WesBell Electronics
Wire and Cable Blog



Category: cutting and stripping value added services

Cable Assemblies by WesBell Electronics – ISO 9001 Certified

When looking for a wire and cable distributor look for a company that offers their customers some kind of additional services. This way you can look for a one stop shopping vendor for all of their wire and cable needs. Specifically look for ISO 9001 Certified vendors to ensure that you get the highest quality products and services. Some companies can now manufacture all different kinds of cable assemblies to meet a customer’s needs.

50’ Cable Assembly

50’ Cable AssemblyThese specific kinds of cable assemblies are manufactured in house for our customers.  What we do is, we remove the outer jacket, then remove the shielding, and stripe the lead wires.  Now we don’t just stop there we also tin dip the lead wires and solder a thermistor to the wires on one end.  Now the customers can change the specifics and let us know just what the length needs to be and the tolerance for each assembly.

Cat5e Cable Assembly

Cat5e Cable AssemblyThe specific kind of assembly we created was a molded Cat5e.  Now we do not do the molding here at WesBell, but our vendor will send us the cable coiled up with molded ends.  Our job then is to remove 2 inches of the outer rubber jacket, and pull apart the bonded pair conductors.  Customers can choose if they want or need heat shrink tubing added onto the conductors.

Electronic 3 Conductor Cable Assembly

Electronic 3 Conductor Cable AssemblyThe particular assembly done here used a General Cable.  This brand of cable has a PVC jacket that covers three PVC wires.  When creating this assembly for our customers we strip off both layers of PVC insulation off of the conductors.  Then the copper strands are crimped and then inserted into a plastic housing unit that will connect the customer’s application.  Most of the assemblies we manufacture are created to specifically meet each customer’s individual and unique application.

Custom Steel Braided Assembly

Custom Steel Braided AssemblyThis is a custom electronic cable assembly for the customer.  This cable had an additional stainless steel braid cover, and had six PVC wire conductors.  In order to create the assembly we had to remove the PVC jacket, the stainless braid and the PVC insulation around each individual conductor.  Next we were able to pull the shield to the side and twist it, then solder the copper strands to hold their form.  Then to make sure no wire was left exposed we added an adhesive lined piece of tubing to help with the transition from the steel braid to the PVC jacket.

Each one of the cable assemblies we create are to each customers specifications.  Being ISO 9001 certified guarantees our customers receive high quality work from us every time.  The assemblies we manufacture are created to meet each and every customer’s specifications.

Written by: WesBell Electronics
ISO 9001 Certified

Cut, Strip and Crimp Wire Assembly – WesBell

We started selling wire and cable products over 25 years ago and customers have been asking us to cut, strip or crimp wire since the day we opened. Aside from electrical installations, it seems almost obvious that a spool of wire is going to eventually be cut to a certain length for an application. So we started letting our customers know upfront that we’ll cut, strip, crimp, solder, twist and assemble their finished product.

Assembly Process

Cut, Strip and Crimp Wire AssemblyIn the picture to the left you’ll see UL1015 PVC wire cut to about 6 inches. It’s an 18 AWG flexible hookup wire used in electronics and appliances that you can buy on our website. The red insulated flag terminal is crimped with a hand tool piece by piece and set up to fit the customer’s application. The opposite end is semi-stripped, leaving the extra piece of insulation on the wire to stop the copper strands from fraying during the shipping process. If the insulation is removed completely before shipping the product we’ll typically “tin dip” the ends in solder to hold all of the copper strands together as one.

Automation

Due to the high volume of this particular part we decided to automate the process a bit more. We bought the red insulated terminals on a reel that feeds into a crimping press with a foot pedal crimping process. The assembler inserts the wire into the terminal, presses the foot pedal for a secure connection and the crimping press automatically slides the next terminal into position. The process is about 4-5 times faster than crimping by hand, but much more expensive.

Quality

WesBell completes “in-process” quality checks after each part of the process is complete, along with a final inspection of the entire assembly. For instance, once the wire is cut and stripped on the wire cutting machine, 5% of the pieces are measured for accurate lengths. If one or more pieces do not meet the tolerance specified another lot will need to be measured and so on. Otherwise, if everything matches the data sheet, the parts move to the next step in the process.

Written by: WesBell Electronics
(800) 334-8400

Wire Assembly Using UL1015 Hookup Wire

WesBell Electronics is a mature ISO9001 certified company that manufactures wire assemblies, harnesses and kits to our customer’s specifications. We no longer need to tell our customers about our quality of product because our ISO certificate proves it. We’re audited on a quarterly basis along with a more in-depth audit annually to confirm that our processes and procedures meet the standard.

Hookup Wire

UL1015 12 AWG Wire AssemblyThis wire assembly is comprised of three 12 AWG wires that are each approved by UL under the UL1015, UL1011, UL1230 and UL1335 categories. UL, Underwriter’s Laboratories, uses each UL designation to show what the wire has been tested to withstand. For instance, UL1015 wire is approved to resist moisture, withstand up to 600 volts and withstand up to 105°C in any given application. These PVC wires were manufactured to be used in electronic devices and appliances as long as they meet the criteria of the UL standard. See our UL1015 12 AWG wire here >>

Cutting Machine

WesBell Electronics has many wire cutting machines that we use to cut large quantities of hook up wire for the biggest companies in the world, including GE. We do not resell our wire cutting machines, we use them for high volume production. In this case, the machine was set to cut the wires to about 12 inches long and semi-strip each end. The slugs remain on the end of the wires so that the copper strands won’t get damaged of frayed when shipped. Our customers set the length and tolerance of each job.

Tie Wraps

Once each of the three wires are cut, measured and checked for accurate lengths, we bundle three wires together and tighten a tie wrap around them. Due to the high volume of production, we also have a tie wrap cutting tool that tightens the tie wrap and cuts the excess plastic for a clean finished product.

Instead of creating our brand name wire harnesses and attempting to find customers that purchase them, we let our customers inform us of exactly what they need. Some jobs are quick and simple while others are much more complicated. More complicated wire assemblies will sometimes require engineering, specification data sheets, sample prototypes, customer visits and months of production. We have a strong online presence and require positive feedback in order to remain a strong player in the wire harness and assembly industry. Feel free to browse around online to find comments and testimonials about our company.

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Twisting PVC and PTFE Lead Wire

Twisting PVC and PTFE Lead WireBuilding a wire harness or twisting lead wires is considered to be a value added service offered by companies. There can be other products also added on to the twisted wires such as solder and terminals. Some companies do offer these services to their customers to make things easier, however only a select few are ISO9001 certified and I suggest you find those companies. This makes things easier for customers because it almost becomes one stop shopping. The customer doesn’t have to twist the wires themselves or even go to another business to get this done.

Twisting Wires

Usually twisting hook up wire is only done for smaller wire harness jobs. These jobs include anywhere from two to four lead wires total. Companies will offer this value adding service to their customers for jobs where the wires are not connecting to the same spot and jacket protection isn’t necessary. However twisting lead wires does give the application a more neat and organized look. This is beneficial because the wires will hold their form together as one.

Cutting the Wire

There are two times when the wire can be cut to length. The wire can be cut before it twisted for shorter lengths, or there is the option of twisting the wires first and then rolling the wires onto a spool to be cut to length later on. Once the wire is cut it is then stripped of its insulation as well. And there is also the option of having the strands tin dipped to keep them together as one instead of them getting bumped and frayed.

Additional Cost

Customers need to be aware that there is an additional cost associated with getting PVC and PTFE lead wires twisted together for a wire harness. Some companies will also offer to include a layer of heat shrink tubing over the twisted wires for better protection and a cleaner look. But the addition of the heat shrink tubing would also cost the customer extra money because it’s an additional step. The added heat shrink tubing not only helps to make the twisted wires look better but it is there for added protection as well.

These value added services vary based on the company you place your order with. There are different types of insulation to be aware of because each type comes with a different cost. Some companies will give their customers the option to add solder to the end of wires to prevent fraying while they’re being shipped. These are all things that companies can offer as an added service for their valued customers.

Written by: WesBell Electronics Inc
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Cutting and Stripping Lead Wire | ISO Certified

In the eyes of the customer it is easier to trust a company that has the ISO9001 certification. This means that the company adheres to strict quality standards. Customers can be sure that the company is making their products properly and not taking and short cuts in the manufacturing process. It’s also beneficial to the company to have this certification.

ISO 9001 Companies

Certified companies are compliant of the standard because they’re audited annually to be sure of it. Failing the audit revokes the certification which means trust is automatically gained by ISO9001 certified companies. By being ISO9001 certified it gives customers some security that the company is both trust worth and high quality. By adhering to the high ISO9001 standards the companies are showing their customers as well as their potential customers that they are a trustworthy company with high quality products.

Value Added Services

WesBell’s value added services include cutting, stripping, spiral striping wire, twisting wires, soldering, wire harnesses, cable assemblies. These are all extra added services companies can offer their customers. This way the customer not only can get the wire or cable they are looking, but if the company were to build a wire harness as well it’s one less step the customer has to do themselves.  Certain companies will also offer to tin dip or even solder hook up wires for their customers. This is just one less thing a customer has to do themselves. It’s convenient and can save a customer both time and money.

How to Become ISO9001 Certified

In order for a company to become ISO9001 certified they first need to find and hire an ISO consultant to help with all the initial paperwork. Talking with the consultant can be beneficial. You as the company and the consultant can discuss all the added benefits of getting certified. It can help to improve the day to day operations of your business and continue to make improvements in sales. Having the ISO9001 certification can be the deciding factor for customers when they are considering buying your products. The certification gives them a sense of security that the product they are about to buy is good quality and it can be trusted.

When it comes to cutting and stripping lead wire make sure you as the customer go to an ISO9001 certified company. With the regular audits there is no way that the certification can be out of date. One failed audit and the company loses the certification. This way any company that is ISO9001 certified can be trusted and is selling high quality products. This means that as the customer whatever value added service you pay for will be done correctly the first time.

Wire Harness with Heat Shrink Tubing

Wire Harness with Heat Shrink TubingWe’re a wire, cable and tubing distributor that also manufactures wire harnesses and cable assemblies to specification. We’ve always distributed bulk wire and cable directly from the manufacture, but recently started building harnesses and assemblies when customers ask the question. As an ISO9001 certified company we’re trusted, without conducting previous business, by large customers such as GE and Parker Hannifin to get the job done right.

That being said, we don’t have engineering employees on staff for large board assemblies, however we’re prepared to handle large volume in harnesses and cable assemblies that require up to 10 steps. For instance, as you can see in the picture to the left, we specialize in cutting lead wire, stripping it, crimping terminals and adding heat shrink tubing.

Heat Shrink Tubing

There are three main reasons for including heat shrink tubing to your wire harness. The first is to bundle the lead wires tightly together for a clean and neat look once the assembly is attached to the application. The second reason is to include a customer part number or details about the assembly that might be important to the person installing it or replacing it later on. The customer will specify the exact ledger, color and length of the tubing to be used on their assembly.

Another reason for using heat shrink tubing is to increase the protection of the copper wires. The insulation over the copper has a temperature rating and voltage rating that shouldn’t be exceeded. If one of the wires get cut into accidentally, heat shrink tubing can be used as a splice kit to repair it back to normal. Just be sure to ask for the same temperature and voltage requirements so that the tubing and wire insulation match.

Striping and Twisting Hook Up Wire

Striping and twisting hook up wire is an additional service provided by your wire and cable supplier. Manufacturers will offer to stripe wire when the quantity is over 25,000’ for a single color, but more often than not, your purchase of striped wire will require your supplier to do the additional work of adding a spiral stripe.

Striping Hook Up Wire

Striping Hook Up WireIf there are 10 basic colors of hook up wire and 10 stripe colors that can be added, how many options are there in total? Quite a few. Contract assembly businesses manufacture wire harnesses with anywhere from 10, 25, 50, 100 or more lead wires that are all connected to the same device. Including a stripe will allow various color options to be used. It will also limit the amount of harnesses needed for a single job because 100 different colors can fit into a single harness instead of breaking it into 10 separate harnesses.

Twisting Hook Up Wire

Twisting Hook Up WireTwisting hook up wire is typically done for smaller wire harness jobs that include two to four lead wires in total. A wire harness with two wires that are 3 feet long will benefit from twisting because the wires will hold their form together as one. We can cut and twist 6 inch wires or we can twist 1000 feet onto a plastic spool for you to cut to length yourself.

Sometimes a 2, 3 or 4 conductor cable will be used instead of twisting lead wires together, however it will be more expensive to purchase. The cable jacket offers more protection to the wires in addition to making it look neat and clean within the assembly.

WesBell can also include a layer of heat shrink tubing over the twist to give the wires more protection and a cleaner look. Shrinkable tubing has voltage and temperature ratings just like wire insulation, so it’s smart to get similar ratings between the wire and tubing based on the environment they’ll be placed in.

Please call with any questions (800) 334-8400

Cutting and Stripping PVC Hook Up Wire

WesBell Electronics is an ISO 9001 certified distributor for wire and cable along with a value added services department of cutting, stripping and assembling lead wires. Being ISO certified means that we document all of our errors in house, analyze them and find ways to continuously improve our procedures.

Kenneth Bell started the company over 20 years ago selling bulk wire and cable. Anything from hook up wire to shielded and unshielded electronic cables. Just like many businesses that grow over the years we started getting inquiries to cut wire and cable to length which lead us into our value added services department.

Once we started cutting and stripping hook up wire we began making small wire harnesses and cable assemblies a short time later. It can be very hard to decline business so we accepted it and performed 100% quality checks to be sure the product matched what the customer was looking to receive.

Over 15 years later we’ve improved our process ten fold with a quality initiative of 0% defective product. While that can be very difficult to achieve with human error possibilities we strive to get closer and closer to that goal every day.

We’re currently located in Merrimack NH and perform kan ban systems in surrounding areas of Manchester, Nashua, Keene, Concord and Portsmouth New Hampshire. A kan ban system is an order for 1000 pieces that require 200 pieces to sit on the shelf ready for immediate delivery by our personnel or via UPS. Once the 200 pieces are delivered another 200 pieces go directly into production and move to the shelf when completed.

Even though we do perform value added services we stand by our niche of electrical wire and cable distribution throughout the USA. We purchase electrical wire, electronic cables, portable cord, hook up wire, PTFE wire and cable and heat shrink tubing from over 50 different manufacturers.

Please call for a quote if you’re looking for bulk wire or cable assemblies.

WesBell Electronics Inc
(800) 334-8400

Electrical Wire and Cable Value Added Services

WesBell has been in business for over 20 years as a wire and cable distributor. As businesses grow they tend to expand into new things and for us it was value added services.

After about 5 years of selling bulk wire and cable we had a customer ask us to cut hook up wire to length for them. We decided that the rest of our customers might be able to benefit from this as well. So we accepted the job and started contacting the rest of our customers about our new services.

Jumping ahead another 5 years WesBell now distributes wire and cable, spools, stripes, cuts to length, cuts and strips lead wire and manufactures wire harnesses and cable assemblies to specification as an ISO 9001 company. Being certified as an ISO 9001 company gives our customers ease of mind knowing that we have to follow strict procedures when manufacturing.

Our value added services department has been a large portion of our growth. We’ve also been able to employ a lot of people because of it in this terrible 2011 economy.

If you need anything done to your wire or cable please let us know. We can quote it which might end up saving you money. We have machines running all day long cutting and stripping wires that need to be crimped or tin dipped.

Tin dipping your lead wires after cutting them is a good idea to keep them from fraying. After the pieces are placed in the bag and shipped to your location they can get a little banged up. So if the ends are tinned then it will be much easier to work with when you get them.

Please call with any questions or comments about wire and cable or about our blog. Let us know if you want a certain topic discussed in our blog as well!

WesBell Electronics Inc
(800) 334-8400