Category: Power Cords 101

A Complete Guide to Coiled Power Cords

The term “coiled power cords” can have several different meanings. Both meanings, however, describe power cords created to provide flexibility, durability, and compact storage. Designed to save space, these power cables offer numerous benefits compared to standard straight power cords.

Keep reading to learn about different types of coiled power cords, their benefits and applications, and how they compare to straight cables.

Coiled Power Cords vs. Coiled Power Cords: The Same or Different?

“Coiled” can refer to either how a power cord is stored and packaged:

Or to the cord’s physical design:

Let’s look at the advantages and applications of coiled jacket power cords, and compare them to power cords that are coiled simply for packing and storage.

Coiled Jacket Power Cords

Power cords with coiled jackets are specifically manufactured with a coiled spring design. This composition means these cables have a retractable cord with a spiral jacket and look visibly “curly.” Coiled power cords have a short length while at rest, but can be stretched during use to much longer lengths.

Advantages

  • Compact storage
  • Reduces clutter
  • Maintains coiled shape even with repeated extension
  • More durable than straight cords
  • Increased flexibility
  • Customizable length

Applications

  • Barcode scanners in retail and warehouse environments
  • Mobile medical carts and equipment
  • Portable power tools in assembly lines
  • Communication devices such as corded telephones

Packed Coiled Power Cords

Technically, power cords that are coiled for packing and storage are just straight cables that have been wound up. Coiling a straight cord when not in use can help prevent tangling, protect the cable, and improve storage space. Uncoiling these cables returns them to their original, straight orientation.

Advantages

  • Compact storage
  • Reduces clutter
  • Prevents cord damage or kinks
  • Reduces risk of tangling
  • Quick to uncoil and use

Industrial Coiled Power Cords vs. Straight Power Cords

When choosing between a coiled or straight power cord for applications, consider the flexibility, space, and durability requirements. The main shared traits between actual coiled power cords and coiled wrapped straight cords are that they reduce clutter and can improve storage space.

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Quail Electronics, Inc. is your go-to manufacturer and supplier of power cords and electrical accessories. We boast an extensive inventory of power cords, adapters, power strips, and other components and resources to meet your every need. For unique orders or special demands, we provide custom cable design services to create the right power cords for your applications. With competitive pricing, low minimum order requirements, and same-day shipping on in-stock items, we get you what you need when you need it.

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How to Crimp Terminals

When connecting an electrical component to a circuit or anther component, safe and durable connections are essential. One method of creating secure connections is by using conductive crimp terminals.

Knowing how to crimp connections is critical to ensuring safety. When done correctly, wire crimping is a reliable method to ensure safe and secure electrical connections.

Overview of Electrical Crimping

In this context, electrical crimping is the process of joining a wire to a terminal connector by compressing a metal barrel around the stripped end of a wire. On power cables, wire crimping is typically performed at the wire ends. Terminal connectors join the cable with a power connector, plug, or directly to the equipment.

As an alternative solution to soldering, wire crimping uses mechanical force to create a secure and durable conductive connection. Crimped connections are resistant to vibration, stress, and corrosion, making them a reliable method for creating electrical connections.

Material List for Crimping Terminal Connectors

Before starting, be sure you have the right tools and gear. Standard electrical crimping tools include:

  • Wire stripper: Used to remove insulation without damaging the wire.
  • Crimping tool: Select the correct size for the terminal you are
  • Terminal connectors: Choose compatible crimp connectors for your wire gauge.
  • Safety glasses: Protect your eyes while crimping.
  • Heat shrink (optional): Adds insulation and extra protection.

How to Crimp Terminals: A Step-By-Step Guide

1. Choose the Correct Terminal Connectors and Wire

The terminal must match your wire gauge. Using the wrong size can result in an incorrect connection or damage. Select the right type of crimping terminal for your wire and connection.

2. Strip the Wire

Use a wire stripper to strip the end of your wire. Remove approximately ¼ inch (6-7mm) of insulation. Avoid nicking or cutting the copper strands, as this can weaken the connection.

3. Insert the Wire into the Terminal

Slide the stripped end of the wire into the terminal until all of the exposed copper is fully inside. The wire’s insulation and the terminal barrel should sit flush, with no gap in between.

4. Align the Terminal in the Crimping Tool

Crimping tools often have multiple sizes. Position the crimping terminal into the correct size, ensuring the wire remains inside the terminal.

5. Crimp the Terminal

Apply pressure by squeezing the crimping tool until the jaws fully compress the terminal barrel around the wire. This creates the crimp.

6. Inspect the Crimp

Gently tug on the wire to confirm the connection is secure. If the wire is easily pulled out, the crimp was not performed correctly and needs to be redone. Always use a new terminal connector to redo the crimp.

7. Apply Heat Shrink (Optional)

Slide the heat shrink tubing over the connection and apply heat until the tube molds around the wire and the terminal. While this step is optional, it is typically recommended as an additional measure of protection, insulation, and durability.

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With over 30 years of industry experience, Quail Electronics, Inc. is your reliable source of electrical components. We offer a large selection of adapters, power strips, and power cables, including:

With competitive pricing, low minimum order requirements, and same-day shipping on in-stock items, we get you the products you need when you need them at prices that work for you.

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How an Electrical Cable is made

Electrical cables are the backbone of a powered society. They carry electrical currents, allowing us to connect to power in all aspects of our lives. From industrial machinery and manufacturing equipment to medical equipment and everyday devices and appliances, these cables ensure that electricity moves safely and efficiently where needed.

But how are electrical cables made? Keep reading to learn more!

What Is an Electrical Cable?

Electrical cables are designed to carry an electrical current from one element to another. They consist of conductors, which are insulated wires suitable for carrying electrical current. Electrical conductors are made from metals such as copper and aluminum. Most wires are made from copper because it conducts electricity with high flexibility and very little resistance.

Electrical wires come in solid-core, stranded, or braided configurations to form a single assembly. The ends connect to two devices, allowing electrical signals to transfer between them. Electrical cables are assemblies of multiple conductors bundled together to transmit electrical power and signals.

How Electrical Cables Are Made: The Process

Step 1

The first stage in the manufacturing process of a conductor is the wire-drawing. Wire-drawing involves gradually reducing the wire’s diameter to its final size. After the diameter is reduced, the wire is drawn further to achieve the required size for each conductor type.

Step 2

In the second stage of this process, the wires undergo a heat treatment called annealing. Annealing is a process of heating metal and slowly cooling it to remove internal stresses and toughen the metal. The purpose of this treatment is to increase the wire’s conductivity.

Step 3

The next step is to add insulation. Because the current runs along the outside of the copper wires, there must be insulation between the inner conductor and the outer conductor. Insulation is the layer of synthetic materials that is applied over conductors for electrical isolation between other wires, conductive surfaces, or from the ground. An inner conductor insulation also prevents any current leakage.

Step 4

Some cables may require additional elements to improve protection. For instance, electrical coverings called “screens” insulate the signals that circulate in the cable, shielding the power cables from external interference.

Step 5

Once the cable’s inner insulation is applied, it requires an outer insulation, called the jacket. The jacket is applied over the insulation for mechanical, environmental, chemical, and electrical protection.

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Quail Electronics, Inc. has over 30 years of industry experience. Our wide selection of electrical products includes:

With low minimum order requirements, competitive pricing, and same-day shipping on in-stock items, we get you precisely what you need when you need it at prices that work for you.

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The Difference Between AC and DC Power

There are two types of current flow in a circuit: Alternating Current (AC) and Direct Current (DC). Understanding the difference in circuitry and application use of AC and DC power is essential when selecting electrical components. There are significant differences between, say, AC inlets and DC inlets, or AC power cords and DC power cords. Consumers interact with power cords and electronic devices daily in a plug-and-play manner; however, OEMs must also consider how current affects the performance and operation of their equipment and account for various factors during the design process.

Here, we examine the differences between AC and DC power, how these currents affect industrial systems, and how to select the appropriate current for different applications.

AC vs DC: What’s the Difference?

AC stands for Alternating Current. AC power relies on a rotating magnet that causes electrons to switch direction repeatedly. The amount of energy carried through AC is economical to transfer over longer distances and provides more power. Most industrial equipment connects to power using AC inlets and AC power cords.

DC stands for Direct Current. With DC, a steady magnetism along the wire ensures that current can only flow in one direction. This provides a stable power supply for electronic equipment. DC power cords are often used to connect low-voltage circuits and systems that require clean, consistent power.

Transmission of AC and DC Power

AC power is the dominant form of electrical transmission because it can be safely used at both high and low voltages, as well as for long-distance transport. It minimizes line loss and supports large power distribution networks. Until more recent years, with the proliferation of data centers, AC power had been the predominant power architecture.

DC transmission requires more complex and costly conversion equipment, typically making AC transmission more popular. However, modern high-voltage DC systems (HVDC) reduce power losses over long distances, making DC transmission particularly relevant for data centers and industrial operations.

Why Many Industrial Systems Use DC Power Internally

Most industrial equipment is powered with an AC inlet. However, many systems convert the incoming AC to DC immediately after power entry. DC is often preferred for these operations because its unidirectional flow provides a stable, consistent voltage required for downstream electronics. Converting AC to DC power for internal use prevents damage to sensitive equipment from AC power fluctuations and improves efficiency.

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Quail Electronics, Inc. is a leading source of high-quality electrical components and parts, including power cords, power adapters, power strips, and more. We offer competitive pricing and same-day shipping on in-stock items to get you the parts you need when you need them. Order electrical components for your business from Quail Electronics, Inc.

Contact us with any questions and speak with one of our experts. Request a quote to get started on your order today.

The Risks of Male-to-Male Extension Cords

Why You Should Never Use a Male-to-Male Power Cord

Male-to-male extension cords are widely considered to be one of the most dangerous cord styles. Often referred to as “suicide cords,” these cables create serious safety hazards that can lead to electric shock, electrocution, fire, and property damage. Despite being sold online, male-to-male cables are not code-compliant nor safe to use.

What is a Male-to-Male Extension Cord?

A male-to-male extension cord is a cable with male plugs on both ends, rather than the standard design with one male plug and one female receptacle. While at first glance, this may seem like a solution for connecting two female receptacles, in actuality, this is a very dangerous design. Once one end of the male-to-male cord is connected, the cable carries live energy, and there is no safe way to handle or connect the opposite end. The overall design of this cord style ignores basic safety rules and regulations for electrical devices.

The Major Safety Risks and Hazards of Male-to-Male Power Cords

Using male-to-male extension cords is dangerous and can cause damage to users, electrical equipment, and property. The Consumer Product Safety Commission (CPSC) has issued formal warnings against the use of male-to-male cords, as they can increase the risk of:

  • Electrocution: Can occur from exposed live prongs and cause electrical shock.
  • Fire hazards: These cords bypass built-in safety protections and can increase the chance of electrical fire and overloading.
  • Backfeeding: The dual male plugs can cause backfeeding, where electricity flows in reverse and bypasses safety systems.
  • Carbon monoxide poisoning: Incorrect circuits and generator placement can reduce the efficiency and accuracy of CO detectors.

Code Compliance and Safety Requirements

Not only do male-to-male extension cords pose significant safety risks, but they also fail to meet established electrical safety protocols. While the National Electric Code (NEC) doesn’t specifically mention male-to-male cords by name, it does prohibit equipment that creates hazardous conditions. The exposed live prongs and unsafe handling and conditions of male-to-male cords violate the NEC code. So, not only are they dangerous to use, but they could also lead to inspections and/or fines.

Additionally, Underwriters Laboratories (UL) and the CPSC do not recognize or certify male-to-male extension cords, meaning any products produced and sold as such have not passed the required tests and approvals for electrical safety.

Alternative Solutions for Male-to-Male Extension Cords

If you need to connect two female receptacles or other equipment, there are better solutions than using male-to-male extension cords. Consider:

  • Standard extension cords: Reroute your existing equipment so a standard cable with one male plug and one female receptacle can safely connect your devices.
  • Transfer switches: These act as miniature circuit breakers to safely connect a generator to an electrical system without backfeeding.
  • Inlet boxes: Designed specifically to prevent backfeeding and power overload.
  • Interlock devices or kits: These help ensure power can only flow in one direction, which is safer than male-to-male extension cords.

Contact Quail Electronics, Inc. Today to Order Safe Power Cords

With decades of experience, Quail Electronics, Inc. is your leading source and supplier of high-quality, safe power cords. We offer competitive pricing, low minimum order requirements, and same-day shipping on in-stock items to get you the electrical products you need at prices that work for you. Our team of experts is prepared to answer any questions and help you determine the best solutions.

Contact us or request a quote to get started on your order today.