Tag: electricity

Electricity

Power Cable Strain Relief

When using power cords, safety is the most important factor. In fact, many cables have built-in safety measures as extra precautions: ground pins, Auto-Lock® mechanisms, and surge protection, for starters. These components help manage the flow of electricity within the cord… but what about the cable itself? What protects the power cord from stress and damage?

Cable strain relief.

But how? What is it? How does it work? Why does it matter? We answer these questions and more below. Keep reading to learn more about cable strain relief!

Strain Relief: What Is It?

Strain relief describes the component at the base of a cable, just before the connector. This part of the cable often experiences the highest levels of stress, whether from pushing, pulling, bending, flexing, or twisting. Over time, continuous strain may cause the cord to deteriorate or break, leading to exposed wires and dangerous handling. That’s where cable strain relief comes in.

The strain relief acts as a hard shell, protecting the vulnerable portion of the cord from excessive stress. Different types of strain relief can be used depending on the style of cord and its application. However, all cable strain reliefs serve the same purpose: to protect power cords from damage.

What Are the Types of Strain Relief?

Standard Strain Relief

Standard cable strain relief components are pre-installed on the cord and are molded to the jacket and part of the plug. This style of strain relief is designed to avoid any damage to the conductors and prevent the separation of the plug from the cord.

Cable Glands

Cable glands, also known as cord grips or cable connectors, are independent fittings that must be manually installed over the connector and the cable joint. These fittings serve as sealing devices, ensuring a secure and effective enclosure where the cable meets the connector.

There are different styles of cable glands, including 90° angled snap elbows, which can be used for specific applications. These designs help minimize wire strain and prevent rubbing against sharp edges when the cord passes through the equipment panel.

Where Are Cable Glands Used?

While nearly all power cords are equipped with standard cable strain relief, cable grips are separate mechanical components that must be manually added. Cord grips are available in a wide range of materials, including:

  • Stainless steel
  • Nylon
  • Silicone
  • Nickel-plated brass
  • PVC
  • Nickel-plated aluminum

The right material for your cable gland will depend on your application. For example, stainless steel and nylon are beneficial for environments with liquid or freezing temperatures, while cords exposed to chemicals or high temperatures would benefit from PVC or nickel-plated aluminum cable glands. In these cases, not only does the cable strain relief protect the cord against damage from bending or pulling, but also against harsh operating spaces.

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How to Crimp Terminals

I bet you’re wondering what an electrical terminal is. A terminal is the point at which the conductor of an electrical component comes to an end and provides connection to external circuits.

And how do we crimp terminals, you ask?
Let me explain. The word crimping, in this context, means to combine two pieces of metal together by deforming one (or both) to hold the other. It’s called “crimp” because of the deformity.

You’ll need a crimping tool in order to correctly crimp connectors onto the wire. Please remember that pliers are NOT crimpers! To verify that you have the right crimper, the crimper Continue reading How to Crimp Terminals

AC & DC — For Those about to Flow We Salute You!

Ever wonder how the Aussie band AC/DC got their name? Or what makes it possible for them to ROCK and ROLL?

There are two types of current flow in a circuit: Alternating Current (AC) and Direct Current (DC).

Have you ever sat down and looked over at your desk lamp and thought, “how does the light come on?” Well, just like every home and office, AC power comes in through the power lines to your home and is what is available to pDifference ACDC 1ower outlets. AC stands for Alternating Current. Your lamp is being powered by AC because of the direction of the flow of electrons. There is a rotating magnet along the wire which causes the electrons to keep switching directions forward and backward. Also, the amount of energy that can be carried through alternating current is easy and also economical to transfer over longer distances and provides more power.

For example: here’s your power plant. It can yield 1 million watts of power. How does this work? Well there’s a way to Continue reading AC & DC — For Those about to Flow We Salute You!

Why You Shouldn’t Buy Male to Male Cords

I’ve read several stories on why people choose to purchase and/or make these male to male power cords, but for some reason, they’re referred to as “suicide cables.”

male to male 1Why? See, power cords have two ends: the male and the female end. The male end is the plug and the female end is the receptacle. When you plug the male end into a wall outlet, the female end or connector is ready to be plugged into a device or equipment, which will allow the electricity to flow through. That is a safe connection. BUT, if you plug the male end into an outlet and have a male plug on the other end, this leaves an exposed conductor (which is the biggest NO-NO).

Continue reading Why You Shouldn’t Buy Male to Male Cords

Ferrite Beads: What are they?

IEC-60320-C13 GREY WITH FERRITE_GREYYou see them all the time on your power cords. They may look like a little mini donuts or tubes close to one end of the power cord but what are they and why do we need them? Those are called ferrite beads and they are very useful in reducing electromagnet interference (EFI) and radio frequency (RFI). This can be important when you don’t want your machines to have any disruptions or interference of other kinds of signals. The beads can also be referred to by different names such as blocks, cores, rings, EMI filters and chokes.

Continue reading Ferrite Beads: What are they?

Difference Between Jacket Types – Brrrrrr!

wiresWell, we all know you have your parkas, pea coats, or even your 80’s stylish windbreakers but do you know the difference between the jackets on your wire? Choosing a cable jacket for your wire can be just as important as choosing a jacket for the snow, the rain, or even one to protect you from a fall on your motorcycle. There are many different types of jackets used for the outside of the wire, all helping it stay protected from different elements. It could be oil, fire or even the nasty weather.

Materials

Let’s start with the material used for wire jackets. They can go mainly into two categories:  the Thermoplastics and the Thermosets. Thermoplastics are more popular as they are lower in cost to produce and lighter in weight.  Thermosets are more flexible and offer heat resistance.  The most commonly used is PVC which is part of the Thermoplastic category. It offers great flexibility for your cord and are typically used for general purpose wire.  Next we have silicone rubber which offers great flexibility and heat resistance up to 2500°. Silicone rubber belongs to the Thermoset category. Continue reading Difference Between Jacket Types – Brrrrrr!