Types of Wiring Services

Below are descriptions of some of the more common types of electrical wiring processes used in industry today, and that our team at Kiski Precision Industries can support for your project.

Wire Stripping

Wire stripping is the process of using a machine or manual tool to strip away a segment (typically from the end) of the outer insulation or jacket on an electrical wire. This process exposes the bare metal (copper) wire underneath and prepares it to be terminated into another component. The wire could be terminated into a connector which then mates to a connector on an electrical component, or it can be hard wired and terminated directly into the component itself. Example components include switches, breakers, relays, I/O, controllers, etc.

Wire Crimping

Wire Crimping is a method of connectorizing or adding terminal connectors to the end of wires. Once the wires are stripped bare, and the wire strands are exposed, they are inserted into a metal sleeve and a special crimping tool is used to compress the sleeve over the wire. This leaves a very robust connection. Wire crimping is often used with connection points that may need to be attached and reattached with some frequency, and the associated connectors used with crimping typically allow for this. Crimping is also commonly used in places where soldering is not a good solution, because of heat or other reasons.

Wire Soldering

Wire Soldering is a form or connecting or terminating wires into another electrical component, such as another wire or a circuit board. Once the wire insulation is stripped back and the bare wires are exposed, metal solder is heated with a soldering iron and melted between the exposed wires and whatever they are being connected to. When the solder cools, it hardens and forms a robust, fixed connection. Solder usually comes in reels or bars of thin rods, and can be made from several different metal alloys, all of which have lower melting points than other common metals like copper.

Wire or Cable Harness

Wire or Cable Harnesses are sets or assemblies of multiple wires or cables into a single component. These multiple wires typically use a jacket to surround the entire group, and commonly multiple wires are terminated and consolidated into one or a limited number of connectors. This not only keeps the grouping of wires or cables clean and more manageable, but also makes for a simplified interface for connectorization and additionally helps to protect the set of wires from other outside environmental conditions or stimuli. The types and lengths of wires or cables and connectorization is usually customized for the specific application.

Our Wiring Process and Approach

At KPI we provide any of the services highlighted above as well as many others. We leverage the expertise and capability of a partner network including in network capabilities located on our business campus, to provide a wide array of wiring services. We can design and build custom cables or cable harnesses, as well as doing complete electrical control panel design and assembly. For more information on wire and panel assemblies visit our Assembly Services page. Whether you have a need for a small volume of simple parts to high volume or highly complex integrated solutions, we can support your needs.

We cover industries from medical, to energy to defense to instrumentation and robotics and more. Have a current or upcoming project? Have a member of our team contact you to discuss.

Wiring Applications

Wiring applications can be found in just about every manufacturing industry. We see wiring requirements most often for things like custom cabling to support electrical components like motors, hydraulic assemblies, sensors, instrumentation and customized machine cables. Electrical enclosures to support manufacturing equipment are another common application. This includes integrating PLC or motion controllers into an enclosure along with the additional peripheral electronics, such as relays, drives, and power supplies.