Specialized Cable Assemblies

Part Number	Description / PDF	Quantity
DELS-1125E Banner Engineering	CBL LP CUSTOM TO LP CUSTOM	1
D-500-0465-1-613-079 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
D-500-L457-4-613-360 TE Connectivity Aerospace Defense and Marine	D-500-L457-4-613-360	0
SGPS12-8FT-L2 Panduit Corporation	12 AWG STRANDED 8" RED, FLANGED	14400
09457251537 HARTING	RJI CABLE8AWG28/7HYBROUT IP67M	0
00250262 Wickmann / Littelfuse	HARNESS L=2500 WITH SOCKET 13P/S	0
D-500-0455-2-612-078-TCS2 TE Connectivity Aerospace Defense and Marine	D-500-0455-2-612-078-TCS2692	0
D-500-0457-2-612-078 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
D-500-0457-2-613-120 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
09457251542 HARTING	RJI CABLE IP67/CAT6METAL HYBRID	0
D-500-L456-2-613-360 TE Connectivity Aerospace Defense and Marine	D-500-L456-2-613-360	0
00521035 Wickmann / Littelfuse	"COMPLETE EBS 24V COIL LU.3.5 ""	0
09457251576 HARTING	HAN 3A METAL RJ45 HYBRID CABLE A	0
D-500-L455-3-612-360 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
D-500-L458-1-612-120 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
D-500-0255-017 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
33572110200001 HARTING	HYBR.CABLE ASSY, AC, 20M -2 X HA	0
D-500-L456-3-612-240 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
D-500-0466-2-612-236C2791 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0
D-500-0458-2-612-240 TE Connectivity Aerospace Defense and Marine	IN LINE COUPLERS	0

Specialized Cable Assemblies

1. Overview

Specialized Cable Assemblies are engineered interconnect solutions designed for specific performance requirements in demanding environments. These assemblies combine multiple cables, connectors, and shielding components into customized configurations to ensure reliable signal transmission, power delivery, or data integrity. Their importance spans across industries requiring precision, durability, and compliance with stringent standards, such as aerospace, medical, and industrial automation sectors.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
High-Temperature Cables	Rated for continuous operation above 150 C, using materials like PTFE or silicone rubber	Aerospace engine sensors, industrial ovens
EMI-Shielded Assemblies	Multi-layer shielding (braided copper, foil) to block electromagnetic interference	Military communication systems, MRI machines
Flexible Robotic Cables	High-flex materials with torsion resistance for dynamic motion applications	Industrial robots, automated guided vehicles
High-Speed Data Cables	Controlled impedance (100-150 ) for signal integrity up to 40Gbps	Data centers, 5G base stations
Submersible Cables	Hermetically sealed connectors and waterproof jackets for underwater deployment	Offshore oil rigs, underwater drones

3. Structure and Components

A typical specialized cable assembly consists of:

Conductors: Annealed copper or aluminum with plating (tin, silver) for conductivity
Insulation: Materials like XLPE, FEP, or TPU based on temperature/dielectric needs
Shielding: Combination of braided copper, aluminum mylar tape, and drain wires
Jacket: Abrasion-resistant thermoplastic elastomers (TPE) or halogen-free compounds
Connectors: Custom-molded interfaces with locking mechanisms (e.g., MIL-DTL-38999, USB 3.1)

4. Key Technical Specifications

Parameter	Importance
Conductor Material	Determines conductivity (60-100% IACS) and corrosion resistance
Insulation Resistance	Must exceed 100M to prevent leakage currents
Operating Temperature	Defines functional range (-65 C to +250 C typical)
Voltage Rating	Safety margin for dielectric breakdown prevention
Bend Radius	Minimum curvature to avoid mechanical failure (3 OD standard)
Insertion Loss	Critical for high-frequency signal integrity ( 0.5dB@10GHz)

5. Application Fields

Aerospace: Flight control systems, avionics, and satellite communication
Medical: Diagnostic imaging equipment (CT/MRI), surgical robots
Automotive: EV battery management systems, ADAS sensors
Energy: Wind turbine pitch control, oil rig monitoring systems

Case Study: A subsea oil exploration project utilized 10km-length specialized assemblies with polyurethane jackets, achieving 10-year deployment without degradation at 3000m depth.

6. Leading Manufacturers and Products

Manufacturer	Representative Product
Amphenol Industrial	MaxGuard High-Temp Cable (200 C rating)
TE Connectivity	MATE-AXAL High-Speed Automotive Cable
Samtec	QSH-DP High-Density Flex Assembly
LEONI AG	ROBUSTEC Robotic Cable Series

7. Selection Guidelines

Key considerations include:

Environmental factors (temperature, chemicals, mechanical stress)
Signal/power requirements (frequency, voltage, current capacity)
Regulatory certifications (UL, RoHS, MIL-STD)
Cost vs. longevity trade-offs for high-reliability applications

8. Industry Trends

Emerging developments include:

Adoption of hybrid cables integrating fiber optics and power conductors
Nanocoatings for enhanced EMI protection and corrosion resistance
AI-driven predictive maintenance through embedded sensor cables
Increased demand for halogen-free materials meeting IEC 62591 standards