Making a Ferrule Wire Harness with UL1015 16 AWG Hook Up Wire
Making a ferrule wire harness with UL1015 16 AWG hook up wire starts with using an automated wire processing machine for the cut and stripped hook up wire. UL1015 wire is a common 600-volt wire used in devices and appliances after being put together into a wire harness. Ferrules are used together with the connector that connects the wires either to another cable or to a transmitter or receiver. The ferrule keeps the fibers accurately aligned within the connector. The copper from the wires connect to the ferrule and the ferrule connects to the screw in the plastic house. The plastic house is plugged into the application and the connectivity is sent from one end to the other, generating less than 600 volts of electricity.
Copper is one of the best conductors of electricity and measured by the diameter to determine the amount of current that can travel through it. In this case, UL1015 16 AWG wire uses a copper diameter of 0.051” without including the insulation. It doesn’t make a difference if the diameter of 0.051” is solid copper or multiple strands wound together, however, stranded copper is more flexible and easier to install into devices and appliances. UL1015 16 AWG is commonly designed and manufactured with 26 strands of 30 AWG copper rather than a single solid strand of 16 AWG.
Once the copper diameter is determined, the strands are coated with tin and known as “tinned copper” in the industry. Tinned copper strands are easier to work with in the field. The layer of tin creates a better connection to the screw within the house for this wire harness and help adhere to other metals in the soldering process. Finally, the PVC insulation covers the copper to protect it from heat, voltage overheating and outside environmental conditions that can harm copper, including water.
Cutting and Stripping UL1015 16 AWG Wire
Once all the materials are gathered for the job and put into a traveler bin, the operator will start to cut and strip the wire on the automated wire processing machine. A few samples will determine if the overall length and strip length are accurate, and the operator will sign the quality sheet once they take all the measurements. The specification sheet doesn’t always specify the insulation strip length on both ends, but this assembly will have crimped ferrules on both ends, so it’s easy to figure out the strip length appropriate for the ferrules. There are 3 UL1015 wires that need to be cut for this job including black, brown and blue. After this step is complete the ferrules will be crimped to the wires and prepared for the plastic house with metal screws.
Crimping Ferrules to UL1015 16 AWG Wire
We’ll be using a hand tool to crimp the ferrules to the wires. An order for 100 pieces will require 600 hand crimps because there are 3 wires and both sides are crimped. Circle connectors that are crimped with a hand tool can be pressed from a North-South position, whereby clamping the ferrule to the copper strands and creating noticeable marks on the top and bottom. There are also hand tools, in this video, that crimp down from all four directions and leave four marks on it. This is something that the customer or user would have to decide based on their preference and the preference of the application itself. Both hand tools are sold and used effectively in the industry.
Once the operator is comfortable using the ferrule hand tool it just a matter of time before they complete all the wires and prepare for the next step of the process. The quality process during this stage will include an inspection of the crimp and the position of the ferrule to the specific type of hook up wire. If the crimp is set too close to the edge of the wire it may not pass a pull test. If the crimp is too far in it could be crimped on the wire insulation. The last thing to check for is a tight and secure crimp that cannot be pull off by hand.
Screwing Down the Ferrules into the Housing
Each of the three wires with ferrules crimped on each end will have to be inserted into the house and manually screwed down. Using a drill will increase the speed of this job. Some customers will require a specific amount of torque when applying pressure to the screw which creates a consistent connection that the electricity can travel through evenly. The operator can get tired after screwing down 600 wires in a few hours, so without a specific amount of pressure notifying the operator of a minimum clamp, the consistency will vary. Without the special torque wrench the operator can simple tug on both ends to assure that the crimp is secured.
The operator will have to be careful about the “pinout” or color code when inserting each of the wires. The connectors are both labeled with “U V W” and they reside in distinct positions from left to right. The detailed specification sheet shows which color wire goes into which letter designation. The operator will have to sign the quality inspection report after checking to be sure that each color is in the designated spot in comparison to the data sheet. When the colors are in the wrong spot the connection will be completely broken within the application, so it’s important to be careful when assembling every wire harness.
Tie Wrapping the Wire Harness
Many times, a tie wrap is used to unify the wires into a bundle and to make the harness look neat and complete. Tie wrapping can be done manually, as most do, or automated with tie wraps on a reel and a foot pedal to tighten them and cut the excess away. The specification sheet simply says to place the tie wrap into the middle of the assembly without much of a tolerance. This tells the operator that it’s used for looks rather than fit, form and function. Nonetheless, the customer requested it and the contract manufacturer must provide a quality product consistently, so it should be checked and signed on the quality inspection report that it’s completed and in the center of the harness.
The final inspection is conducted by the shift supervisor to be sure that the entire wire harness is cut to the right length, crimped correctly, secure in the housing and meets all the specifications and measurements mentioned on the customer supplied data sheet. By the time the wire harness is ready for shipment, the quality inspection report has been signed numerous times, even for the easiest of jobs. Nothing can ship out the door with only one signature which guarantees that at least two people have checked the major materials and measurements of the harness.
How to Make a Twisted Wire Harness Using UL1015 14 AWG Hook Up Wire
This article will explain how to make a twisted wire harness using UL1015 14 AWG hook up wire, a ferrite bead and plastic tie wraps. Once the black, brown, gray and green/yellow wires are cut to length using a wire processing machine, the assembler will show you how to slide the wires through the ferrite bead, twist the wires by hand and secure the assembly with plastic tie wraps. There are multiple processes that include in-process quality checks to be sure that mistakes are caught quickly, without producing an entire batch of harnesses to find out the was a mistake made that deems them all nonconforming.
Machine Cutting UL1015 14 AWG Hook Up Wire
Each of the four wires are different lengths in this wire harness, but each of them is about 17” or less in length. Once the operator sets up the machine to cut the wire 17”, they also have to set the insulation strip on each end to 0.25” and set the vertical blades to 14 AWG. To fulfill the quality inspection report, the operator needs to run a few pieces, check the accurate length, check the accurate strip on each end and check to see if the blades cut or nick any of the copper strands. After approving all the quality checks, the operator can set the machine to run the balance of the pieces, bundle them and place them in the traveler bin for the next step in the process.
When small companies or basement-companies complete the manual process of cutting and stripping hook up wire, it can save them money to outsource to a contract manufacturer that has automated equipment. Firstly, the contract manufacturer buys hook up wire in bulk at better prices than individuals on Amazon. Secondly, the quality of machine produced wire is far better, more consistent and less time consuming than doing it manually. Finally, they already have all the tools and equipment ready to produce small jobs without added costs. So, when individuals total all the costs of material and labor it would be far cheaper to outsource to a contract manufacturer that produces wire harnesses daily.
UL1015 14 AWG wire begins with 41 (30 AWG) bare copper strands that are run through tin, so they appear to be silver, but it’s just a layer of tin coating. Each of the 41 strands are wound together tightly before the insulation process. The term “14 AWG or Gauge” designates a diameter of 0.064” which is the exact measurement of the 41 copper strands once wound together. From there, a PVC (Polyvinyl Chloride) is wrapped around the copper and labeled with “UL1015”. The UL style designates that the wires is approved to run 600 volts and sit in temperatures up to 105 degrees Celsius. If you only need 300 volts, for example, you can purchase UL1007 wire for a slightly lower price per foot.
Measuring, Twisting and Tie Wrapping
While all four wires are different lengths, the operator starts by lining up all four wires on one side and securing them together with a plastic tie wrap. With the help of a tool specifically made to help with tie wrap installation, the assembler can attach the hand tool against the tie wrap and pull the trigger, which pulls the tie wrap as tight as possible and cuts the excess away. Otherwise, the operator would have to pull it very tightly by hand, then cut the excess with wire cutters.
Next, the assembler needs to twist the cable roughly one twist per inch and attach another tie wrap to secure the twist. You’ll notice in the video that the assembler continues to measure the cable because there are multiple measurements on the specification sheet that the customer requires. The first tie wrap, for example, needs to be 2.25” from the end, and the second needs to be 6” from the end. These tie wraps are in place to easily fit into the customer’s application, such as a servo motor. 2.25” is just enough room to bend the wires into place once the customer receives the harnesses to their facility. If the operator puts them 1.50” from the end, perhaps there won’t be enough room to fit the wires into place.
The ferrite bead is slide into the wire harness next. It abuts the second tie wrap and a third tie wrap comes right behind it. The second and third tie wraps are tightened closely to each side of the ferrite bead to hold it in place. A ferrite bead is made with a ferrite material and that is used to suppress or filter the amount of high frequency electromagnetic interference (EMI) noise found in electronic circuits. When wires are twisted it also helps limit EMI noise. You might understand EMI when your radio switches back and forth between channels or your phone call is interrupted with an external conversation. In these cases, the wires are running close to each other and need to be twisted or have ferrite beads to help limit the circumference of the magnetic field.
Finally, the fourth tie wrap is placed about 1.50” from the 3rd tie wrap and about 5” from the end of the wire harness. Then the assembler will check the measurements and move on to the next piece.
The last step of the process is for the assembler to double check all the measurements, colors and parts within the assembly to assure a consistent product that conforms to the customer’s specification data sheet. There are 4 wires, 4 tie wraps, 1 ferrite bead, 4 different length wires, 2 different semi-strips on each end and almost 10 different measurements to check against the customer data sheet. The assembler must check and sign their name to the quality inspection report, not just as the assembler that completed the tasks, but as reference that they completed all of the quality checks before moving on.
How to Cut, Strip and Tie Wrap UL1015 12 AWG Hookup Wire
This article will explain the manual and automated ways of how to cut, strip and tie wrap multiple UL1015 12 AWG hookup wires into a neat unified bundle. Contract manufacturers do their best to automate when the quantity of the job creates a return on investment, but other times it’s not worth the investment of tooling and equipment. In this case, the job is fully automated and very efficient compared to the manual process.
Cutting and Stripping UL1015 12 AWG Hookup Wire
Cutting and stripping the manual way will create 2 steps with a pair of wire cutters. Hand held wire cutters are equipped with ridges at the end, and numbers designating the AWG size. In this case, the wire states that the copper conductor inside the insulation is 12 AWG which tells the electrician how many AMPs can travel through it. The thickness of the insulation is much less important because the wire cutters are created to find the outer diameter of the copper based on the gauge size.
First, the assembler will cut the wire from the spool to the desired length, and in this case, 8 inches. We need 3 pieces of wire cut to 8” and each end will have a 0.25” strip as well. Secondly, once the 3 pieces are cut manually, the assembler will use the correct 12 AWG hole to strip 0.25” of insulation from each side of the wire. The data sheet requires that the insulation remain on the wire so that the copper strands aren’t frayed during shipment.
The automated way of cutting and stripping UL1015 12 AWG hook up wire is to set up a wire cutting machine to 8 inches with a strip on both ends of 0.25”. Wire processing machines cost anywhere from $8,000 to $100,000 depending on the AWG size requirements, speed requirements, tolerances and attributes. The contract manufacturer will have to weigh those costs against the amount of production they plan to run each year. But it takes less than a second to cut and strip one piece compared to 10-15 seconds doing it manually.
There are a few quality checks that happen during the process to be sure that the entire batch doesn’t get cut to the wrong overall length and that the insulation strips on each end are accurate. Also, the machine operator needs to be careful about how far down the blades cut the wire, to be sure that the copper strands aren’t getting cut or nicked. In this case, the copper has a tin coating over it as requested by the end user, so it’s easy to see if the strands are nicked because it will turn from a silver color to copper.
Tie Wrapping UL1015 12 AWG Hookup Wires Together
The customer requires that the tie wrap is placed in the middle of the wires and that all three wires are even matched rather than jagged. The manual process can be broken into 2 or 3 steps, starting with looping each of the tie wraps before wrapping them around the wire. It takes two hands to connect the tie wrap to its opposite end, so starting each loop beforehand can save a lot of time. The second step in the manual process is to line up 3 UL1015 12 AWG wires against a ruler, slide the looped tie wrap to the half-way mark and pull it tight. The third step is to cut the excess plastic for a clean and neat finished look. This can take up to 20 seconds doing it manually.
The automated process requires a tie wrap gun and a tie wrap reel that feeds into the gun. This piece of equipment also comes with a foot pedal operation so that the operator can use both hands without the need to pull the trigger each time. As you can see in the short video, this process takes about 5 seconds to tie wrap and cut the end off. The entire process is automated and saves hours of time when thousands of pieces needs to be produced.
Quality – ISO 9001 Certification
When producing pieces manually you can decide which pieces pass inspection and which ones need to be thrown away. But when you’re producing wire assemblies on behalf of a company it’s important to have more in depth quality inspections and controls. For example, if you have an employee producing 500 parts for you, how many will you check before approving the lot and before sending them to your customer? That’s up to you as the vendor, but as you become more established as a wire harness or assembly provider, you’ll need to tell customers about your quality process to assure them that every shipment is ready to use upon arrival.
Getting certified as an ISO 9001 company requires similar steps along with several types of documentation such as, documenting errors, creating a plan to correct similar errors from happening again and documenting each process and procedure as controlled records that are followed with every order. Customers feel comfortable placing orders with companies that are ISO 9001 certified because, big or small, they’re forced to adhere to the organizational standard.
How to Crimp a Ring Terminal to UL1015 10 AWG Hook Up Wire
There are a few ways to explain how to crimp a ring terminal to UL1015 10 AWG hook up wire because it could be done manually or automated during each step. The manual way has cheaper upfront costs for tooling and equipment, but it will cost more in labor to create each piece. The automated way costs quite a bit more for equipment but completes the job in a tenth of the time. Both processes will be explained in this article using basic hand tools compared to expensive technical equipment to show you how individuals complete the job compared to contract manufacturers.
UL1015 10 AWG Hook Up Wire
UL1015 is a common 600-volt PVC hook up wire used in electronic devices and appliances when heat levels stay below 105 degrees Celsius. There are more than 100 (30 AWG) copper strands that make up a 10 AWG wire, and in this case, the individual strands are “tinned copper” because they are coated with a layer of tin. The end user, that usually solders the wire to something, requests the tinned copper strands because it helps to adhere the wire to the connection. When heat is applied, the tin melts just enough to bond with the melted solder, creating a more secure connection than solder-to-bare copper.
Cutting and Stripping UL1015 10 AWG Wire (Manually)
If you need to cut and strip 10 AWG wire by hand hopefully you have less than a day worth of work, or else you hand will start to hurt. My recommendation would be to set up a ruler in front of a piece of wood and mark the length with a piece of tape or a marker. This way, you can pull the wire from the spool and quickly push it against the wood and cut it at the mark. Then you’re going to have to strip the insulation off both ends, or in the case of this assembly, only one end. This assembly is 25” long from the beginning of the ring terminal, not the end. So, the wire should be cut longer than 25” to make this specification accurate. However, as you can see in the image below, the customer is giving a big tolerance of 1” too long and 0.5” too short. In most cases, being too long is better than too short!
Cutting and Stripping UL1015 10 AWG Wire (Automated)
The first thing to do is to set up the wire onto a “dereeler” which is a group of pullies that flatten the wire out to prevent curled wire pieces. It runs through the machine that it set to 25.25” with a semi-strip on one side of 0.25”. The wires come out of the machine in a few seconds compared to 30-40 seconds of manual labor. Also, the operator could start crimping the ring terminals as the machine is running to save even more time. It’s always smart to test a few pieces from the machine before letting it run for a lengthy period, but the set-up is quick and easy. The last thing to consider when setting up the wire processing machine is the blade levels that come down and pull off the insulation. If the blades don’t come down far enough then the insulation won’t strip, and you’ll have to manually complete the rest of the strip. Conversely, if the blades come down too far they could cut into some of the 100+ copper strands, whereby hurting the connectivity later. Part of the quantity procedure during the cutting and stripping process is for the operator to check for scrapes and nicks on the copper strands, and to look for loose copper strand clippings on the table, which is clearly a bad sign of the batch.
Crimping Ring Terminals to Hook Up Wire (Manually)
Crimping ring terminals can be universal in some respects, but it depends on the specificity of the customer because there are various hand tools that crimps the variations of terminals. Typically, when doing home projects and projects for small customers, it’s sufficient to use generic tooling. In this case, the hand tool needs to have a slot for 10 AWG terminals. Most tools have at least 3-4 slots for similar gauge sizes. You’ll want to strip the insulation in relation to the length of the ring terminal barrel, so that the copper strands poke through the other end by less than 1/16 of an inch. That insures a full and solid crimp connection in the center of the exposed copper.
Crimping Ring Terminals to Hook Up Wire (Automated)
The automated way to crimp ring terminals is like the manual process. The same hand tool is fixed into a hydraulic unit with a motorized food pedal. It cuts the time down by 75% which would have to be weighed against the amount of business the individual or contract manufacturer is conducting on a regular basis. You can watch the video below to see how the terminal doesn’t have to be set into the tool first and how the foot pedal is quicker and more accurate. UL1015 10 AWG wires can be difficult to manually crimp with ring terminals by hand because high quantity can injure hands and wrists in time.
The operator begins with created one full piece as a sample for the rest of the assemblers to view as they work. This allows for visibility to play a part in quality. Next, the manager fills in a quality inspection report for each step in the process, and in this case, cutting the hook up wire, crimping the terminals and bagging/labeling. Each individual operator checks roughly 5% of the product against the specification sheet to be sure the measurements are correct and that the crimp is fully secure. Once each step is complete, the operators have finished their inspections and signed the report, the supervisor completes another final check of the assembly against the specifications set by the customer.