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A key component of any electronic or electrical system is the cable assembly/cable harness, yet it typically is one of the last components to be addressed. When designing a system the cable assembly should be addressed as early in the design stage as possible to allow for the best design to be specified for the application at hand. Many components will be involved in the assembly design, and each component will have an impact on the performance of the finished cable assembly or wire harness. If an assembly that is either over-designed or under-designed is used, there will be negative consequences of the performance of the finished system.

In this second of a two-part series, we continue discussing options to consider when designing a cable assembly or wire harness, such as the best materials to use to meet the expectations of the assembly installation, the proper termination method for the type of signal that will be transmitted over the assembly, and what safety certifications the assembly will need to comply with based on the environment. Here in Part 2: conductor twisting/cabling, shielding, outer sheaths, connectors/strain reliefs, and safety certification.