Case Study – Computer Custom Cable Assembly

The Challenge

Build two custom computer cable assemblies and provide 50 units of each cable, each month, on an ongoing basis.

A client who manufactures custom computer systems came to Compatible Cable with a request to build two custom cable assemblies that they were unable to source elsewhere. The first cable needed to connect a Qualtek 723W-X2/04 power inlet to a Meanwell RS-50-12 power supply with a 12” cable. It required quick connect terminals on one side and need to be stripped and tinned on the other end for attachment to the power supply. The second cable needed to connect the Meanwell RS-50-12 power supply to a Aaeon EMB-CV1-A11 motherboard. This cable needed to be 18” long, with a 4-pin ATX connector on one end and needed to be stripped and tinned on the other end. Both cables required a General Cable Ultraflex style cable to be used.

The Solution

After submitting our quote with pricing, lead time, and details of the custom cable assembly builds, the client discussed the project more with their customer. They decided  to shorten the cable lengths, and instead of stripping the ends and tinning, attach AMP #10 ring lugs to each conductor. We also noticed that the ATX cable assembly called for two 16awg conductors terminated into a #10 ring lug. The ring lug part number the client provided was not designed to accommodate two 16awg wires and we believed that the connectors shown in the photo the client provided was a different part number. We had AMP #10 ring lugs in stock, noting that the lugs with blue plastic insulation are designed to handle 14-16awg wire, it fit two 16awg conductors perfectly. The client thought our solution was an improvement on their design, as they were cramming the two cables into a single lug, and they appreciated the correction.

After testing the first set of first article samples, the client made two more changes. First , we changed the ring terminals to spade lugs, and second, we used insulated quick connects. After these changes were made, the samples were approved, and we were ready to proceed with production of the balance of the order. One last consideration we made for the production balance involved the connector orientation. We checked with the client to see which way they want the clip on the ATX connector to be facing in relation to the power supply. For example, when facing the power supply terminal block, would they want the clip on the ATX connector to be on the right, left, top, or bottom? Since the wires naturally want to lay a certain way, we can make the cables so that the ATX connector lines up with the spade terminals so that the installer does not have to twist the connector in order for it to plug into the motherboard.