Processing UL1007 26 AWG Wire for a Motor Assembly


Table of Contents

This article will explain how a contract manufacturer uses UL approved copper wire, equipment and labor to manufacturer a motor assembly. The process is much easier with an ERP database system that allows the user to enter an order with a bill of materials so that the inventory is depleted accurately and for a simple-to-read production ticket. The first step is to locate and compile the necessary inventory needed for the job and to schedule the equipment and laborers time on a master schedule. It can be done in software as simple as Microsoft Excel or Project.

  1. Add the production work to the schedule
  2. Locate and compile the bill of materials
  3. Cut the UL1007 wire on the machine
  4. Tin Dip the UL1007 26 AWG wires
  5. Crimp the terminals to the opposite end
  6. Insert the wires into the white housing
  7. Solder the wires to the motor
  8. Apply heat shrink tubing

Wire Assembly Production Schedule Template for People and Equipment

Locate the UL1007 26 AWG hook up wire based on the location in the system, and in this case black and red will be needed for the job. The part number below is descriptive on purpose, “UL1007-26-7”, mentioned the UL style, the AWG size and the Copper Strands used to create the AWG size. In this case, 7 strands of 30 AWG copper wound together creates a diameter equate to 26 AWG and it’s been located on the shelf.

Photo of UL1007-26-7 hook up wire in warehouse.
Photo of UL1007-26-7 hook up wire in warehouse.

Cut and Strip the UL1007 26 AWG Hook Up Wire

The wire will need to be cut and stripped on the wire cutting machine manufactured by KOMAX in this case. It’s important to put checks and balances in place to be sure you create a quality product every time. Each assembler or laborer should sign their initials after producing any portion of the assembly to show that they used a calibrated measuring device to assure accuracy. Later, a production manager should quality check the entire job, but it’s important to also complete in-process checks to document each assembler that touched the assembly and to assure customers that these quality checks are completed.

Notice the partially signed paperwork near the machine:

Tin Dip the Black and Red UL1007 26 AWG Wires

As the machine cuts the wires it’s also stripping the insulation from each end, as specified by the customer. One end will be tin dipped to tightly bind each of the copper strands together and to help adhere to solder in another step. The other end will have a terminal crimped to the black wire and the red wire which will both be inserted into a plastic housing. The housing is the part of the assembly that the customer will plug into their device to connect both the red and black copper wires as conductors of electricity that powers the device.

The picture below shows the assembler dipping the wires into an incredibly hot pot of tin (solder). Before dipping the UL1007 26 AWG wire into the tin it should be noted that the 7 copper strands inside the insulation could be bumped and fray excessively. Therefore, it’s important to keep the strands together by dipping them into tin before the wires are transported around the production room. Believe it or not, the spoon in the picture is used to scoop the top layer of burned tin so that it creates the nice mirror-like view that this picture is showing.

Photo of UL1007-26-7 hook up wire being tin dipped.

Insert One Black and One Red Hook Up Wire into the Same House

The other ends of these wires are getting crimped by hand and poked (inserted) into the white plastic house. There’s a little piece on the terminal that bends as it’s inserted into the house and it clicks once it’s pushed all the way in. A quick pull test after hearing the click assures the assembler that the wire is securely inserted into the house and gives them the confidence to sign their initials on the quality form. As you can see in the picture below, each assembly requires one black and one red wire that have already been tin dipped and crimped.

Photo of UL1007-26-7 Hook Up Wire being assembled.

Notice that the paperwork is being filled in along the way with what’s called a “traveler package”. The traveler package includes a data sheet provided by the customer, a quality inspection report initialed by the assemblers and a bill of material list for assemblers to double check part numbers and quantities when necessary. Here is a closer view of the nearly completed assembly:

Photo of assembled ul1007-26-7 hook up wire.

Solder the UL1007 Wires to the Motor

The next step is to solder the right side of the above assembly to the customer’s motor. There are two hooks that the exposed copper ends will wrap around and solder will be applied to secure the wires to the motor. The solder iron heats up to 750 degrees to melt the solder for a short moment. Once the iron is removed the solder will harden within a few seconds. Many of the soldering projects require the overhanging magnified glass with a light to see exactly what they’re doing and to assure exceptional quality. Here is a short video of this process being completed using UL1007 26 AWG wire:

Apply Heat Shrink Tubing and Shrink Until Tight

You might also notice the black heat shrinkable tubing that’s now covering the UL1007 black and red conductors, which is going to shrink down tightly against the wires as a protective layer against anything that might complicate the wire assembly later when it’s connected to a much bigger device. For instance, some devices get very hot when being used and the assembly needs to resist heat, or there might be oil dripping from random areas that the wires cannot resist. Small wire assemblies used in large equipment can cause major problems and need to be considered early in the process so that these complications don’t cause multiple people to spend hours of labor to find a failed wire somewhere in the middle.

The completed wire harness assembly is in the picture below:

Photo of ul1007-26-7 hook up wire motor assembly.