

No Stress To Terminations Or Conductor InsulationLike Cable Clamps


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Examples of Successful

Electronics Incorporation


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Marriage of Assembly and Electronics

Situation:

– Assembly To Be Used In Marine Environment

Requirements:

– No Fungal Growth Allowed

– Watertight

• Pressure Test For Water Penetration

– Electronics Included

• PCBs

– Had To Be Flexible

• No Memory Of Cable Coil

– No Impact From Temperature Extremes


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No Fungal Growth Allowed

Inhibitor Added to Compounds

Tested to ISO 16869– The test for fungal growth for life saving appliances is that the

assembly gets sprayed with a suspension of mold spores and is then paced in a mold growth chamber.

– The chamber maintains a temperature of 29°C +/- 1°C with a relative humidity of not less than 95%.

– The assembly remains in the chamber for a period of 28 days and after the incubation period is inspected for mold/fungal growth.

– A passing assembly would display little or no mold growth.


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Water Tightness

Pressurized Tank

Test Cycle 20 Minutes At 35 PSI

Conductivity Measured Before And After Test


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Embedded Electronics

Two PCBs

No Movement Allowed

Used Pogo Pins To Control Downstream Circuits

Watertight

Rib Between PCBs

Solid Baseplate


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Cable Flexibility

No “Coil” Memory Of Cable

Strain Relief - Watertight Regardless Of Bend

No Impact Due To Temperature

Adhere To PCB Baseplate


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Customized Pins

Center Spacing Critical

“Friction” Retention

Watertight Seal

Inner/Outer Molds


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Result

No Fungal Growth

– ISO 16869 Compliant

Watertight

– “The cable assembly has been submerged in water under the pressure of 35 PSI for 20 minutes which is equivalent to a depth of 80 Feet of Water.”

Flexible At Any Temperature


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What Does the Future Hold?


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What Does the Future Hold?

Assemblies With Electronics More Reliable

Withstand Almost Any Environment

Space Savings

– What Can Be Included:

• RFID

• Eprom

• Battery Charging Electronics

• PCBs

• LEDs

• “Smart Cables”


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Summary

Including Electronics In Cable Assemblies:

– Improves Reliability

– Potentially Frees Up Real Estate

– Allows Electronics to Be Protected For Use in Almost Any Environment

As Assembly Performance Increases More Electronics Will Be Used


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Our Products

Battery Packs Flex & Rigid-Flex PCB’s User Interfaces

Fans & Motors Cable Assemblies Printed Circuit Boards


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Design Centers & Technical Support

Battery Pack & Power Management – Denver, CO

User Interfaces – Largo, FL

Fans & Motors – New Bedford, MA & Wales, UK

PCB’s – New Bedford, MA & Shenzhen, China

Flex & Rigid Flex – Toronto, Canada

Cable Assemblies – Largo, FL

Our Engineering and Design teams are ready to help our customers create world class and cost effective product solutions.


22

Q&A

Questions?

– Enter any questions you may have in the Control Panel

– If we don’t have time to get to it, wewill reply via email


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Thank YouCheck out our website at www.epectec.com.

For more information email [email protected].

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combining various electronics into your cable assembly

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