In most cases PBEs avoid water condensation and therefore corrosion inside a housing. For some critical situations a drain plug will be the right choice. Sometimes we are asked whether a combination of PBE and drain plug can be used. As most our drain plugs are specified for IPx5 this could be an alternative – depending on the application.

In some specific cases neither PBE nor drain plug could solve the problem. Just keep in mind that both products are passive products; their functionality is depending on the environmental and operational situation. This means some applications need active air conditioning inside the housing; this cannot be realized by passive PBEs or drain plugs.

Conduit Systems: As an official sales partner of FLEXICON, we have added an important product group to our portfolio. We now offer our customers conduit systems made of metal and plastic, as well as the matching cable glands and accessories.

Enclosure Systems: Enclosure to protect the internal eletronics against water, dust and mechanical influences.

Customized Solutions - Tailor-made solutions

We are the contact for product developers, engineers and purchasers who need application-specific solutionsfor special requirements and applications in the areas of cable entries, pressure equalisation, conduit systems and connectors. We offer you our services in a 5-step concept:

I. Consultancy and analysis before the contract is awarded

We advise you at an initial customer meeting and clarify the approach together with you on site. We then analyse the market in order to find the right system partner for you before the contract is awarded and to match the development and production costs to your budget. We can call on an existing pool of partner companies in this respect who are considered experts in their respective fields.

II. Contract conclusion and administration

Our team regulates the entire development process. Important framework conditions, such as tool type, ownership rights, maintenance intervals and production quantities are clarified and defined in the contract. We coordinate and document the entire project and can also obtain patents and approvals where necessary. The tools supplied for your product can also be transferred to your ownership if this suits your investment strategy.

III. Developing innovative products

In the next step, we develop your individual product with our team, focusing entirely on your specific requirements and visions. We use 2D and 3D drawings for you to visualise how the end product will look and operate. And we optimise the product with you until it fits your requirements.

IV. Handling the communication process

You don't have to worry about a thing. As a full-service provider we handle all communication with our partner companies. During the project we clarify with you whether we can use existing basic tools or if completely new tools are required. The costs of developing your product can be significantly reduced if basic tools already exist. We also work with you to determine which tool size is best for your product, what the annual production quantity should be (2-fold, 4-fold, etc.) and what costs this will incur.

V. Monitoring tool production

After the product's construction phase, we support and monitor the entire production process: from manufacture of the tool to start of production. We define the material with you, perform checks, document them and handle the sampling. Once the product has reached the production stage, you approve the prototypes on the basis of all the technical data and we start production for the first series.

Cable Assemblies

What exactly are cable assemblies?

Cable assemblies are the manufacture and production of ready-to-connect cables, cable harnesses and complete cable harnesses including assembly with various connectors and contacts. These are required in many industries where the transmission paths are electronic, preferably for connecting cables for servo drives.

Activities and procedures in cable assemblies

The particular application, the quantity and the specific requirements of the customer determine which cable assemblies are used. Three connection methods are mainly used: crimping, soldering and insulation displacement connection (IDC) . Grade customer-specific developments with precision-fit design are in demand in addition to the standard solutions of cable assemblies.

Why design is so important in cable assemblies

Cable assemblies are an essential element of functionality in plants, vehicles, industrial equipment and processes. It is therefore all the more important to be able to rely on their functionality and performance. High demands are therefore rightly placed on the development of cable assemblies and cable harness production. To meet these, cable assemblies are designed as ready-to-connect segments, depending on the application. For complex applications, the cable assemblies are designed or represented three-dimensionally using CAD programs. This makes it possible to define specific assembly points and other technical parameters such as cable lengths and fasteners as early as the development phase.

Cable assemblies with numerous possibilities

We offer customized solutions for cable assemblies in all application areas. A wide product range of electromechanical components and cables allows us to meet almost any requirement. We accompany you from product development and sampling to the supply of small or large series and are happy to use our expertise to point out alternative solutions if necessary.

We manufacture a wide range of connector and cable combinations for various industrial applications for the transmission of power, signals and data.

• Cable and wire assemblies with various connectors, contacts and other peripherals.
• Hybrid cable assemblies
• Manufacturing of connecting leads for PCB
  • Board-To-Board
  • Wire-To-Wire
  • Flat ribbon cables
• Single strand processing
• Connecting cables for servo drives for all manufacturer standards
• Manufacturing of component potting

Our service includes labeling or marking of cables and wires according to customer requirements. We deliver in specified packages (for example, rolled and/or bundled). Cable and wire ends can be supplied pre-tinned or fitted with ferrules. In addition, we offer demand-oriented production on modern machines and continuous quality monitoring as well as the preparation of initial sample inspection reports (EMPB) and batch traceability in accordance with UL Wiring Harness according to ZPFW2 and ZPFW8.

Cable Assemblies - UL Wiring Harness

For end products that contain cables and wires and are intended for the North American market, UL Wiring Harness labeling is often required. This ensures that the installed components can be traced.

RST has obtained UL certification as a manufacturer of cable assemblies to UL (Underwriter Labratories) and, with the Wiring Harness label to ZPFW2 (USA) and ZPFW8 (CANADA), ensures that all components and materials under UL file number E520455 comply with current UL standards.

On the one hand, this traceability program guarantees that UL-specific product requirements and processes for cable assemblies are met by our production facility. Second, it ensures the identification and traceability of all cable assemblies based on lot numbers, manufacturing dates and manufacturing locations. The outer packaging is marked with special labels to indicate that these cable assemblies have been manufactured in accordance with UL Wiring Harness requirements.

In particular, customers and prospects who supply cable assemblies as components for end-use applications in the North American market are assured of this. Underwriters Laboratories Incorporated continuously monitors compliance with the required standard in terms of components, materials and processes through inspectors using a validated and traceable process. Annual audits ensure that the specified standards are permanently maintained.

If you have a requirement for cable assemblies, please contact us. We look forward to your inquiry.

Connectors: Large selection of connectors, circular connectors from Hummel and rectangular connectors from Ilme for different applications.

Accessories: For example lock nuts for fastening components with an external thread if there is no threaded hole. Flanged to prevent surface damage during assembly.

Our EURO-TOP EMV AMPACITY LF: In modern production lines, cable glands with high current dissipation capabilities are becoming increasingly important. Conventional EMC glands are not necessarily suitable for this.

Applications in the railway sector, or control systems such as VFD (Variable Frequency Device) or PWM (Pulse Width Modulation), where high-frequency signals are used, require further consideration: the high-frequency electrical signals used in these applications can cause induced (false) currents - even in the cable shields. The supply cables must therefore be dimensioned in such a way that these induced currents are grounded with low impedance. Otherwise, the system may fail because it can be heated up too much by the fault currents.

Although the grounding of electromagnetic signals is already realized by means of EMC glands, these still have to undergo a modification in order to be able to discharge electrical currents of several hundred amperes without damage. Our "Euro-Top Ampacity gland" was developed for these applications (Ampacity = maximum current carrying capacity).

External laboratory tests according to IEC 60512-5-2 (current carrying capacity) and IEC 60512-5-1 (temperature rise) showed that even at leakage currents of several 100 A, no significant temperature rise of the system is observed when using our Euro-Top Ampacity glands.

In addition to the excellent current dissipation properties, our Euro-Top Ampacity glands naturally also offer the well-known excellent EMC shielding values up to the GHz range. They are shock and vibration resistant according to international automotive standards and are also easy to install.