What Is Electromechanical Assembly?

Integrating electrical and mechanical components to produce functional devices is at the core of the electromechanical assembly process. This integration is key to the success of various applications, from small household appliances to complex industrial machinery.

Custom cable assembly typically involves contract manufacturing according to customer-provided drawings, schematics, or designs. It includes making connections between multiple devices to meet exact customer specifications. Read on to learn more about these essential assemblies and their wide-ranging applications.

Key Components of Electrical Harnesses and Cables

The main components of electrical harnesses and cable assemblies are:

  • Wires and cables: Conductive materials that transmit power or electrical signals between components.
  • Connectors: Devices that join electrical circuits to form a secure, reliable connection.
  • Insulation and protective sleeving: Includes tubing, tape, spiral wrap, and cable ties. These materials effectively encase cables and wires to protect against environmental factors and prevent electrical leakage.
  • Labels: Properly identify wires, cables, and other key components of the electrical harness.
  • Terminals and crimps: End-point connectors that enable the attachment of wires to other systems or components.

How Electromechanical Assembly Powers Industry

Many industrial and commercial applications rely on electromechanical assemblies to enable enhanced automation, control, and machinery operation. These assemblies form the backbone of modern systems that demand the integration of precise electrical and mechanical components.

The electromechanical assembly process relies on detailed customer-provided schematics, drawings, and specifications. They focus on the application as a whole instead of individual parts and components.

Wire Harness Manufacturing Applications

  • Consumer electronics: Compact wire harnesses connect electronic components in computers, smartphones, and other devices.
  • Electronics: Specific electronics applications include audio/video equipment, household appliances, communication equipment, computers, and peripherals.
  • Gaming/Amusement: Slot machines, arcade games, vending machines, and fitness equipment contain various types of wire harnesses.
  • Industrial equipment: Wire harnesses facilitate the seamless operation of packaging, agricultural, construction, and other industrial machinery by protecting and organizing electrical wiring.
  • Medical devices: Precision wire assemblies are vital for the proper functionality of X-ray equipment.
  • Motor: Cable assemblies are found in brushless DC motors and drives, DC-motor drive solutions, and AC-induction motor drive systems.
  • Telecommunications: Cabling systems, data center infrastructure, optical network equipment, satellite receivers, and DSL routers utilize wire harnesses.
  • Transformers: Power distribution, industrial control, step-up/down, and high-frequency pulse transformers also require robust electromechanical assemblies.

Precision Testing for Electromechanical Assemblies

Rigorous testing methods verify that every electromechanical assembly meets stringent safety and performance standards. Quality control measures identify and correct any defects that may occur during the manufacturing process.

Partec’s Quality Control Measures

  • Continuity testing: Verifies electrical connections can conduct current without interruption and remain intact.
  • Dimensional gauging: Measures physical dimensions to ensure the proper adherence to desired tolerances.
  • Failure probing: Proactively identifies potential failure points within the assembly.
  • Hi-pot testing: Assesses the insulation strength of various electrical components to verify their ability to withstand high-voltage conditions without failing.
  • Press force monitoring: Ensures terminals and connectors are assembled with the correct force to maximize integrity.

Choosing the Right Wire Harness Manufacturer

Selecting a reputable provider for wire harness manufacturing is vital for obtaining top-quality harnesses that conform to specific requirements. Also consider factors such as the manufacturer’s certifications, experience, and production capabilities. Other aspects that influence the assembly’s performance and longevity include:

  • Assembly techniques: Proper techniques, such as accurate soldering and crimping, are essential to achieving reliable connections.
  • Customization capabilities: Tailored solutions effectively address unique application requirements.
  • Environmental resistance: Custom cable assemblies that can withstand various environmental conditions have a longer service life.
  • Material quality: High-quality materials enhance performance and durability.

Streamline Production With Contract Assembly From Partec

At Partec, Inc., we are experts in delivering exceptional contract services with a proven reputation for our electromechanical assembly process. Our team is adept at handling labor-intensive, complex projects, with value-added assembly services for controls and enclosures. We can accommodate small quantities and prototyping if the parts are in our system. Our extensive library of materials and state-of-the-art equipment enables us to handle high-volume production runs that fulfill our customers’ expectations.

Outsourcing electromechanical assembly to a specialized contract manufacturer like Partec, Inc. can help you:

  • Improve product quality
  • Scale and optimize production processes
  • Reduce costs

Our customers typically complete design and material selection before coming to us for the custom cable assembly part of the process. We collaborate with customers to deliver innovative solutions and can offer design modification suggestions if needed.

Partec, Inc. operates a state-of-the-art ISO-9001:2015 certified facility specializing in contract assembly for any size business. With 125,000 square feet of assembly space, we also have a fabrication and tooling department and can perform in-house acceptance and customer acceptance runs.

Request a quote today to get started on your electromechanical assembly project.