simplebooklet thumbnail

Serving the Electric Wire and Cable Processor

(Wiring Harness News recently attend-
ed IMTS 2016 in Chicago where Harry
Moser of Reshoring Initiative
®
gave an
update on reshoring efforts in America.
Mr. Moser was a past speaker at the
WHMA Annual Conference. His organi-
zation has released a new infographic
on reshorenow.org. Following is his
summary and a breakdown of some of
the key components.)
A Reshoring Initiative Infographic
Supports Manufacturing D
ay 2016
Chicago, Illinois, September 23, 2016
The Reshoring Initiative
®
is announc-
ing the availability of a new infographic,
“New Dawn for Manufacturing Careers
in America”, to support the goals of Man-
ufacturing Day 2016. Manufacturing
Day, Oct. 7, 2016, “is a celebration of
modern manufacturing meant to inspire
the next generation of manufacturers,”,
said Harry Moser, founder/president of
the Reshoring I
nitiative. He went on to
say, A strong skilled workforce is key to
reshoring and manufacturing growth,
and development of a skilled workforce
begins with motivating a higher quanti-
ty and quality of recruits. Moser assert-
ed that by demonstrating that the trend
is now away from offshoring and
towards reshoring, we make the case
that manufacturing is once again a great
choice for career stability and grow
th.
The Infographic mirrors the Reshoring
Initiative’s Workforce Development pro-
grams, which are designed to motivate
recruitment.
By balancing the $800 billion per
year manufactured goods trade deficit,
the U.S. will add 5 million manufacturing
jobs, an increase of 40%. Workforce
development is key to the required
capacity and competitiveness as
explained by Mr. Moser in his recent
IMTS press briefing.
Shrinking Wage Gap
The wage gap (shown in Figure 1)
with China is rapidly shrinking. In fact,
the labor cost savings that drove many
companies to offshore have narrowed,
causing many to reevaluate the total cost
of offshore manufacturing.
W
ith few exceptions, wire
harness assemblies have
been built using the same
methods ever since people have been
building wire harnesses. That is about to
change. Delta Sigma Company (DSC),
working on a USAF grant with several
aircraft manufacturers, has just released
the next generation of their Augmented
Reality (AR) system called Harness-
Works
TM
, this time specifically for build-
ing wire harnesses. DSC’s CEO Roger
Richardson, noted After seeing enor-
mous savings using AssemblyWorks
TM
on
the F-35 for mechanical assemblies
where returns of 4,000% on the initial
investment were being generated, the
Air Force asked DSC if a similar concept
would work for electrical assemblies. We
looked into the requirements that such a
system would have, found some OEM
partners that could define system
requirements, and determined that it
was not only feasible, but our early indi-
cations were that the cost benefits
would likely be similar to the benefits
seen for mechanical assembly.
With t
hat, the project was under way.
“The data used to build wire harnesses
is significantly different today, in most
cases, than the data available for
mechanical assemblies. Design technolo-
gy moved faster and has been much
more broadly accepted in the mechani-
cal world than the electrical world. The
aviation industry is moving fast to catch
up, but there are other industries where
the only fundamental difference
b
etween the documentation methods
used by the Egyptians in 3,500 BC to
build a fleet of boats and the methods
used today is that it is written on paper
instead of papyrus. When we first start-
ed developing AR work instructions in
2005, technologically speaking, docu-
mentation for assembly instructions had
not advanced much in 5,500 years” com-
mented Dr. Brett Haisty, Chief Technolo-
gy Officer a
t DSC.
The folks at DSC thought that it was
time to change that. Virtual Reality (VR)
is a computer generated world some-
times containing virtual beings called
avatars that move around in an environ-
ment that is completely created by a
computer. Augmented Reality is the
application of VR onto physical reality.
That is, physical reality is augmented by
virtual reality so that the user sees at the
same time things that are real (physical-
ly present) and things that are virtual
(computer generated). Properly used,
AR opens up a world of opportunity
never before available to explain things,
especially things that are long, tedious,
and somewhat complex – yet require
absolute perfection in production. Air-
craft wire harnesses would be a good
example.
“The first issue is scale. It is essential
that we display
the data in exactly one-
to-one scale, so that the virtual part will
match the physical part. The process of
scaling the data through the optics is
called calibration. Once the scaling
problem is solved, the next challenge is
to place that perfectly scaled virtual
object onto a physical object so that
they are perfectly aligned a process
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2012 1
This
Issue
Features:
Meet Jim - Not Your Average Joe
Industry Suppliers Host Octoberfest
New Dawn for US Manufacturers
Wire Wisdom - Cable Jacket Types 101
Partnering with Customers: Myth or Reality?
Strategies to Strengthen Subassembly Sourcing
25 Years of Quality Lacing Tapes and Yarns at Breyden Products
Augmented Reality Manufacturing - Delta Sigma’s Harness Works
NOVEMBER
DECEMBER
2016
________________Continued on page 19
21st Century Wire Harness
Assembly - Delta Sigma
Rolls Out Pilot Program
HarnessWorks Projector and Board
New Dawn for Manufacturing Careers in America
Figure 1
________________Continued on page 35
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 1
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 2
SHORTEST
POSSIBLE DELIVERY!!!
BRAIDERS NEW & REBUILT
Specializing in New England Butt:
#2 Harness Braiders
CB1 Cable Braiders
Specialty Application Braiders
ASK ABOUT OUR NEW DESIGN DRIVE SYSTEM
ASK ABOUT OUR NEW DESIGN DRIVE SYSTEM
Contact: Jack Dennehy
COMPOSITE & WIRE
MACHINERY, INC.
490 Old Baptist Road,
North Kingstown, RI 02852
Phone: (401) 884-4760 • FAX: (401) 885-2499
Visit: www.compositewire.com
Email: compositewire@aol.com
We Purchase
Good Used
Braiders
International Harness Resources, Inc., dba Wiring Harness News, reserves
the right to reject advertisements which in its sole judgment it considers,
in whole or in part, inappropriate or unprofessional.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 3
EDITORIAL CONTENT MANAGER
Joe Tito
joe@wiringharnessnews.com
Phone (407) 739-9811
ACCOUNT MANAGER
Jim Brown
jim@wiringharnessnews.com
Phone (708) 594-7764
ACCOUNTING
Marion Gray
marion@wiringharnessnews.com
Phone (708) 594-7762
INTERNET
http://www.wiringharnessnews.com
SUBSCRIPTION RATE:
1 Year, U.S. & Territories $39.00
Canada & Mexico
$54.00 U.S. Funds
All other countries $64.00
Internet Subscription Only $
30.00
Credit Card Only
Please visit www.wiringharnessnew.com to
subscribe to Wiring Harness News
Copies of Wiring Harness News (ISSN 1097-0789)
are distributed bi-monthly to wiring harness &
cable assembly shops, cord set manufacturers,
companies that process electric wire & cable
(including fiber optic) for use in their own prod-
ucts, their suppliers and other interested parties.
Copyright 2016
International H
arness Resources Inc., (IHR Inc.)
Wiring Harness News
PO PO Box 669
Schererville, IN 46375
USA
http://www.wiringharnessnews.com
Office Hours:
7:00 a.m. - 3:30 p.m. CST - (Monday-Thursday)
Printed in the USA.
S
TORMTRONIC
S
SEMI-AUTOMATIC WIRE TWISTING SYSTEMS
MINI-TWISTER II
• Automatic Programmable Counter
• Air Pressure Gauge & Regulator
Variable Speed & Reversible
• Automatic Batch Counter
• Foot Switch Activated
• Repeatable Accuracy
• Rugged Construction
• Automatic Resetting
• Low Maintenance
• Simple Operation
• Custom Adapters
NOW…
a low cost, highly reliable
wire twisting system designed
and built to meet your specific n
eeds.
THE MELLO COMPANY, INC.
P.O. Box 29301 Dallas, TX 75229
PH: 214-350-7377 FX: 214-350-0521
www.themellocompany.com
NOVEMBER
DECEMBER
2016
1
21st Century Wire
Harness Assembly
Augmented reality makes its way into
harness production.
1
New Dawn for
Manufacturing
Careers in
America
The stage has been set for the return
of manufacturing to the US.
5
Meet Jim - not your
average Joe
Cultivating superstars within our
ranks.
5
Partnering with
Customers: Myth or
Reality?
Partnerships that stand the test of
time.
13
News Plugs
Read about the latest products on
the market and points of interest about com-
panies and people in the industry.
28
Strategies to
Strengthen Sub-
assembly Sourcing
Look into the thinking of OEM’s as
they select subassembly suppliers.
31
Six Suppliers Host
Octoberfest
Panduit, Schleuniger, Cirris, GEM
Gravure, Telsonic, and Delta Sigma host an
information/exhibition event.
39
Wire Wisdom
Cable Jacket
Types 101
This Wire Wisdom explores some of
the different cable jacket types and provides
an overview on the jackets’ mechanical and
chemical properties.
44
25 Years of Quality
Lacing Tapes & Yarns
at Breyden Products
Inside look at this solid producer of
mil-spec lacing tapes, twines and cords.
Classified
59........................ Machinery, Job Line & Misc.
60 ..........................................Advertiser Index
INSIDE
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 3
4 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 4
By Paul Hogendoorn
__________________________________
I
met Jim last year when I visited
the plant he works at, near
Ottawa. He’s a down to earth guy,
about my age, (getting up there!), and
has a knack for figuring things out and
getting things done. He’s been doing it
for 38 years.
At first glance, he’s the kind of guy
you wish you had in your plant, or per-
haps think you already have, but as you
read on, you’ll see his story is much
more than t
hat. Jim is now intentional
and committed to the continuous
improvement process, but he wasn’t
always that way. He started his first job
at 9 years old delivering papers and
he has worked every year of his life
since. He heeded his mother’s advice
that “it’s work and work ethic you need
to worry about”, and for many years that
was enough. In his youth and early
years, he spent all of his weekends and
s
ummers working, and was never out of
a job. From washing dishes, cooking
food, stocking shelves, renting cars, and
doing oil changes, to steadier and higher
paying factory jobs, he progressed to the
point of operating the big machines.
About 6 years ago, 15 years into his
job running the big machines, he
reached the top of his pay scale as a
“lead hand”. There was not much left to
learn and nowhere else to go
. After
much reflection, and with encourage-
ment and support from his wife, he
decided to pursue other positions at the
company, but it soon became apparent
that his computer skills were inade-
quate. Excel and Power Point were a
mystery to him, and Word was equally
daunting. Younger people with more
computer skills, but not near as much
manufacturing skill, had the clear advan-
tage.
At the time, his daughter wa
s attend-
ing a local school that had courses for
adult alternative and continuing educa-
tion, where she was finishing her grade
12. He decided to check with them, and
to his surprise, found they had courses
running that suited his needs. On his
days off, and on his own volition, he
enrolled. (It was his “personal continu-
ous improvement” initiative.)
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 5
Paul Hogendoorn
Meet Jim - not your average ‘Joe’
_________________Continued on page 7
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 5
6 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Thermal Transfer Printers, Software,
Labels and Wire Markers
Insulation Supply Company
An Electrical Interconnect Distributor
We Stock and Distribute Heat-Shrinkable Tubing, Adhesive Coated Heat-Shrinkable Tubing, Heat-Shrinkable Molded
Parts, Crimp Splices, Solder Splices, Heat Guns, Wire Identification Solutions - Labels, Software, Label Printers, Tape,
Electrical Protection Sleeving, Lacing & Tying
C
ord, Cable Ties, Spiral Cut Tubing, Split Loom Tubing, Corrugated
Tubing, Medical Grade Tubing, PVC Tubing, PTFE Tubing, PEEK Tubing and Value Added Services.
Industries We Support:
Aerospace Electronics
Aircraft Energy
Automotive Medical
Defense Rail
Electrical Appliance Utilities
Our Top Product Lines:
Atkins & Pearce/Ben-Har & Suflex LS Cable/Dunbar
Brady Product, Facility & Safety Identification Panduit
Breyden/Gudebrod Permacel
CYG/THERMOSLEEVE/USA Steinel
DSG-CANUSA TE Connectivity/Raychem
Federal Mogul/Bentley Harris Protection Products Thomas & Betts
Grayline Varflex
Hilec/Delfingen Western Filament
Insultab Zeus
Judco/Focus-Lite
www.inscoinc.com (800) 457-7715 info@inscoinc.com
Since 1952
Electrical Interconnect
Heat-Shrinkable Solutions
Heat-Shrinkable Wire Identification
PTFE Heat-Shrinkable Tubing
Nomex & PPS
Abrasion & Bundling Solutions
PTFE Spiral-Cut Cable Wrap
Heavy Wall Heat-Shrinkable Tubing
Judco/Focus-Lite
Heat-Shrinkable Tubing Processing Machine
TE Connectivity (Raychem Products)
Americas Specialty Distributor of the Year – 2012
TVU USA Inc.
ISO 9001:2008/AS9100C
Certificate Registration No.14-1561
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 6
He was nervous and intimidated
at first, but he soon felt comfort-
able. There were about a dozen
people in the class, including high
school students, new immigrants,
and other people his age there for a
reason similar to his to face their
fear of computers and all things IT.
After that initial course, he felt con-
fident enough in his abilities to
take a position within the compa-
ny’s CI (Continuous Improve
ment)
department. He worked in a
process technician role for 2 years,
and then in 2012, moved into a
management role.
That by itself would be a great
‘Continuous Improvement’ story,
but this story doesn’t end there.
As a manager, he took a
keen interest in the devel-
opment of others, especial-
ly people around his age or
a bit older people that
had been there for 2 or 3
decades; people with great
working skill and experi-
e
nce, but little or no expo-
sure to new technology.
Some did not have cell
phones or computers or
experience with email and
messaging systems. In my
mind, this is perhaps the
biggest single lost continu-
ous improvement opportu-
nity in many manufacturing
companies today. The tactile
experience that our sea-
soned people have is over-
looked and not taken
advantage of because they
lack basic computer s
kills
skills that are quite easily
taught. Whatever risks there
are to training them are
quickly mitigated by the
fact that most of these peo-
ple have already demon-
strated their loyalty and
dependability things that
can’t be taught or calculat-
ed. (Someone that has been
with you for 20 years, and
still has 10 or 20 in the
tank, is a far safer bet to stay
with the company than
someone hired fresh.)
Jim had an individual on
his team that needed to be
moved to an office position
to accommodate a health
condition. The person was
basically computer illiter-
ate, but the new role was
80% computer related.
Remembering his own
experience, Jim recom-
mended that this person be
sent to a program similar to
the one he attended. The
company agreed. A couple
weeks later, the individual
returned to work like a new
man, competent and confi-
dent that he could find
answers to any computer
related issues that might
crop up for him. More than new
computer skills, he gained a confi-
dence that transformed his attitude
from fear of failure to one where
new challenges were welcomed
and learning opportunities
embraced. He now routinely creates
complex excel spread sheets, edits
documents in the companys docu-
ment control system, and effortless-
ly communicates with coworkers
electronically.
T
he change was so dramatic that
it wasn’t long before other man-
agers and coworkers started to
notice. Some wanted to know
where to send their people, while
others wanted to go for the training
themselves. Other departments
began to send people, and the story
repeated; every person that
received the training became a
more valuable employee of the
company. Jim made sure that all
employees in his department went
through the same program he did.
Every plant I visit has a lot of
people with a tremendous wealth
of experience and potential, ready
to be tapped into. All they need is
the chance to learn a few new
skills. And all it may take to get start-
ed is one person like Jim to make it
his mission in your plant. Jim may
be your average guy, but he’s no
ord
inary Joe.
Paul Hogendoorn is co-founder
of FreePoint Technologies. “Mea-
sure. Analyze. Share. (Don’t forget
to share!) For more information on
this topic, he can be reached at
paulh@getfreepoint.com
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 7
Continued from page 5 __________
Meet Jim - not your average ‘Joe’
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 7
By Loren Smith
__________________________________
The concept of a “partnering” rela-
tionship with a customer has been
around for a while, and it is often met by
harness makers with skepticism. “Part-
nering” can come across as just another
corporate platitude designed to achieve
price reductions from suppliers. Given
the long life of the phrase “three quotes
and a cloud of dust”––referring to the
use of competitive leverage to squeeze
the l
ast penny out of every quote––it is
not hard to understand this wary atti-
tude.
I, too, used to be a skeptic. But then I
had the eye-opening experience of inter-
acting with a construction equipment
company who, after embarking on a
global best purchasing practices study,
had decided to go down the road of
truly partnering with his suppliers.
Because this customer had previously
directed teams of engineers t
o extract
fractions of a penny from supplier rev-
enue, his turnaround was remarkable.
Here’s how the company partnered:
First they sought buy-in from the highest
levels of a select number of suppliers so
they could describe their concept in the
finest detail. They did this by explaining
that they had adopted their new
approach because they were convinced
it would yield them the highest quality
and best serv
ice at the lowest price—
and that their adversarial approach had
not consistently yielded those desirable
outcomes. They said that, instead, the for-
mer relationships had yielded question-
able quality and service, and that while
purchase prices may have appeared
optimal, when they measured compo-
nent cost, they often discovered costs
were excessive.
8 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Loren M. Smith, CEO
Blue Valley Capital
Partnering with Customers:
Myth or Reality?
_______________Continued on page 10
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 8
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 9
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 9
Their dialogue initially focused on
gross margin, which is often misunder-
stood. It is, according to a generally
accepted accounting principle (GAP),
the dollars the supplier has left after
covering material, labor and factory
overhead.
Once the hurdle of identifying a
product’s gross margin is surmounted,
the harness user and harness manufac-
turer engage in a collaborative, intensive
exercise focusing on t
he cost drivers.
How can they work together to mini-
mize the “cost of goods sold”: material,
labor and overhead? If this can be
accomplished without attacking the
gross margin percent, the exercise
allows for the harness maker to realize
true cost optimization––a result that
should yield a lower cost base without
affecting the supplier’s bottom line
Okay, so youre thinking this all
sounds good, but it also sounds
l
ike something out of a textbook as
opposed to real life. But I can tell you I
had the experience of this actually
workingwith amazing results. The
world-class construction equipment
company concluded that it did not need
a half-dozen wire harness suppliers; it
needed only one. We were exceptionally
fortunate to be chosen as that supplier,
and we went on to be selected as the
company’s first "vendor o
f the year."
That designation, however, did not
mean we could then coast. We were
expected to play an active role in the
early design process for new products,
as well as in finding ongoing cost reduc-
tions for existing products. To meet
expectations, we had to have people
who were thoroughly dedicated to this
new way of doing business.
But on the plus side we weren't wor-
ried we’d encounter a flurry of quoting
every year that could put our volume of
business with this customer in jeopardy.
Our partnership with the company
stood the test of time, and it is still in
place.
Loren Smith can be reached at
lms@blvcapital.com or www.bluevalley-
capital.com
10 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Partnering with Customers:
Myth or Reality?
Continued from page 8 ______________
Subscribe to Wiring Harness News
www.wiringharnessnews.com
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 10
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 11
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 11
12 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 12
Cicoil Announces New Web-
Based Flat Cable Configurator
Cicoil, the leading manufacturer of
Flexible Flat Cables and Assemblies,
is pleased to announce its New EZ-
Flexx Flat Cable Configurator.
Located at www.cicoil. com/flat-
cable/configurator, an entire section
of the website is dedicated to this
Free Web-Based Tool, which allows a
user to easily design a cable in min-
utes and possibly seconds.
And the new E
Z-Flexx™ cable
design makes Cicoil flat cables easy
to separate and strip, just like any
round cable, and also makes the flat
cable more light and flexible. With a
few simple mouse clicks or touch of
a screen, Flat Cables can be con-
structed of many elements,
including power conduc-
tors, shielded signal pairs,
video & coax wires and tub-
ing for liquid and air. To
make the process even
quicker, Cicoil has added
Specialty Modules (Camera
Link
®
, Cat 6A, FireWire, USB
3.0) to the Configurator. Any
of these elements can be
combined in any position
within the flat cable profile,
which means that over 1
million flat cable designs
are available for immediate
production and quick deliv-
ery. In addition, users can
move around, add and
remove any elements in
their flat cable, in any varia-
tion up to 3.75 inches wide.
Once the flat cable is
designed, users receive a
price quotation, custom
part number and an engi-
neering drawing delivered
to their e-mail inbox within
seconds. Once the cable is
ordered, Cicoil guarantees a
1-2 week delivery on any
cable designed using the
Cable Configurator.
If you are new to the
website or the world of
Cicoil Flat Cables, they have
put together a Quick Tutori-
al on the website to walk
you through the process
and help you to become a
Flat Cable Designer in just a
few minutes.
Reptronics Announces
Steven L. Olson as VP of
Sales
Reptronics is pleased to
announce that effective
September 6, 2016, Steven
L. Olson joined the Reptron-
ics team as Vice President of
Sales.
Olson has over thirty
years of experience in sales
and marketing of electro-
mechanical and passive
components as well as electro-
mechanical a
ssemblies. Olson was
most recently the Sales and Market-
ing Director of TLC Electronics, Inc.
Prior to TLC he was a Regional Manag-
er for Winland Electronics, an
account manager for manufacturer
rep firm Murnco, and direct sales for
Lambda.
Reptronics’ President Dana
Fredrickson stated, Stevens sales
and marketing experience in direct
OEM sales, distribution sales and
support, and manufacturing will
make him a great asset to the Rep-
tronics team. I am confident that his
skills will greatly contribute to pro-
viding an exceptional customer
experience while increasing new
growth opportunities for the manu-
facturers we represent.”
Olson may be reached at 763-
360-3746 or steve@reptronicsllc.
com.
Reptronics manufacturer repre-
sentative of electromechanical com-
ponents, interconnects, electromag-
netic components, p
assive compo-
nents and sensors.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 13
NEWS PLUGS
NEWS PLUGS
Steven L. Olson,
Vice President of Sales
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 13
Digicom Electronics Incorporates
Nitrogen in Soldering and
Reflow Processes to Maximize
Device Reliability
Digicom Electronics, Inc., a technology
and quality-driven electronics manufactur-
ing services company, now generates its
own nitrogen to use in its solder reflow,
selective soldering, and hand soldering
manufacturing processes to strengthen the
bonds and improve solder adhesion.
Adding nitrogen minimizes d
evice failure
and ensures printed circuit board integrity,
especially for mission critical products for
the medical, military and aerospace, indus-
trial, and RF wireless industries. The addi-
tion of nitrogen is part of Digicom's Dia-
mond Track Manufacturing Processes.
“Manufacturers must seek every way
possible to eliminate failures of the devices
they manufacture,” said Mo Ohady, general
manager, D
igicom Electronics. “Many major
failures result from a weakness in the solder
joint that connects the wire bond to the
PCB or the solder connecting the device or
package to the board. Processes that seem
to benefit the most are the ones that have a
narrower pitch, so the narrower the pitch,
the more that nitrogen use is recommend-
ed. Studies show a 50-60% reduction in
defect level when using nitrogen in t
he
reflow process. Digicom seeks to employ
technologies that produce products of the
highest quality. Towards that end, we have
implemented nitrogen in our manufacturing
process.” The nitrogen is generated and
piped directly to machine inputs and work
areas at a prescribed volume and pressure
to achieve optimized saturation of the inert
gas and to eliminate oxidation at critical
moments of the soldering operation.
D
igicom’s white paper, Can Nitrogen
Reduce Failures in Medical Devices,
explores the use of nitrogen in the manu-
facturing process and ways to minimize
device failure.
A copy is available for download on the
Digicom.org website at www.digicom.org
14 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
NEWS PLUGS
NEWS PLUGS
continued
Adding nitrogen minimizes device failure and ensures printed circuit board
integrity
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 14
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 15
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 15
UL 94 V-0 Rated Potting &
Encapsulating Compounds
Today’s electronic assemblies
must perform in some of the harshest
environments. Many highvalue
designs require the use of an Under-
writers Laboratory (UL) Listed Potting
and Encapsulating Compound. Engi-
neers can now select from several
different products that have passed
the difficult self-extinguishing UL test.
The following epoxy and urethane
products will meet many of the engi-
neering design demands of today’s
electronic and aerospace assem-
blies:
20-2362 FR - Low durometer
and low viscosity urethane.
50-2369 FR - Thermally conduc-
tive and thermal shock resistant ure-
thane.
50-3150 FR - Thermally conduc-
tive epoxy. It can provide an RTI rat-
ing of 130°C with Cat. 30.
50-3152 FR - Thermally conduc-
tive epoxy with an easy to use 1:1
mix ratio and C
TI rating of >600 volts.
Epoxies, Etc. has been formulat-
ing solutions for electronic circuitry
and assemblies for over 25 years.
Our chemists and engineers are able
to provide specific application sup-
port.
More information about the UL
Listed Products is available the web
site at epoxies.com.
Technical Support can be
reached by phone 401-946-5564 or
sales@epoxies. com Samples are
available.
Zuken and Aras P
artner to Deliv-
er Ideal EDM/PLM Environment
New approach improves cross-
discipline product development
processes and data integrity from
design to manufacturing Zuken
®
, and
Aras
®
, a leader in enterprise Product
Lifecycle Management (PLM) soft-
ware, have entered into a partnership
to develop a new approach for man-
aging cross-discipline product
development processes that include
electrical and electronic design data
from design creation to manufactur-
ing. The new solution will span enter-
prise processes across the lifecycle,
as well as detailed electrical design
and manufacturing.
The partnership will deliver func-
tionality that couples a domain-spe-
cific work-in-process (WIP) library
and design data management sys-
tem, with the enterprise PLM plat-
form. The result will replace
traditional “zip-up-the-
directory” functionality with
significant new capabilities
that include where-used
traceability for IP blocks and
components, merging of
design and manufacturing
processes, and enhanced
ECO processes.
“Zuken and Aras see a
future where the electronic
and mechanical design
processes are coordinated
more effectively to enable
true systems engineering,”
said Peter Schroer, CEO of
Aras. “We believe that by
working together we can
provide a more holistic
approach to support the
b
usiness of engineering.”
Zuken will provide DS-
2™, an engineering data
management (EDM) solu-
tion for managing work-in-
process library and design
data for circuit/board
development. DS-2 is a
domain-specific solution
for managing native design
data across multiple sites in
a project-oriented fashion.
“Manufacturers are using
digital solutions in increas-
ingly sophisticated ways to
dramatically boost produc-
tivity,” said Kazuhiro Kariya,
Managing Director and Chief
Technology Officer at
Zuken, Inc. “We are partner-
ing with Aras to enable new
processes for multi-discipli-
nary collaboration across
the enterprise.”
Aras will provide Aras
Innovator, an enterprise-
level PLM platform and
suite, for the complex sys-
tems engineering processes
in product development,
m
anufacturing, quality and
the supply chain. The com-
bination will provide engi-
neers across the organiza-
tion with improved data
integrity and more efficient
processes from design
16 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
NEWS PLUGS
NEWS PLUGS
continued
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 16
through to manufacturing.
The new solution is planned to be
available early in the 2017 calendar
year.
For further information see
www.zuken.com/ds-2 and www.
aras.com.
Teknor Color Concentrates
For Halogen-Free Applications
Receive UL Certification of
Compliance
PAWTUCKET, RI, U.S.A., October
3, 2016: A series of color concen-
trates for wire and cable and other
electronics applications required to
be halogen-free (HF) has been certi-
fied by UL as conforming to its stan-
dard for HF materials, it was
announced today by the Color Divi-
sion of Teknor Apex Company.
The UL certification applies to 14
concentrates supplied by Teknor
Color in pellet form, using ethylene-
vinyl acetate (EVA) and polyethylene
(PE) polymers as carrier resins. These
new concentrates can be used with
the EVA or polyolefin-based halo-
gen-free flame retardant (HFFR) com-
pounds currently available.
“Compliance with HF require-
ments has become increasingly
important in North America, particu-
larly for electronics, cables, and
cords used in confined spaces in
office, building and construction,
automotive, public transit, marine,
and military installations,” said Edwin
Tam, manager of marketing and busi-
ness development. “The HF require-
ments for these applications include
the concentrates used to color the
HFFR compounds. We worked close-
ly with our wire and cable customers
to develop the new concentrates
specifically for this market.”
EIS, Inc., Acquires
Communications Products
and Services
EIS, Inc., a wholly-owned sub-
sidiary of Genuine Parts Company
(NYSE: GPC), has acquired Commu-
nications Products and Services
(CPS), headquartered in Englewood,
C
olorado on October 3, 2016. CPS is
a leading distributor of outside plant
product solutions for both aerial and
underground broadband cable and
wireless network infrastructure. CPS
primarily services the western USA
from their single location in Engle-
wood, Colorado.
Bob Thomas, Chief Executive Offi-
cer of EIS, said, “We are very pleased
to bring Communications Products
and Services into our Genuine Cable
G
roup and the EIS family. CPS is one
of the most successful distributors in
the markets they serve and their team
has built a great regional business
since their founding in 1986. This
acquisition will strengthen our
business in the west and is a very
important business building oppor-
tunity for the Genuine Cable Group
and EIS”.
Fred Briggs, CEO of CPS, com-
mented, “I strongly believe that this i
s
an excellent opportunity for both
organizations. CPS brings more than
30 years of product and application
knowledge and an established posi-
tion in the markets we serve. CPS will
complement the Genuine Cable
Group / EIS reputation for customer
service and geographic reach and
Genuine Cable Group / EIS will
enhance the ability of CPS to service
our national accounts as well as
expand our product offering and
s
ervice capabilities. I believe this is a
win for our companies and our cus-
tomers”.
EIS is a wholly-owned subsidiary
of GPC and a leading distributor of
process materials, production
supplies, specialty wire and cable,
and value added fabricated parts
supplying the electrical OEM, appa-
ratus repair and various assembly
markets with over 100,000 critical
products from 39 branches and 7
fabrication facilities l
ocated in North
America.
For more information on EIS,
please visit www.eis-inc.com.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 17
Teknor Color Concentrates for
Wire and Cable
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 17
18 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 18
called registration. We figured out how
to do both of these processes concur-
rently in 3D and it is very fast and accu-
rate. Migrating that concept from 3D to
2D for wire harnesses was more chal-
lenging that we had expected. But, that
has been completed for well over a year
and our attention has been focused on
developing easy-to-use methods of
importing data that people already have
and converting it into something that
can be displayed in an AR format” says
Dr. Haisty.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 19
1 - ARTOS MTX10 Multi-Task Wire Processor
2 - ARTOS STX5 Single-Task Wire Processors
2 - ARTOS CS337 Cut & Strip Machine
1 - ARTOS CS336 Cut & Strip Machine
1 - ARTOS CS326 Cut & Strip Machine
1 - ARTOS CS29 Cut & Strip Machine, #42774A
4 - ARTOS CS26, CS26A Cut and Strip Machines
1 - ATS Crimp Press, Series T3000, with Applicator
1 - AUTOJECTOR HS30-S Injection Molding Machine
1 - AUTOJECTOR VS10-S Vertical Injection Molding Machine
1 - BLUE M Oven, Model POM-1406G1
1 - BRADY Wraptor Label Machine
1 - CAMI M2U Basic Cable Tester
1 - CARPENTER 93 Automatic Cut & Strip Machine
1 - CARPENTER 56A Dereeler
3 - CARPENTER Model 70B Strippers
1 - ERASER Model C200 Wire Stripper, Part #AR-4901
1 - ERASER Model 1256 Wire Stripper, Part #RC-1071
1 - EUBANKS 4000-04 Tandem Cut and Strip Machine w/extra Blade Sets
3 - EUBANKS 8000-01 Cut and Strip Machines
1 - FELINS PakTyer 2000 Semi-Automatic Tying Machine
1 - IDEAL ‘Stripmaster’ Model 940 Wire Stripper, Part #45-940
2 - J.B. HYDE 24-C, 48-C Braiding Machines
2 - KAWA Splicing Machines, Model KW-IT, New
1 - KINGSLEY Model MCM-650 Sleeve and Tube Marker
2 - KODERA Model C556 Seal, Crimp and Tinning Machines
1 - KOMAX DPS 272 Coiler, 2012
1 - KOMAX Gamma 333PC Automatic Crimping Machine
2 - KOMAX Alpha 411 Automatic Crimping Machines
1 - LOCTITE Model 10-50 Posi-Link Volumetric Dual Cartridge Dispensing System
2 - MEGOMAT ASM3001 Wire Cutting/Crimping Machines
1 - METRONIC Alpha Jet C Inkjet Printer, 2006/07
1 - MORGAN Injection Molding Machine, Model G-100T
5 - MORGAN Injection Molding Machines, Model G-125T
1 - NEW ENGLAND BUTT 72-Carrier Braider (w/flat strap capability)
1 - NEW ENGLAND BUTT 56-Carrier Harness Braider, 24” Capstan Wheel
3 - NEW ENGLAND BUTT 48-Carrier Harness Braiders, rear delivery chutes
1 - NEW ENGLAND BUTT 32-Carrier Harness Braider, 24” Capstan Wheel
1 - NEW ENGLAND BUTT 16-Carrier Harness Braider, 24” Capstan Wheel
1 - PANDUIT CP-861 Crimp Press
1 - SCHLEUNIGER CC36S Automatic Crimping Machine
2 - SCHLEUNIGER CC1000 Coilers
1 - SCHLEUNIGER CP1500 Heavy Duty Coiler
1 - SCHLEUNIGER C
S5300 Coax Stripper
1 - SCHLEUNIGER CS9100 Cut/Strip Machine w/PF2000 Prefeed
1 - SCHLEUNIGER CT32 Crimp Press, 2008
1 - SCHLEUNIGER EC9300 EcoStrip Cut/Strip
1 - SCHLEUNIGER ES9320 EcoStrip Cut/Strip, 2006
2 - SCHLEUNIGER JS8300 Jacket Strippers
1 - SCHLEUNIGER MP257 Stripper
1 - SCHLEUNIGER PS9500 Power Stripper
1 - SCHLEUNIGER PT26 Pull Tester, 2008
2 - SCHLEUNIGER US2100 Bench Strippers
4 - SCHLEUNIGER WS1000 Wire Stackers
2 - SCHLEUNIGER Uni-A Applicators
1 - SM CONTACT Splice Machine, SM CRIMP 2000
1 - SPECTRUM ‘Sienna 210S’ Radial & Axis Laser Wire Stripper (modified to Model 210D)
1 - T&B Electric Hydraulic Pump, Model 13810
1 – TRI-STAR TECHNOLOGY Table Top Laser Marker, M100L FG-TT
★★★
FOR SALE
★★★
Contact: Martin Kenner
COMMISSION BROKERS, INC.
P.O. Box 8456 • Cranston, RI 02920-0456
Tel: (401) 943-3777 Fax: (401) 943-3670
Website: www.commissionbrokers.com • E-mail: marty137@aol.com
21st Century Wire Harness
Assembly
Continued from page 1 _______________
________________Continued on page 21
System execution of HarnessWorks.
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 19
20 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 20
High Mix, Low Volume
Fast Reconfigurable Wire Board
But, long and tedious are not the only
applications that can benefit from AR.
One of the ideas that came up in the ear-
liest concept was the notion of a quick-
ly reconfigurable board. For companies
that build just one or a few units of a
large number of different harnesses, the
reconfigurable board concept can
streamline the build process, even for
fairly
simple harnesses. This was a bene-
fit that was not originally anticipated by
the development team, as they we
focused on process optimization of har-
nesses ranging from 20 to 200 hours of
assembly time.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 21
21st Century Wire Harness
Assembly
Continued from page 19 ______________
________________Continued on page 23
Multiple system usage.
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 21
One of the development partners had
over 4,000 harness boards in storage for
aircraft that were no longer in produc-
tion all of which must be maintained
as long as there is still at least one air-
craft of that type flying. The prospect of
being able to digitize all those harnesses
and replace 4,000 boards with one sin-
gle board that can be configured to
make the needed harness in a couple
minutes was extremely appealing.
Later as non-aerospace partners
joined the group, DSC quickly realized
that even harnesses that take less than
one hour to build can benefit from the
technology but for them the bigger
benefit is the reconfigurable board.
Working on the same board all day and
not having to file away a completed
board and retrieve the next board can
be a real time saver, as well as space
saver. In mid-2016 D
SC and Panduit
teamed up to integrate the Panduit
Quick-Build system with HarnessWorks.
Panduit made some modifications to
some of the Quick-Build components to
facilitate the AR instructions, and DSC
created a library of Panduit components
for fast board layout. The combination
makes for a fast system setup that is
highly repeatable.
Data Sources
In 2015, DSC partnered with Mentor
Graphics using their C
apital software to
project harness assembly instructions.
Work instruction files created in Capital
can be executed by HarnessWorks
directly, with only a mouse click or two
required to generate the entire work
sequence. In July 2016, DSC partnered
with EPLAN to present their harness
assembly instructions in HarnessWorks.
That integration is scheduled to be avail-
able in 2017 and will even allow legacy
documentation t
hat was hand drawn
onto a board to be digitized quickly,
accurately and easily. Once the informa-
tion is digitized, the world of Augmented
Reality opportunities opens up.
Traditional 2D CAD drawings can also
be used along with wire lists in a spread-
sheet or csv format to create sequenced
work instructions. This process can be
somewhat automated with the templat-
ing feature in the authoring s
oftware
package called ManuScript
TM
. This fea-
ture allows the manufacturing engineer
to create a template by writing a script
that defines how to use the selected
data and how to sequence the work and
display the data. Once legacy data is in
a sequenceable format the template can
create assembly instructions in a few
seconds.
Harness Testing
HarnessWorks can integrate harness
testing in with the build as we
ll. An inte-
gration with DIT-MCO is complete, and
an interface with Cirris is underway,
which will be complete in 2017. Har-
22 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
21st Century Wire Harness
Assembly
Continued from page 21 ______________
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 22
nessWorks provides instructions where
the user can see not only exactly what
to do, but exactly when and where to do
it. Test data, particularly a failure can be
immediately shown, including the wire
route of the problem.
Time Saved, Errors Reduced
There is no data yet for how much
time can be saved and how much error
can be reduced specifically for wire har-
nesses, but a controlled experiment was
conducted by DSC over about 6 months
in 2016. The experiment was simply to
compare how long it took to build a
small assembly and how many errors
were made when the same object was
built using traditional methods (drawing
and words) verses using AR instructions.
With 110 participants the results of the
experiment are:
Labor is 0.29x using AR or 71%
less than using traditional methods
Standard Deviation of build time i
s
0.28x or 72% tighter than tradi-
tional methods
Errors were a mind boggling 0.07x
yes, a 93% reduction from tradi-
tional methods
“The numbers above can be a bit
hard to accept a person is working
over 3 times faster and making well less
than 1/10th the errors. But it is true, and
the data from this controlled experi-
ment correlates well with actual use on
production lines. Not only are techni-
c
ians faster and make far fewer errors,
they are not working as hard, and are
less fatigued at the end of a day. Aug-
mented Reality accesses a part of the
brain that it not available via traditional
documentation methods. Direct access
to the visual cortex is what makes these
astounding results possible. There is
good reason to expect that we will see
similar results with harness building”
reports Richard
son. A white paper on
the experiment can be found at
www.projectionworks.com/downloads.
Pilot Program
“The Air Force has a rigorous set of
rules for a development program like
this. We had weekly teleconferences to
discuss progress and exchange ideas to
keep the direction of the development
on track. Things like data input formats,
what the users sees, and how the user
interacts with the system were dis-
c
ussed regularly to ensure that all stake-
holders needs were being met all along
the way” noted Haisty.
As the last step before the general
rollout of HarnessWorks, DSC has creat-
ed a beta test program where qualified
candidates can participate in the last
stage of development. Partner compa-
nies can submit the candidate pilot proj-
ect to DSC for review. DSC will evaluate
the projects and select a few
that pro-
vide a variety of installation scenarios.
The selected Partners would purchase
the appropriate HarnessWorks hard-
ware/software package for their pilot
project. DSC will provide, at no cost, up
to 100 hours of engineering support to
aid in the integration of the pilot system
with the partner’s existing infrastruc-
ture. DSC will provide an additional year
of warranty support for the pilot system.
We believe HarnessWorks is ready
to go to work in a production environ-
ment, but, as with any new product
launch, there may be bumps in the road
on the first systems. We are looking for
partners that are willing to work with us
to smooth out those bumps, and save
some money doing it. Ideal candidates
are companies that already intend to
buy HarnessWorks systems, but want to
start early and evaluate the system, c
al-
culate the ROI, and perhaps provide
feedback into product improvement.
Once the pilot program has been suc-
cessfully completed, we will release the
system for general sale. reports Cappai.
If you are interested in becoming a
partner in the HarnessWorks pilot pro-
gram, please contact Craig Cappai at
craig@deltasigmacompany.com.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 23
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 23
BURNDY
®
Announces the
Release of the BMCSS line of
Integrated Bonding Clamps
BURNDY
®
, a leading manufacturer
and provider of bonding and
grounding solutions to the Solar PV
industry, announces the addition of
the new BMCSS integrated bonding
clamps to their WILEY line of prod-
ucts.
The BMCSS integrated bonding
mid-clamps are made of corrosion
resistant 304 stainless steel, which
makes them a durable, long lasting
a
nd reliable solution for all environ-
ments. The down-turned points are
designed to pierce the anodized
coating of the module frame. The
result is excellent conductivity bond-
ing the PV modules together. Essen-
tially, the modules become one sin-
gular piece of metal, creating a clear
electrical path to the ground.
Innovative design that
allows for quick and easy installations
High quality, long-
lasting, l
abor saving bond-
ing solution
Corrosion resistant
304 stainless steel provides
outstanding durability and
performance in all environ-
ments
Down-turned
points pierce the anodized
coating and make electrical
connection
Accommodates
M6 (1/4”) or M8 (5/16)
hardware
Allows for 17MM
module spacing
UL2703 Listed with
certain systems
UL2703 evaluation
and testing available
Lasts for the life-
time of the Solar P
V system
Custom product
designs are available upon
request
Please visit Wiley website
for more information on
other Wiley Products:
http://www.we-llc.com.
For System Compatibility
information, visit:
http://www.we-llc.com/ref-
erences/technical-refer-
ences. For Installation manu-
als, visit: http:// www.we-
llc.com/references/ installa-
tion-manuals.
Contact BURNDY
®
at 47 E.
Industrial Park Drive, Man-
chester, New Hampshire,
03109, call our Londonder-
ry, New Hampshire-based
Customer Service at 1-800-
346-4175, or visit our web-
site at www.BURNDY.com.
24 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
WIRE HARNESS ASSEMBLY STATIONS
Designed for the ergonomic assembly of wire harnesses
Surfaces tilt and adjust up and down
Holds boards from 24” x 24” up to 48” x 96”.
Two models to choose from — Electric or Manual adjust
Adjustable front lip holds boards from .250” to .750”.
The Leading Edge in
Modular Ergonomics
10 Avco Road
Haverhill, MA 01835
Ph: 800-739-9067
Fx: 978-374-4885
www.1proline.com www.industrialworkbenches.com
E-mail Bench@1proline.com
NEWS PLUGS
NEWS PLUGS
continued
BMCSS integrated bonding clamps
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 24
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 25
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 25
Siemon Interconnect Solutions
Exhibiting at SC16
Siemon Interconnect Solutions, a
business unit of Siemon that pro-
vides custom network infrastructure
solutions to OEMs, value-added
resellers and system integrators, is
pleased to announce participation in
Super Computing 2016 in Salt Lake
City, Utah.
SC16 is the world’s largest market-
place for high performance comput-
ing professionals. Super Computing
attracts s
cientists and engineers, soft-
ware developers, policy makers, cor-
porate managers, CIOs, and IT
administrators from universities,
industry, and government agencies.
SIS will be showcasing their V-Built™
Solutions including preconfigured
Top of Rack, Aggregation Rack and
Cable Tray Rack solutions. Also on
display in exhibit booth #3462, will
be the newly launched 100G QSFP28
and 25G SFP28 as well as a l
arge dis-
play of copper and fiber intercon-
nects, intelligent PDUs and cable
management solutions.
“We are excited to launch the V-
Built™ series of preconfigured solu-
tions at SC16”, says SIS Sales and
Marketing Manager, Robert Lock-
wood. “V-Built addresses the
needs of today’s mega-scale data
centers that require custom precon-
figured solutions to maximize effi-
ciencies and increase throughput.
For e
xample, one part number from
the V-Built™ series specifies a server
rack completely integrated with
PDUs, cabling, cable management,
airflow management and any other
complimentary product our cus-
tomer needs for their rack build-
outs”.
SIS is a proven supplier in rapid
deployed system builds offering:
quality, service, innovation and value
as well as in-stock availability of most
common products needed for
t
oday’s mega scale data centers. As
an industry leader, SIS also supports
OCP: End Users, OEM's, VAR's and
SI's of all sizes with the most com-
prehensive offering of data center
infrastructure products available.
Siemon Interconnect Solutions
(SIS) is a business unit of Siemon
comprised of a team of dedicated
technical sales professionals sup-
ported by Siemon Labs, mechanical,
electrical and signal integrity e
ngi-
neers, committed to solving industry
and customer driven interconnect
challenges. SIS provides custom net-
work infrastructure solutions to
OEMs, value-added resellers and
system integrators. Established in
1903, Siemon is an industry
leader specializing in the
design and manufacture of
high quality, high perform-
ance low voltage infrastruc-
ture solutions and services
for Data Centers, Enterprise
and Intelligent Buildings.
H
eadquartered in Connecti-
cut, USA, with global sales,
technical and logistics
expertise spanning 100
countries, Siemon offers the
most comprehensive suite
of copper and optical fiber
cabling systems, cabinets,
racks, cable management,
data center power and
cooling systems and Intelli-
gent Infrastructure Manage-
ment solutions. With more
than 400 patents specific to
structured cabling, S
iemon
Labs invests heavily in R&D
and the development of
Industry Standards, under-
lining the company’s long-
standing commitment to its
customers and the industry.
Through an ongoing com-
mitment to waste and ener-
gy reduction, Siemon’s envi-
ronmental sustainability
benchmarks are unparal-
leled in the industry, includ-
ing 179% global carbon
negativity and zero-landfill
status.
For more information
about S
iemon Interconnect
Solutions (SIS) please visit:
www.siemon.com or con-
tact Siemon Interconnect
Solutions, 101 Siemon Com-
pany Dr, Watertown, CT
06795.
26 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
APPLICATION RANGE:
WIRE CODING WIPERS
1/2” & 1” Dia in silicone, foam & felt
Also 1-3/16” Dia gum rubber scrubbers.
For complete list & prices go to
WWW.EICWIPERS.COM
Tel: 619-303-7924
Fax: 619-303-7925
Same Day Shipping Ask for Pete
NEWS PLUGS
NEWS PLUGS
continued
Wiring Harness Manufacturer’s
Association 2017 Conference
February 7-March 1, 2017
San Antonio, Texas
www.whma.org
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 26
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 27
Mando Can Do.
HAPPY ENDINGS
Eubanks Engineering Co.
950 E. Royal Oaks Drive, Monrovia, CA 91016
(626) 357-7011 Fax (626) 357-4718
www.eubanks.com
When Armando Zacarias goes out on a
Eubanks service call, unusual things happen.
“Once I helped round up a cow that got
loose in a customers plant.
Another time, while driving to a
customers site, our reps car caught fire.
We eventually arrived there that night and
finished the job in time for the morning
shift,” Mando reports.
Customers report something unusual too:
Mandos can-doattitude.
Ge
orge Pr
ice, vice president of J&M
Products, for example, writes how Mando
takes time to answer questions, explain
machine operation and even gave tips on
stripping some shielded cable that others
said could not be done.”
“Cant be doneis not in Mandos
vocabulary—either English or Spanish.
On his own initiative, he solves problems,
leads training classes, helps boost plant
efficiencies,
and make
s
l
asting friend-
ships while
doing it.
Mando
exemplifies
the Eubanks
business experience—highest-quality, U.S.A.-
built wire strippers and markers backed
by dedicated people itching to solve your
wire problems.
Call us today. We’ll put this can doattitude
to work for you till the cows come home.
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 27
S
electing subassembly manufac-
turers with specific capabilities
can speed turnaround, improve
product performance and functionality,
and increase an OEM’s bottom line.
With electrical and electronic com-
ponents and features like touch screens,
flex circuits, keypads and membrane
switches becoming more technological-
ly advanced, OEMs are becoming
increasingly dependent on sourcing sub-
assemblies to expert third-party suppli-
ers.
At the same time, subassemblies are
critical to the OEM’s finished product
and must be sourced carefully to
achieve consistent quality, timely turn-
around and competitive pricing. In
many cases, contracting with suppliers
that offer access to global manufactur-
ing facilities and in-house engineering
support can be instrumental to the suc-
cess of an OEM.
One of the most significant chal-
lenges is locating reliable suppliers that
can meet these qualifications with pric-
ing that can improve profitability. Some
of the more successful OEMs point to a
few uncomplicated strategies that help
strengthen subassembly sourcing,
achieving faster turnaround, ensuring
product quality and functionality, and
increasing added profitability.
1. Access to Global Resources
Selecting a domestic subassembly
supplier with global manufacturing
re
sources can provide OEMs with signif-
icant economic advantages provided
the manufacturing processes are well
managed by the supplier.
For example, many OEMs that con-
tract directly with offshore suppliers
experience communication difficulties
that can lead to errors with subassembly
materials or dimensions, avoidable logis-
tical difficulties, or even cost miscalcula-
t
ions.
However, some OEM suppliers have
no problem in providing high quality
products through relationships with off-
shore fabricators that work seamlessly
with the domestic supplier’s engineer-
ing and management team.
“We have found that offshore fabrica-
tors can be effective partners in manu-
facturing for North American subassem-
bly suppliers, provided the proper com-
munications and management contro
ls
are in place, says Hector Macias, direc-
tor of Northpoint Technologies, El Paso,
Texas. Macias adds that such fabrication
partnerships can also be financially ben-
eficial to OEM customers by providing
saving on costs and eliminating the need
for capital investments.
Northpoint Technologies is a manu-
facturer of components and subassem-
blies used in electronic and electric
devices used in the medical, a
utomotive,
defense, telecommunications, industrial
and consumer markets. The company’s
expertise includes silicon and mem-
brane switches, flexible PCBs and assem-
blies, touchscreens and wire harnesses.
When Justin Blush was in search of a
silicon membrane for a microscope con-
trol switch, he found Northpoint Tech-
nology. Blush, lead technician at
Prescott’s Inc., a remanufacturer of sur-
gical micro
scope, says his company’s
own molding and machine shop was
unable to fabricate the membrane,
which was incorporated
into a switch that enabled
a model of microscope to
zoom in and out on a sub-
ject.
Northpoint advised
Blush that the membrane
would be designed at its
headquarters in El Paso,
but would be fabricated at
a plant in Asia.
“I was happy just to
have a supplier and
expected the fabrication
and shipping process to
take at least six-to-eight
we
eks, as with our tradi-
tional suppliers, Blush
explains. “I was amazed to
learn that the membrane
required only a two-week
turnaround, and at a frac-
tion of the price I expect-
ed.
2. Faster, Functional Pro-
totypes
The timely delivery of
prototypes and quick turn-
around of revisions are
vital to expediting the
manufacturing process.
When subassembly suppli-
ers with o
ffshore manufac-
turing facilities can pro-
duce prototypes in-house
with quick turn-around
times, the process is much
more efficient.
Due to those factors,
prototyping is one of the
functions that successful
suppliers seldom out-
source. Macias considers
prototyping a critical step
in product development.
These are produced via
aluminum or “soft” molds,
and are of such quality that
they are usually consid-
ered t
o be product sam-
ples or the equivalent of
first article production
pieces.
“The prototypes we
require are real, functional
samples that we send to
customers to inspect and
test, says Terry Swick, pres-
ident and co-founder,
28 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Subassembly Sourcing - How OEM’s Plan Strategy
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 28
Swick-White Inc. (Davisburg, MI), a
manufacturer of electric enclo-
sures, control panels, membrane
switches and graphic overlays.
Assuming they meet specifica-
tions, they can install them as fin-
ished subassemblies in products
and ship them out to customers
with confidence.
At other times OEMs
will have requirements
that are outside of the
usual request. Suppliers
who have the in-house
capabilities produce c
om-
plex items domestically
can satisfy the extra
demand by producing
additional functional pro-
totypes that have been
approved for production.
For example, Stoehr
says that on occasion, he
made such a request. “I
said, ‘We’re doing a proto-
type run of 10 control pan-
els, so can you provide 10
sample keypads?’ And they
were able to do that with
no delays.
3. Look for Volume Flexi-
bility
Whether subassemblies
o
r piece parts are fabricat-
ed domestically or over-
seas, minimum volume
requirements can force
OEMs to purchase more
parts than they require.
However, a few subassem-
bly suppliers are moving
away from volume require-
ments to better serve the
OEM.
When Steve Stoehr,
Engineering Manager at GS
Global Resources (GSGR)
was sourcing a keypad as
part of switch and control
panels installed on some
heavy-duty equipment
such as agricultural
machinery or fire trucks,
he expected to make a siz-
able volume commitment
to the keypad manufactur-
er.
Based in Mukwonago,
WI, GSGR develops and
implements a broad range
of electronic and hydraulic
control systems for various
OEMs.
“Most of our suppliers
want high-volume orders, just like
other industries, explains Stoehr.
“Five or six years ago we found
Northpoint Technologies, which
h
as been very good about taking on
even low volume projects. That’s a
real plus for us and our customers.
4. Adding Significant Value
Finally, many OEMs are finding
suppliers that provide significant
value-added services, with offerings
ranging from engineering assis-
tance to recommendations for
streamlining the manufacturing
process.
In some cases, graphic design
assistance, such as special icons or
other symbols on keypads and
o
ther controls, can provide impor-
tant safety or security features.
In another example, GSGR’s
Stoehr found that subassembly sup-
pliers could bring important value
added through the kitting of loose
piece parts. He arranged with
Northpoint to have special kits,
containing 20 loose keypad but-
tons, to be packaged in order to
expedite assembly on the produc-
tion line.
“Getting great value-added s
erv-
ices through a single source is
important to GSGR, Stoehr says. “It
is not only more convenient, but
when you couple that with consis-
tent quality, quick turnaround and
competitive prices, it helps us pro-
vide better service to our cus-
tomers, as well.
For further information contact
Northpoint Technologies, Inc.;
13321 Tobacco Rd., El Paso, TX
79938. Phone: (915) 591-6300 or
visit website northpointech.com
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 29
Print a bar code label only Restrict an operator from Identify the operator for Verify the bar code label
if the harness passes? altering the program? labels and data collection? is applied to the harness?
Transfer programs to tester Send alert if harness is Connect to a network for file Work as a standalone system
via a memory card? removed prematurely? transfers and data collection? without needing a computer?
145 Lively Boulevard Fax: (847) 290-8689
Elk Grove Village, IL 60007 Phone: (847) 290-8686
CHIEF SUPPLY INC.
E
M
P
T
Y
R
E
E
L
S
W
A
N
T
E
D
We buy
empty reels…
Plastic Wood Cardboard
Almost any size or shape
CHIEF SUPPLY INC.
(847) 290-8686
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 29
30 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 30
Joe Tito
Wiring Harness News
____________________________
S
ix world class providers of wire
processing equipment teamed
up for a fun and informative
Octoberfest themed trade event on Sep-
tember 22. The event was hosted by Pan-
duit at their world headquarters in Tin-
ley Park, IL, and co-hosted by partners
Schleuniger, Cirrus Systems, GEM
Gravure, Telsonic, and HarnessWorks.
Panduit’s impressive LEED Gold Certi-
fied facility houses an expansive exhibit
area where each company set up live
demonstrations of their products. The
suppliers had lively one-on-one interac-
tions with well over 100 harness manu-
facturers. Each vendor to gave short pre-
sentations focused on new and evolving
wire processing technologies and solu-
tions.
The combination of the festive atmos-
phere, active displays, and informative
presentations, meant visitors could
d
elve deeper into conversations with
these select partners. Attendees were
treated to an excellent array of tradition-
al German foods and deserts, and there
was plenty of Warsteiner beer on hand
to raise a toast. Music was provided by
Der Musikmeisters, a local German
band, who really got everyone in the
spirit of Octoberfest. The event was
complete with a beer stein holding con-
test and festive sing-alongs.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 31
Six Suppliers Host Octoberfest
Der Musikmeisters got the crowd rolling.
________________Continued on page 34
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 31
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 32
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 33
Amid the food and fun, the hosts dug
into their presentations. Adam Simms
outlined Panduit’s commitment to devel-
op equipment designed to save space
and reduce capital investment. He
described how Panduit relies heavily on
the partnerships they have developed
with the other host companies. In sup-
port of this notion, he reviewed Quick-
Build 2.0, the modular alternative to
cumbersome harness nail boards that
wo
rks well with HarnessWorks, and also
the new PAT 4.0 Cable Tie System. Adam
also highlighted the interchangeability
of dies across automated and bench top
platforms. He concluded with Panduit's
Test Drive program where manufactur-
ers can take temporary delivery of
equipment for a no-risk evaluation. Pan-
duit provides two weeks of consum-
ables, and offers free training for the
evaluation period.
Rob Boyd of Schleuniger discussed
the latest in crimp quality management,
and gave an update on the LV 214-4 Ger-
man Automotive Connector Test Specifi-
cation. Rob spoke about this back in May
at the EWPT Expo in Milwaukee and
thinks the specification, which is still in
draft form, will become an important
component of crimp quality monitoring
for OEM suppliers. The specification
deals mostly with in-process crimp mon-
itoring. In support of this and other
crimp monitoring strategies, Rob out-
lined the MicroGraph modular crimp
cross-sectional analysis system that is
scalable to individual needs, and small
34 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Octoberfest
Continued from page 31 ______________
From left, Greg Wilson, Event Manager and Ralph Liebner VFI Marketing take
charge of Panduit's exhibit trailer.
________________Continued on page 34
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 34
U.S. Advantages
Companies are starting to use Total
Cost of Ownership (TCO) to qualify
these and other costs (See Figure 2).
They are reducing cost via lean improve-
ments, product design, and automation.
They are finding they can often manu-
facture more profitably in the United
States
U.S. No Longer Losing Jobs to Off-
shore
Net annual job loss to offshoring
went from around 200,000 in 2003, to
zero today! (See Fi
gure 3)
Top 10 Reasons Companies Are
Coming Back
Many companies are using the Total
Cost of Ownership Estimator found on
reshorenow.org to calculate the actual
cost of their offshore sources. (See Fig-
ure 4)
About the Reshoring Initiative
The Reshoring Initiative offers many
tools and resources to help companies
make supply chain sourcing decisions.
The Reshoring Initiative’s Total Cost of
Ownership Estimator
®
is the best-known
tool for this purpose. It uses advanced
metrics that allow users to easily deter-
mine the total cost of offshoring by
accounting for and understanding the
relevant offshoring costs, which include
inventory carrying costs, shipping
expenses, intellectual property risks and
more.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 35
New Dawn for Manufacturing Careers in America
Continued from page 1 ______
Figure 2
Figure 3
Figure 4
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 35
36 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 36
enough to reside on the shop floor close
to crimp stations.
Complex wiring systems with non
visible components, increasing reliabili-
ty standards, and increased testing
requirements are all reasons for a heav-
ier reliance on non-destructive test sys-
tems. Kevin Denning of Cirris Systems
outlined many of the surprisingly afford-
able systems that meet these needs. As
with the other host partners, Cirris has
embraced the ideas of scalability and
mobility in the development of new sys-
tems.
Telsonic Ultrasonic Welding equip-
ment is used across many industries, but
the metallurgic bonds created by this
technology make it ideal for wire har-
ness production. Nader Denning went
in-depth to describe the technology
behind ultrasonic welding and
described some of the applications,
especially in areas where dissimilar met-
als are involved. He highlighted the
importance of this by not-
ing that BMW has
informed the industry that
by mid 2020's, 50 percent
of the wire and cable used
in their vehicles will be
aluminum. Nader followed
the scalability theme by
noting the generators on
their newer systems can
be upgraded in 1.2 kW
increments to accommo-
date any future expanded
needs.
Huck Hyde of GEM
Gravure spoke of the dif-
ferences a
nd applications
of pigments and dyes, and
outlined their applications
for wire marking. He also
outlined the challenges of
developing ink colors that
can be visible against a
vast array of insulation col-
ors. Following the theme
of portability and scalabili-
ty of equipment, Huck
spoke about the alphaJet
line of Continuous Ink Jet
printers for wire and cable
marking. This equipment
boasts space saving attrib-
utes and is versatile
enough to print font sizes
from 10mm, all the way
down to 0.7 mm.
Finally, Roger Richard-
son of HarnessWorks
spoke about their system
for harness board assem-
bly. It has been in develop-
ment for a few years, and is
now ready for rollout. The
system uses an overhead
projector to provide step-
by-step harness build
instructions on scalable,
reusable boards. As men-
tioned, it works well in
c
onjunction with Panduit's
Quick Build 2.0 and repre-
sents a revolution in aero-
space harness manufactur-
ing. Look for more in-
depth coverage of Har-
nessWorks in a feature arti-
cle in this issue.
Panduit also had their
mobile display unit on
hand for all to tour. This
rolling exhibit is updated
at least once a year and has
full working displays of the latest Pan-
duit products. The unit spends 300 days
a year traveling throughout the US and
Canada stopping at distributors, OEM's,
and other locally scheduled events.
Wiring Harness News caught up with
Todd Maines of TACK Electronics to get
his impression of the event. He felt it
was a really good intimate event which
allowed for more in-depth conversations
with the suppliers that were there. “I
enjoyed the tour of Panduit and the hos-
pitality was amazing. The flow of the
event was great and I would definitely
attend next year of they held it again.
In previous years, the Octoberfest
was hosted by Schleuniger, and these
partners intend to build on the success
of this year’s function with other local-
ized events. If you would like to be
included in one of these events, or
would like to see the Panduit rolling
exhibit, contact your company represen-
tative at o
ne of the hosting companies.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 37
Full working displays inside the trailer.
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 37
CMC Introduces the ROTO-LUG™
Line of Electrical Connectors
Featuring Turning Point Technology
Connector Manufacturing Company
(CMC ) has introduce the new ROTO-
LUG™ connector product line. ROTO-
LUG™ connectors have the built-in Turn-
ing Point rotational feature that allows up
to 219º positioning in all directions: front-
and-back and side-to-side.
The built-in rotation feature significantly
reduces installation t
ime and the amount
of conductor needed as it allows the
installer to bring the connector to the con-
ductor by quickly adjusting the angle of
the connector to accommodate the con-
ductor. ROTOLUG™ connectors are range
taking and accommodate both copper
and aluminum conductors. ROTO-LUG™
connectors are cULus Listed for wire ter-
minations.
Over the years, wire has become larger
in size while at the same time switchgear
boxes and breaker boxes have become
smaller and more compact. Electrical con-
tractors must bend large diameter wire in
order to install it in the fixed lugs available
today. Often, bending is accomplished by
heating and machine-bending the wire
beyond limits allowed by codes and safe-
ty for lack of an alternative.
CMC’s ROTO-LUG™ connectors pro-
vide a superior connection in 50% less
time as standard termination methods
w
here the need to bend the wire is pres-
ent.
Acquired by BURNDY in 2013, CMC
was established in the early 1940s and
relocated to Cincinnati, Ohio, in 1976.
CMC has 3 primary sites totaling over
206,000 square feet of production. CMC is
a full line manufacturer of aluminum and
copper connectors, offering both
mechanical and compression designs. In
addition to its utility p
roducts, CMC man-
ufactures connectors for meter socket ter-
minals, load center neutral bars, switch
gear terminations, commercial panel
boards, circuit breakers, motor controls
and pole line hardware, wind energy
products, solar energy products, and
enclosures.
For additional information contact 513-
860-4455 or visit: www.cmclugs.com.
38 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
NEWS PLUGS
NEWS PLUGS
continued
ROTO-LUG™ Electrical Connectors
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 38
CABLE JACKET TYPES 101
A
lmost every cable has a jacket
and for good reason: jackets
help mechanically protect the
insulation and conductor core of the
cable. Without a jacket, cables are sus-
ceptible to abrasion, heat damage and
oxidation damage, as well as weather-
related damage. But not every jacket is
created equal; it is imperative that each
cable have the correct jacket type for
each application in order for the cable
to operate properly. This wire wisdom
will explore some of the different cable
jacket types and provide an overview on
the jackets’ mechanical and chemical
properties.
WHAT IS A CABLE JACKET?
A jacket is the outermost layer of a
cable whose primary function is to pro-
tect the insulation and conductor core
from external physical forces and chem-
ical deterioration. In a sense, the cable
jacket is the first line of mechanical
defense for a cable by protecting the
cable’s inner components. Cable jackets
offer mechanical, moisture, flame and
chemical protection, while also protect-
ing the cable from damage during or
after installation. It is important to note
that the cable jacket has little to do with
the electrical performance of the cable.
CABLE JACKET TYPES
Cable jacket types can be broken
down i
nto two categories: thermoplastic
jackets and thermoset jackets. A thermo-
plastic jacket is a type of material that
when hot enough will melt and reform,
whereas a thermoset jacket is a “set”
material it doesn’t have the ability to
reform when heated. There are many dif-
ferent types of both thermoplastic and
thermoset jackets, and the options listed
below are only a small array of the
choices one has with cable jacket types.
Thermoplastic
PVC Polyvinyl Chloride (PVC) jack-
ets, while not exhibiting a wide range of
thermal characteristics, do have the abil-
ity to resist oils, acids, sunlight, heat,
weathering and abrasion. By having such
strong physical assets, PVC is an ideal
jacket for cables that will be used for
direct burial, street lighting and control
cable. Since PVC is inherently flamere-
tardant, it is the most common jacketing
material for electronic cable.
Polyurethane A polyurethane
(PUR) jacket has excellent oxidation, oil,
and ozone resistance, and when special-
ly formulated, a polyurethane jacket can
also have good flame resistance. These
types of jackets also have great “memo-
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 39
____________________________________________________________________________________________
In every issue of Wiring Harness News Anixter will bring you
informative articles about wire and cable technology.
________________Continued on page 40
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 39
ry” properties, which make it an ideal
jacket for retractile cords.
CPE Chlorinated Polyethylene
(CPE) is one of the few polymers that is
available as both a thermoplastic and a
thermoset jacket (thermoset CPE would
be a cross-linked version). The thermo-
plastic CPE jacket has excellent oxida-
tion, heat, oil, weather/sun and flame
resistance. Although the thermoset ver-
sion has better high-temperature prop-
erties, the thermoplastic version con-
tains other excellent properties.
Thermoset
Neoprene Neoprene is a synthetic
rubber that allows for a resilient jacket.
By not embrittling at cold temperatures,
resisting permanent deformation under
heat, and resisting aging due to oxida-
tion and sunlight, neoprene jackets are
suitable for cables in rugged environ-
ments, such as mine trailing cables and
dredge cabl
es.
EPR Ethylene Propylene Rubber
(EPR), another form of synthetic rubber,
is a type of jacket that is a modified form
of the EPR insulating compound. EPR
jackets have excellent heat, abrasion,
oxidation resistance and can also with-
stand cold temperatures down to -60°C.
With fairly good high-temperature char-
acteristics overall, when formulated cor-
rectly, EPR can be fairly flame retardant
as well.
CPE The thermoset CPE jacket
(cross-linked) has excellent ph
ysical
properties that make it suitable for many
cable jacket applications. This polymer is
resistant to ozone and ultraviolet degra-
dation, and if properly compounded, can
also withstand prolonged immersion in
water. With strong resistance to most
acids, bases, and solvents, thermoset CPE
jackets are well-suited for chemical plant
use.
PROPERTIES OF C
ABLE JACKETS
As stated earlier, jackets provide
mechanical protection to the insulation
and conductor core. In order to provide
the best possible protection for the
cable, a jacket can be modified by the
addition of fillers, plasticizers, activators,
and inhibitors to enhance a particular
physical characteristic. Some of those
physical characteristics are as follows:
Toughness, tear and abrasion
resistance
F
lexibility during cable
installation, at low temperature
Stability over a range of
temperatures
Resistance to heat aging
Resistance to cable deformation
Flame resistance
Oil resistance
Low moisture absorption
Resistance to abnormal
concentrations
If you would like more information
on cable jackets, please see the Anixter
Wire and Cable Technical Information
Handbook, as well as the IEEE 532
guide.
40 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
MINI
MINI FUSE HOLDER CAP
Use our ES10 Cap with Delphi/Packard components
to build a 280 Series Sealed Metri-Pack MINI Fuse Holder.
Designed for harsh environments and
engine compartment conditions
Phone (440) 871-0800 • Fax (440) 871-0799
E-mail sales@whiteproducts.com
925 Bassett Road, Unit D, Westlake, OH 44145
www.whiteproducts.com
IMDS CERTIFIED
Continued from page 39 __________
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 40
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 41
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 41
TE Connectivity’s New Single Wall
Heat Shrink Tubing Products Meet
the Halogen-Free Requirement and
UL VW-1 Flammability Test
TE Connectivity (TE), a world leader in
connectivity and sensors, introduces its
new single wall, flame retardant (SWFR)
product line. These single wall heat shrink
tubing products are rated for the UL VW-1
flammability test specified by the UL 224
standard. Because the highly flame-retar-
dant polyolefin jacket is non-halogenated,
SWFR tubing can be used in confined-
space applications where it is unaccept-
able for materials containing halogen to
burn and potentially emit toxins. SWFR
products offer an optimum solution for
insulating and mechanically protecting
components, connections and termina-
tions across many applications from
industrial controls to home appliances
and mass t
ransit vehicles.
“Advances in material technology and
manufacturing processes have allowed us
to introduce this relatively low-cost, single
wall tubing product that is halogen-free
and meets the UL VW-1 flammability test,”
said John Sandwell, tubing product man-
agement director, TE’s Appliances busi-
ness unit. “As a Zerohal tubing product,
it’s particularly suitable for applications in
confined spaces that must maintain air
quality. With its combination of highly
attractive properties, our new SWFR tubing
is a key addition to our already broad line
of Raychem heat shrink tubing products.”
SWFR tubing products are offered in
either thin wall (X2) or very thin wall (X4)
versions. The products shrink at a 2:1 ratio
and install quickly, due to their relatively
low full-recovery temperature of 90
degrees Celsius. Both types of tubing
p
roducts are very flexible and can be
used across operating temperatures rang-
ing from minus 30 degrees Celsius to 125
degrees Celsius.
The SWFR thin wall X2 products are
available in 17 sizes ranging from 1.0 to
30mm. The very thin wall X4 tubing prod-
ucts come in 13 sizes ranging from 0.8 to
25mm. (The sizes refer to approximate
unrecovered inside diameter.) Thin wall
X2 versions afford somewhat better
r
esistance to physical abuse. The very thin
wall X4 tubing products enable protected
components to be packed more closely
together. The X4 versions also shrink
more rapidly to reduce application time,
which may be helpful in preventing the
overheating of temperature-sensitive com-
ponents.
In addition to insulating and mechani-
cally protecting in-line components and
connections, SWFR tubing can be used for
bundling wires in very flexible, light-duty
harnesses, and for strain-relieving electri-
cal wire connections to enhance reliabili-
ty.
All TE’s Raychem tubing products can
be easily installed using many different
types of heating tools, which are also
available from TE. These range from basic
heat guns for low-volume
requirements to conveyor-
equipped ovens for high-
volume production environ-
ments.
TE Connectivity (NYSE:
TEL) is a $12 billion global
technology leader. Our con-
nectivity and sensor solu-
tions are essential in today’s
increasingly connected
world. We collaborate with
engineers to transform their
concepts into creations
redefining what’s possible
using intelligent, efficient
and high-performing TE
products and solutions
proven in harsh environ-
ments. Our 72,000 people,
including over 7,000 engi-
neers, partner with cus-
tomers in close to 150
countries across a For fur-
ther information visit
www.TE.com.
42 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
NEWS PLUGS
NEWS PLUGS
continued
WHMA 2017 Conference
February 7-March 1, 2017
San Antonio, Texas www.whma.org
Single Wall, Flame Retardant
(SWFR) Tubing
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 42
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 43
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 43
By Greg Miller
Breyden Products
______________________________
T
he curing oven looks
solid if unimpressive,
almost the same way it
looked 25 years ago in a garage
2,200 miles away the day it was
built. It sits waiting in a building on
Radio Road—so named because
the building was originally the
police radio post in town—in
Columbia City, Indiana. Millions
upon millions of feet of polyester,
nylon, Nomex, Teflon, and Kevlar
lacing tapes and over-braiding
yarns passed through that garage-
built oven on their way to being
sold across the world by a compa-
ny named in a kitchen with the
help of a bottle of wine, a few
beers, and a dictionary.
The word “Breyden” has its roots
in old English, and it means “to
braid or twist quickly. For a new
company specializing in braided
and twisted products, the name
that Jay and Janice Miller found late
at night in a
Webster’s New Ameri-
can dictionary just made sense.
Breyden Products was founded
soon thereafter in Hesperia, Califor-
nia, squeezing that brand new
garage-built oven into a rental unit
along with a few lines of braiding
machines that were decidedly not
new. As the Millers organized and
prepared the facility, one of the
other founding parties set out to
generate sales, developing relation-
ships with distri
butors that he and
Jay had started in their previous
years in the industry.
The first years were lean years.
Jay and Janice were the entire
workforce and performed every
task in the office and factory. The
company got lonelier within the
first two years, as the two other
founding members opted out, dis-
couraged by the slow start and
unable to continue financially. If
things continued as they’d been,
the Millers
would have to fold, too.
Breyden’s luck soon turned
around. A revolutionary high-
strength, low elongation fishing
line became an overnight sensa-
tion. Demand was high, supply non-
existent. At around the same time,
Juan Flores joined Breyden. He had
worked as a production manager
with Jay for ten years at another
44 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Coastel
Cable
Tools
International Corp.
344 East Brighton Avenue
Syracuse, NY 13210
Ph: (315) 474-4707 • Fx: (315) 472-1765
Internet: www.coasteltools.com
The CT4 Coastelmatic
The CT4 Coastelmatic
Pneumatic Tool Holder
Pneumatic Tool Holder
The CT4 Coastelmatic hand tool holder is a
device that uses air to activate spring
retracted hand tools. The CT4 Coastelmatic
is a great low cost alternative to automatic
crimping, stripping, and cutting machines.
The CT4 Coastelmatic can be set up to work
crimpers, strippers and cutters. The patent
pending tool holder in the applicator
securely holds all tools in place, allowing
the operator to use his hands freely. This
new and improved cylinder delivers 10%
more power through dual activation for
tough jobs. Each unit is pre-assembled, test-
ed and ready for use.
Call NOW for details!
Call NOW for details!
You Expect
You Expect
More From
More From
Coastel
Coastel
Made in the
U.S.A.
25 Years of Quality Lacing Tapes and
Yarns at Breyden Products
The Breyden Team
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 44
braiding company. Originally an immi-
grant from Mexico, Flores devoted him-
self to Breyden’s success, even foregoing
a salary for a time. With the additional
experience and labor, Breyden capital-
ized on the growing fishing line market.
Revenues doubled in one year and near-
ly tripled in two. Eventually the growth
cooled, then slowed, then stopped.
Major players in the fish line industry
moved in and soon dominated the mar-
ket, but success there allowed Breyden
to develop its core business in the elec-
trical and aerospace industries. A small
number of employees had
joined the business, and
there was even enough
money to pay the Millers a
small salary.
Growth slowed as Brey-
den grew and by 2001, it
was clear that to grow at
anything faster than an
incremental, plodding
pace, Breyden would have
to add a full time s
ales pro-
fessional. A chance meet-
ing on a cruise led to the
addition of Mike Zuber,
who had spent 14 years at
Phelps Dodge culminating
in his position of head of
distribution sales. Zuber
came equipped with a
strong relationship with
Breyden’s major distribu-
tor, and he was able to par-
lay that relationship into a
significant increase in busi-
ness. Zuber’s salesmanship
also helped to enable Brey-
den to e
nter new markets
and find other outlets for
their goods.
By the mid-2000’s, Brey-
den grew into another
issue: the business climate
in California. High taxes,
expensive insurance, and a
growing cost of living all
limited Breyden’s growth.
In 2004, Jay and Janice
Miller and Mike Zuber
agreed to relocate the
manufacturing operation
to Indiana, where Zuber
lived. A building was
found—the former police
radio post in Columbia
City—and by the end of
2005 the company operat-
ed solely in Indiana. The
Flores family, who by that
time handled various
important functions in the
factory, followed the com-
pany to Indiana along with
a few other employees.
In 2010, a rumor that a
competitor was struggling
turned over the course of
six months into Breyden’s
acquisition of the assets of
Gudebrod Electronics, one
of Breyden’s two major US-
based competitors. Long
considered the premier
producer of lacing tape,
Gudebrod had fallen on
hard times after its entry
into the dental floss indus-
try. The acquisition allowed Breyden to
improve its products and production
techniques and connected Breyden
with a number of new distributors to
sell through, primarily in the European
market.
Breyden Products has always been a
family company, and as the company
grow
s, the values that brought it to this
point are as important as ever. The past,
present, and future success are owed to
the sacrifices and cooperation of many:
families from Southern California, from
Latin America, from the Midwest, distrib-
utors and suppliers and end users all
over the world.
At Breyden’s new facility a few miles
away from the old radio post, the new
ovens fit in better than the o
ld, original
garage-built oven. They were custom
built in a machine shop, engineered
with computerized help to maximize
airflow and minimize heat loss. They
were built to look good, and when they
run a multitude of various colors and
sizes of tapes and cords, it’s impressive.
It looks slick. But that slickness has
roots, and you can seem them looking at
that garage-built oven that’s gone 25
years without a
problem. It was built to
last, and it has.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 45
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 45
46 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:40 PM Page 46
New XLPE Control Cable Joins
HELUKABEL Product Portfolio
HELUKABEL, a leading cable manufac-
turers, formally launched its latest cable
product offering at the bi-annual Interna-
tional Manufacturing Technology Show
(IMTS), held in Chicago, IL in September.
The new TRAY X is a NFPA 79-2012
conformant flexible control power cable
with cross-linked (thermoset) polyethyl-
ene (XLPE) insulation. These tray cables
are suitable for all machinery in tool and
plant construction, and can be installed in
dry, humid and damp environments, in
pipes, underground, and for open,
unprotected installation from the cable
rack to industrial plant machinery. They are
600 V and WTTC 1000 V rated allowing
them to be used in 1 kV wind
turbine cable tray applications.
Additionally, it is CE approved
for machine builders exporting
to Europe.
T
he XLPE insulation is ideal for
applications that require long
cable runs due to its low capac-
itance. A higher current load rat-
ing is possible due to the con-
ductor temperature resistance of
105°C. This enables a smaller
cross section to be used when
designing electrical networks in
machines or systems. In addition
to the resulting lower costs and
use of copper, the much smaller
outer diameter offers a
dvantages
for installation in tight spaces
due to an increase in the cable‘s
maximum bending radius.
Additional TRAY X specifica-
tions:
Temperature Range: -40°C to
+105°C
Nominal Voltage: TC 600V /
WTTC – 1000V
Min. Bending Radius: 10x the
cable O.D.
Approvals: UL TC-ER (AWG
18 & larger), ITC-ER, PLTC-ER
(AWG 12 and smaller), Type
WTTC (AWG 18 & larger), Type
XHHW-2 (AWG 14 & larger) 13,
44, 1202, 1277, 1581, 2277,
2250, AWM 2586 - 105C 600V,
NFPA 79 2012, Oil Res I/II, 90°C
dry / wet, Class 1 Div. 2 per NEC
Art. 336, 392, 501 / CSA c(UL)
CIC-TC FT4 (AWG 18 & larger)
CSA AWM I/II A/B FT4
It is currently available in sizes
20 AWG - 500 kcmil with various
conductor configurations. For
customers working in facilities
where high levels of electromag-
netic interference are prevalent,
a shielded variant is available
u
pon request.
HELUKABEL USA, Inc. is the
wholly owned U.S. subsidiary of
HELUKABEL GmbH, a leading
international manufacturer of cables and
wires with 26 locations throughout the
world. In its 45,000-square-foot, subur-
ban-Chicago facility HELUKABEL USA
stocks over 4,000 cables, wires and
accessory line items for a multitude of
industrial and commercial applications
across a wide range of vertical mark
et s
eg-
ments. Direct access to a 1.72-million-
square-foot, fully automated warehouse
with 33,000 line items, enables HELUKA-
BEL USA to provide extremely short deliv-
ery times.
For more information please contact
HELUKABEL, 1490 Crispin Drive, Elgin, IL
60123. Phone 847-930-5118 or Fax 847-
622-8766. Visit www.helukabel.com.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 47
CABLE SUPPLIER OF CHOICE!
37 Horizon Dr. Bristol, CT 06010
Tel: 860.589.9035
Fax: 860.589.7520
NEWS PLUGS
NEWS PLUGS
continued
HELUKABEL Tray X Cable
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 47
CableEye
®
Generic Surface
Mount & TH Connectors, CB51
CAMI Research Inc. (Acton,
MA) announces another new
board for its CableEye cable and
harness testing systems. Populated
with solder pads to accept both
aligned and staggered, 1.25mm
and 1.5mm pitch, surface mount
and through hole (TH) connectors,
the board addresses any market
with a demand for board-to-
board connections. Rated to
700Vdc/500Vac, the CB51 may b
e
used on all CableEye models.
Configuration
A leader in development of PC-
based Cable & Wire Harness Test
Systems for over 20 years, CAMI
offers the CableEye suite of Low
and High Voltage products com-
plete with accessories including
connector boards. The selection of
boards is constantly growing and
is currently numbering over 60 –
most of which are populated with
‘families of connectors. These
connectors are shown graphically
correct with CableEye’s
standard
dynamic user interface.
The CB51, sold without connec-
tors, contains four sets of 60 solder
pads accommodating numerous
configurations of surface mount
and TH connectors – aligned or
staggered pins at 1.25mmm and
1.5mm pitch. There are four preset
locations for automatic detection
& display of any-pin-count con-
nector up to 60- pins. Yet, any sin-
gle set may be fitted with any
combination of lower p
in count
connectors that total to 60 or less
(e.g. a 40-pin with a 10-pin). Con-
nectors soldered in non-preset
positions will also appear graphi-
cally correct once they are
mapped with PinMap
(optional software).
Sold as a set of two
boards, each test board
may be paired with other
CableEye adapter boards to
accommodate any combi-
nation of connectors.
Application
Customers requiring this
board typically have prod-
ucts that may need HiPot
testing and that have board-
to-board connections such
as box builds or other con-
tained devices e.g. AV
Equipment & Telecom
products.
Warranty
Connector boards are
included in CableEye’s stan-
dard, renewable one-year
warranty of the tester for
which it was purchased.
CAMI Research produces
expandable and upgrad-
able diagnostic Cable &
Harness Test Systems for
assembly, prototyping, pro-
duction, and QC of stan-
dard or custom cables.
CableEye
®
Testers display,
and document basic elec-
trical properties such as
continuity, resistance,
dielectric breakdown, insu-
lation resistance, miswires,
and intermittent defects.
For further information
please visit www.camire-
search.com
48 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
NEWS PLUGS
NEWS PLUGS
continued
CableEye
®
Surface Mount
and TH Board
Wiring Harness Manufacturer’s
Association 2017 Conference
February 7-March 1, 2017
San Antonio, Texas
www.whma.org
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 48
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 49
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 49
M
entor Graphics Corporation
announced it has joined the
Partners for the Advance-
ment of Collaborative Engineering Edu-
cation (PACE) program and the General
Motors and U.S. Department of Energy
(DOE) sponsored EcoCAR 3 program.
The move is part of Mentor Automotive’s
ongoing effort to accelerate productivity
of automotive engineering R&D efforts,
from OEMs and Tier 1 suppliers to many
of the world’s leading automotive engi-
neering universities.
Under the auspices of Mentor’s High-
er Education Program, Mentor Automo-
tive is providing tens of millions of dol-
lars’ worth of industry-leading software,
support and training to universities and
student teams in both the PACE and Eco-
CAR 3 programs. This enables students
to be proficient in today’s skills and
methodologies before graduation and be
ready to contribute to leading automo-
tive companies immediately.
PACE
The PACE program was established
by General Motors to develop the auto-
motive Product Lifecycle Management
(PLM) team of the future. Each of the 65
PACE universities worldwide, which
General Motors targets in its recruiting
efforts, will be offered the same set of
Mentor Automotive engineering tools
adopted by General Motors. These
include the Capital
®
product line for
electrical systems and harness design
with SystemVision
®
for electrical sys-
tems simulation, FloEFD™ 3D thermal
and fluid analysis software (integrated
with the Siemens NX 3D CAD package),
and FloTHERM
®
software for electronics
cooling analysis, plus the Xpedition
®
printed circuit board (PCB) design plat-
form with HyperLynx
®
software for
high-speed design reliability verification.
In addition to General Motors leader-
ship, PACE is supported by Autodesk, HP,
Oracle, MathWorks, Siemens PLM Soft-
ware and Mentor Automotive. Through
PACE, engineering students develop
practical skills in the core software and
processes they will use in high-technol-
ogy careers in industry.
EcoCAR 3
EcoCAR 3 is the latest DOE Advanced
Vehicle Technology Competition (AVTC)
series, sponsored by DOE and General
Motors and managed by Argonne
National Laboratory. The 4-year program
challenges 16 North American university
teams to redesign and convert a 2016
Chevrolet V6 Camaro into an advanced
hybrid car to reduce its environmental
impact, while maintaining the muscle
and performance expected from this
iconic American car. The teams even
design in new Advanced Driver Assis-
tance (ADAS) functions. Mentor Automo-
tive is providing EcoCAR 3 a wide range
of tools from its automotive product
portfolio, including tools for electrical
system and harness design (Capital,
VeSys
®
and SystemVision), mechanical
analysis tools (FloEFD, Flowmaster
®
,
FloTHERM), vehicle networking tools
(Volcano™), embedded software tools
(Sourcery™ CodeBench, Nucleus
®
), and
PCB design and verification tools
(PADS
®
, Xpedition, and HyperLynx).
“Mentor’s Capital software suite has
greatly improved our electrical design
and documentation practices. Its deep
configurability has allowed us to capture
the finest details of our hybrid power-
50 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ATLAS WIRE CORPORATION
Insulators of Electrical
Wires & Cables
www.atlaswirecorp.com
9525 River Street 4705 S. Coach Drive
Schiller Park, IL 60176 Tucson, AZ 85714
(847) 678-1210 (520) 747-4500
(847) 678-1281 fax (520) 747-5800 fax
info@atlaswirecorp.com tomatlas@worldnet.att.net
ISO 9001:2000 Certified Lead & Hook Up Wire
Facilities in Illinois & Arizona 125C & 150C Cross-Link
Huge Inventory of Conductor UL & CSA
Customized Print & Packaging MTW
Striping (Spiral & Extruded Line) Building & Fixture Wire
Bonding & Twisting Military
Drum Pack Automotive/Marine
Small Min. Order Quantities Nylon
Short Lead Times Speaker Wire
ATLAS WIRE CORPORATION
Registered to ISO9001:2000
Certificate No. A4894
“WORLD’S LARGEST INVENTORY OF TERMINALS AND FUSES”
ELECTRICAL PRODUCTS
SALES CORP.
1333 S.W. 30th Avenue
Deerfield Beach, Florida 33442
❖❖❖ Established 1947 ❖❖❖
Tel: 954-428-1788 Fax: 954-429-1511
Toll Free: 1-800-342-1422
E-mail: sales@electricalproducts.com www.electricalproducts.com
LUGS TERMINALS • SPLICES FERRULES • DISCONNECTS
END CAPS • JUMPERS • CABLE TIES • SOLDER SLEEVES
HEAT SHRINKABLE TUBING FUSES • FUSEHOLDERS
FUSE CLIPS • MIL SPECS OUR SPECIALTY
MS25036 MS20659 MS17143 MS3367 MS3368 MS3339 - MS3341
MS21980 • MS21981 MS35431 • MS77066 - MS77074 MS25274
MS25435 - MS25439 M83519 • M23053 MS21266 • M23190
NAS1744-NAS1746 • MS25083 MIL-C-83413/8 AND MANY OTHERS
Interconnect Products, Inc.
ELECTRICAL GROUP
Your Best Source Since 1947
Call Today 1-800-342-1422 Fast Delivery!
Please visit our new on-line store at electricalproductsstore.com
ELECTRICAL PRODUCTS SALES CORP. has one of the largest
inventories of terminals and fuses in the United States. When you
receive requests for these items, use our vast inventory to draw from.
AUTHORIZED DISTRIBUTORS FOR:
Access our Line Card and Inventory on the World Wide Web:
http://www.electricalproducts.com
Bussmann
®
Higher Engineering Horsepower in Higher Education
_______________Continued on page 52
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 50
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 51
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 51
train electrical system design, said
Jonathan Moscardini, electrical team
lead engineer for McMaster University’s
EcoCAR 3 Team. “Capital has given us
enterprise-grade collaboration and user
management tools without any of the
usual enterprise-grade IT headaches. The
MCAD integration enables us to more
accurately define and route our custom
harnesses for the 2016 Chevrolet
Camaro. The Mentor tools revealed mu
l-
tiple design insights, before we touched
a single physical wire. The ease-of-use of
the entire suite has helped us complete
our work faster than ever.
The specs of McMasters hybrid
Camaro suggest a bright future for ener-
gy-efficient, high performance vehicles.
The 600 combined horsepower car has
a total range of more than 300 miles and
an electric-only range of 30 miles. Fuel
efficiency is impressive
as well at 42
miles per gallon, and muscle car enthusi-
asts will appreciate the acceleration
(zero-to-60 mph in 4.6 seconds).
“EcoCAR 3 is one of the world’s pre-
mier vehicle technology competitions,
said Nick Smith, business development
director at Mentor Automotive. “The fact
that in just four years students can build
cars that perform as they do is testament
to the ingenuity of these engineering
students, but also to the increasing
power of advanced design tools and
software, such as those supplied by Men-
tor Automotive.
Mentor Automotive has built a reputa-
tion for solving the most complex
design challenges, earlier, more efficient-
ly and with less program risk. Our solu-
tions span software, hardware, integra-
tion, connectivity and compliance and
are used by nearly every major automo-
tive OEM and Tier 1 supplier. Mentor
Automotive focuses in four key areas of
the industry:
Connectivity - connecting car, driv-
er & the external world
Autonomous - autonomous driving
& driver assist systems
Electrification - electric vehicles &
supporting technology
Architecture - EE architecture & sys-
tem implementation
For further information visit
www.mentor.com/automotive
52 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
H
H
ARNESS
ARNESS
Braiding & Shielding
Braiding & Shielding
As the industry leader in
cable harness shielding,
Hamilton Products will
meet your most
demanding requirements
for textile and/or wire shields.
Our capacity of 1 to 1,000
harnesses and our extensive
knowledge of specialty braiding and
shielding allows us to manufacture to your
specifications, or custom design to meet your
installation requirements.
For the best, call the best. Call Hamilton Products.
HAMILTON PRODUCTS, INC.
P.O. Box 1100 43A Rte 12 South • Sherburne, New York 13460
Phone: (607) 674-2030 FAX (607) 674-9367
E-Mail: a_critton@iwgbwd.com or s_malloy@iwgbwd.com
Home Page: http://www.hamprods.com
EcoCar3 Camaro
Continued from page 50 _____________
Higher Engineering
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 52
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 53
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 53
54 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 54
T
he wide use of HD video,
emergence of 4K and 8K ultra-
high broadcast standards, and
increasing popularity in the audio-video
sector is placing greater demands of
data transmission systems. Fiber optic
technology, with its ability to deliver dig-
ital, high-bandwidth and low signal-loss
streams, provides an ideal solution for
coping with those demands.
However, when it comes to remote
broadcasting from harsh c
onditions, the
advanced needs of permanent broad-
casting studio infrastructures, and the
increasingly popular use of audio-video
technology among businesses and gov-
ernment agencies, a new set of demands
is being placed on the fiber optic cable
industry.
Field deployment applications
Sporting events are among broad-
cast's toughest venues, requiring the
rapid pulling of miles of field-deployable
fiber optic cable across fences, through
water, around rough-hewn rodeo arenas
and along frozen ski slopes or blazing
racetracks.
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 55
Meeting Increasing Demands for
Broadcast & AV Applications
Broadcasting from remote venues like the Professional Bull Riding (PBR)
event in Las Vegas, seen here, required 15,000 ft. of OCC cble to be
unspooled by hand around a ring where it is exposed to considerable foot
traffic, rough fences, water, and a wild bull or two.
_______________ Continued on page 57
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 55
56 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
15490 101st Ave N Suite 100
Maple Grove, MN 53369
763-235-6467
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 56
Remote broadcasts demand the brisk
deployment of dozens of strands of
cable to cameras that fly over football
fields, hang from cranes, and are then re-
gathered and tossed into crates to be
shipped to the next tough venue. Most
important, in all of these harsh broad-
casting environments, it must survive
again and again.
Remote broadcasting specialists such
as IMS Productions are involved with
such rigorous field environments
throughout the year. Headquartered
across from the famed Indianapolis
Motor Speedway, IMS Productions
Mobile Unit Group travels the nation in
heavy-duty
trucks equipped with studios and satel-
lite uplinks that provide live production
services for national sports
and entertainment broad-
casts and events.
“Our fleet of mobile stu-
dios travels to hundreds of
events across the country
throughout t
he year, some-
times having to set up and
tear down the same day
before heading to the next
venue, says Paul Nijak, IMS
Productions Director of
Engineering. “Even with all
the rigors of meeting this
schedule, remarkably little
fiber cable gets broken
perhaps one or two pieces
a year.
One of IMS Productions
typical weeks includes
providing broadcast pro-
duction for the Verizon
IndyCar Series, in locations
such as St. Petersburg,
w
here the 1.8-mile, 14-turn
circuit incorporates city
streets and a section of air-
port runway where
100,000 ft. of broadcast
cable are laid behind tem-
porary walls and fences,
flown across sections of
track and sometimes
pulled through swamps
and waterways.
Immediately following
the race, IMS Productions
crew will gather up the
cable and head cross coun-
try to a PBR (Professional
Bull Riders) Built Ford
To
ugh Series event, where
an average of 15,000 ft. of
cable is unspooled by
hand around a ring where
it is exposed to consider-
able grime and foot traffic.
The cable that IMS Pro-
ductions utilizes for all the
field events it covers is
deployable broadcast-qual-
ity fiber manufactured by
Optical Cable Corporation
(OCC). Nijak says the cable
looks and feels like OCC’s
acclaimed MilTac, 12-
strand, field deployable
tactical grade cable, but is
somewhat lower in cost.
The broadcast quality of this fiber
cable is high enough to meet the 4K
ultra-high-definition broadcasting stan-
dard that IMS Productions is currently
field testing with Time Warner Cable
Sports.
“Our installations range from
extremely hot to extremely cold temper-
atures, Nijak explains. “For example, this
year we covered the Alberta A
lpine Ski
event in Calgary, Canada. At that venue
we trenched down into the snow with a
chain saw to bury the cable so that
groomers could pack snow over the top
to help protect the cable. In total, we
laid about 50,000 ft. of OCC fiber run-
ning all the way up the side of the moun-
tain.
Nijak adds that OCC invests time
with his group, going out into the field
and seeing firsthand how installers han-
dled t
he cable.
“OCC has also begun making their
cable specifically tailored for us so that
we can deploy and connect it more
quickly, Nijak says. “So, they’re partner-
ing with us, as opposed to just saying,
‘Here’s our product, go use it.’”
Permanent broadcast infrastructures
Permanent broadcast fiber installa-
tions, such as TV production facilities,
require the pulling of cable through a
conduit that will s
tay in place as lasting
infrastructures.
Diversified, a leader in custom media-
related solutions, has a deep heritage in
broadcast systems. The company pro-
vides design and integration services for
TV stations, broadcast and cable net-
works, professional and collegiate sports
venues, mobile production units, as well
as production and post-production facil-
ities.
Many facilities require unique cable
infra
structure so Diversified has a strong
appreciation of the advantages fiber
optic cable offers for greater durability
and ease of installation. OCC’s 6- and 12-
strand DX Series indoor/outdoor distri-
bution cables are often a good solution
for many challenging installations.
“OCC’s fiber cables are very easy to
pull and manage, says Justin Guzman,
Project Engineer. “This saves time and
keeps our projects o
n track. The OCC
cable has the inclusion of a rigid central
strength member, which is of vital
importance in permanent installations.
Fiber cable is pulled through conduit
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 57
Meeting Increasing Demands for Broadcast & AV Applications
Continued from page 55 _____________
_______________ Continued on page 58
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 57
and is often exposed to 10 times the ten-
sion that it would normally incur. Guz-
man adds, “Our team has total confi-
dence in handling OCC cable and
knows signal continuity is maintained in
the toughest installations.
On one project, Guzman’s team had a
situation where the cabling in the build-
ing needed to be plenum rated. Howev-
er, the final 200 feet of cable was in an
underground conduit that was subject
t
o flood-out. “For our copper cable types
we had to run both an underground-
rated cable and a plenum-rated cable,
Guzman explains. “Where the conduits
emerged from underground we spliced
them together. For the fiber, we were
able to utilize the OCC DX indoor/out-
door cable series, which met the criteria
for water blocking and plenum rating.
This enabled us to forgo a lot of addi-
tional fiber splicing a
nd management.
Guzman added that the unique capa-
bilities of OCC cable met both criteria
and saved tremendous labor and unnec-
essary splicing.
Expediting AV applications
Companies large and small are
dependent on using AV applications for
critical services ranging from training to
teleconferencing. Many of these applica-
tions require the integration of a variety
of different AV devices within facilities a
t
many geographic points. This often
requires staffing installation people with
installation skillsets such as crimping
and soldering, particularly when various
types of AV gear are not configured to
work together.
When the companies transition AV
facilities from analog to digital, it
requires a new type of cabling to carry
digital signals. This means a different
type of installation technician is needed
-
IT integrators. These technicians have
the tools and skillset required to install
fiber optic cable to transport packetized
data, alongside cable to power the
equipment. Performing this type of
installation entails pulling both types of
cable, cutting it to length,
terminating it and then
plugging it into AV gear.
However, if this process
can be simplified, installa-
tion becomes more effi-
cient and less ex
pensive.
In some instances, OCC
has provided AV users
hybrid cables that includ-
ed both the fiber optic and
power cable all in one.
Additionally, OCC has pro-
vided the cabling in kit
form, with each kit con-
taining pre-terminated,
pre-cut cabling for con-
necting specific equip-
ment housed in each of
multiple (sometimes hun-
dreds of) AV rooms. Each
“plug & play” hybrid cable
is labeled with a specific
part number and each
cable box would be desig-
nated for a specific AV
location, such as a confer-
ence room, lab or com-
mand center.
This “kitting” of the plug
& play cable for specific AV
room locations has
allowed standard installa-
tion contractors to handle
the installation tasks rather
than requiring the expert-
ise of IT or AV contractors.
This result has been a
reduction in of as much as
25 percent in installation
t
ime as well as saving sig-
nificant money on labor.
Additional savings on
the plug & play cable can
also be realized when it is
pre-terminated at the fac-
tory, which means it has
also been pre-tested by fac-
tory technicians. This pro-
vides a greater degree of
reliability, reducing the
time to certify the installed
system.
For further information
congact Optical Cable
Corp, 5290 Concourse Dr,
Roanoke, VA, 24019; Visit
the web site www.occ-
fiber.com.
58 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
Sales Manager
Wire harness company in Cleveland, Ohio seeks a Sales Manager to man-
age and grow its sales opportunities. We have been in business for 30 years
and mainly serve the lawn & garden, snow, automotive, engine, and small
appliance markets. We are looking to expand in those markets as well as pur-
sue market penetration in other areas.
A qualified applicant will have several years of sales experience and contacts
in the wire harness industry. Travel is required but a home base in Cleveland
must be maintained.
Qualified applicants should send resume and salary requirements to
THORNE@WRWP.COM
Meeting Increasing Demands for Broadcast & AV Applications
Continued from page 55 _____________
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 58
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 59
crimptools.com
crimptools.com
“Specializing in Crimp Tool Needs”
Authorized Distributor For:
Pico Corp, Burndy, Rennsteig Tools,
Thomas and Betts, Sargent
Many Other Manufacturers:
Amp/Tyco, Daniels, Astro, Raychem, Kings,
Molex, Panduit, and many more
Stocking: Same Day Shipping
AMP Hand Tools 1000’s
Hydraulic Crimpers/Crimp Heads and Dies
Pneumatic Crimpers
Hand Crimp Tools & Positioners
Install & Removal Tools
Raychem Heating Tools AA400, IR550, IR1759
ALWAYS LOOKING TO
ALWAYS LOOKING TO
BUY EXCESS INVENTORY
BUY EXCESS INVENTORY
Dakota Electronics Inc.
512-852-8119
sales@crimptools.com
ALL SIZES, TYPES, OR QUANTITIES.
ANY CONDITION
BRAIDERS WANTED
Call: Tony Ross, Hamilton Products
Voice: 607-674-2030
Fax: 607-674-9367
E-mail: t_ross@iwgbwd.com
CLASSIFIEDS
BRAIDING
MACHINES
We Build, Buy & Sell Harness Braiders
We also supply braider bobbins wound with material.
Products and Services
Braids; Wire and Textile Bobbin Winding
Harness, Overbraiding, & Shielding Buss Wire
Visit www.gladdingbraid.com (315) 653-7211
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 59
60 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
American Hakko ...................................................... 5
Anixter.........................................................................39
An-Mar Wiring Systems ............................................7
APEX Expo Expo IPC 2017...................................54
Applitek Technologies Corp...................................18
Artos Engineering Company ..................................2
Atkins & Pearce ........................................................35
Atlas..............................................................................50
Cablescan....................................................................49
CAMI Research, Inc .........................................10, 55
Carpenter Mfg. Co., Inc. .........................................17
Chief Supply Inc. ......................................................29
Cirris Systems Corp.................................................64
Coastel Cable Tools..................................................44
Commission Brokers Inc.......................................19
Composite & Wire Machinery, Inc.........................3
Connector Microtooling Syste
ms I
nc.................22
Daniels Manufacturing Corp...............................15
Dynalab Test Systems..............................................29
East Penn Manufacturing Co, Inc. .....................31
ECC ...............................................................................16
EIC Wipers ..................................................................26
Electrical Products Sales ........................................50
Electrical Wire Processing Technology Expo....61
Eraser Company, The..............................................14
Etco Inc. ......................................................................12
Eubanks......................................................................27
FreePoint Technologies Inc ............................14, 52
Fuses Unlimited........................................................21
Gamma Electronics ...................................................8
Hamilton Products, Inc..........................................52
Henkel..........................................................................44
Heilind Electronics .......7, 16, 28, 37, 48, 57,
5
8
HellermannTyton.....................................................30
Imada, Inc ....................................................................5
Industrial Wire & Cable Corp ..............................55
INSCO/Insulation Supply .......................................6
Judco Manufacturing Inc................................38-39
JWB Manufacturing ................................................48
Kingsley Machines...................................................13
Komax Wire...........................................................9, 64
Lakes Precision Inc..................................................40
LTL Tooling & Assembly .........................................17
Mark-10.......................................................................11
Master Appliance Corp..............................................3
Mecalbi....................................................................... 50
Mechtrix Corporation.............................................51
Mello Company Inc., The .........................................3
Mentor Graphics.......................................................20
Micro Plastics .....................................................35, 53
Molex............................................................................25
Multi/Cable Corp. ....................................................4
7
N
u-Tech, US ...................................................................9
Odyssey Tool...............................................................47
OES Inc ........................................................................31
Panduit........................................................................41
Phoenix Contact.......................................................43
Power & Signal Group............................................34
Pro-Line .......................................................................24
Schaefer Megomat USA Inc...................................46
Schaefer Technologies LLC .......................................4
Schleuniger Inc ...................................................32-33
ShinMaywa ................................................................38
Spring Mills Manufacturing .................................34
Stapla ...........................................................................24
Strunk Connect.........................................................26
Techflex....................................................................... 10
Telsonic Solutions.....................................................36
Tesa Tape .....................................................................42
Thermosleeve.............................................................13
TLC Electronics .........................................................23
Tri Star Technologies .............................................45
TTI...................................................................19, 21, 23
Waytek, Inc.................................................................22
White Products..........................................................40
WHM
A.....
.....................................................................56
ADVERTISERS DIRECTORY
Subscribe to Wiring Harness News
www.wiringharnessnews.com
The yearly subscription rate is:
Digital Only (World-Wide) = $30 Print and Digital (US) = $39
Print and Digital (Canada & Mexico) = $54 Print and Digital (International) = $64
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 60
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 61
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 61
62 NOVEMBER/DECEMBER 2016 Wiring Harness News INDUSTRIAL INFO-TAINMENT
WHN Promotional Ad for Media Kit...????? Yes?
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 62
INDUSTRIAL INFO-TAINMENT Wiring Harness News NOVEMBER/DECEMBER 2016 63
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 63
ND 2016 PGS_Layout 1 11/1/16 12:41 PM Page 64