Category: Value Added

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.

Quail Electronics., Inc. is Your Leading Expert in Electrical Supplies

We have over 30 years of experience and expertise in power cords, plugs and receptacles, and electrical accessories. With competitive pricing, same-day shipping on in-stock products, and low minimum order requirements, we are proud to be your go-to source for electrical components. Contact us today to learn more or request a quote to get started.

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.

Quail Electronics, Inc. is Your Trusted Source of Electrical Products

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.

Contact us for more information or to speak with a knowledgeable team member. Request a quote to get started on your order today!

Hospital-Grade Labels: Explained

In medical environments, electrical safety is non-negotiable. Every electrical component, from monitors to cables to patient beds, must meet strict performance standards to ensure safety at all times. In North America, all cords used to power medical equipment must carry a “hospital-grade” label. This stems from UL standards requiring that patient care equipment used in a patient’s vicinity must have hospital-grade attachment plugs.

Hospital-grade labels are used to identify specific electrical components, verify compliance with predetermined standards, and allow users to easily confirm a product is safe, reliable, and approved for use in medical areas.

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Label Your Power Cords: Vol. 2

bread-tie-label-for-cordsFact: behind every computer desk lies multiple power cords and connecting peripheral cables.  Usually, not all of them are neat, and in fact- most are a complete mess.  Some may even pose a shock and fire hazard. In Part 1 of this series, we learned how to make useful labels for power cords out of file folder labels. This form of organization works to de-clutter and minimize your workspace, allowing for clarity and peace of mind. In this next installment, we’ll take a look at how to make power cord labels out of even more readily available household items: plastic bread tags and duct tape.

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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.

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