Tag: power cords

electrical power cords

Put the Power Cord to the Test

Today we’ll be discussing the various “testing” cords must go through in order to be 100% ready to go and meet the requirements for the UL standards (or international safety agency approvals) of cord sets and power cord supplies.

UL generates standards and test procedures for products and equipment focusing on product safety. Power cords undergo some of the most common tests:insulation

  1. A grounding test. The purpose of a grounding test is to protect the consumer from hazards that can be caused by a faulty ground connection. A ground bond test is a high current AC test that measures resistance of the ground path under high current conditions.
  2. The continuity test is carried out under high current, simulating a fault to earth. This test is performed by applying an AC or DC current between the conductive surface and protective earth.
  3. There is a hi-pot test. This is a stress test of the insulation of a device under test DUT (Device Under Test). This means the voltage used in a hi-pot test can either be AC or DC.

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Coiled VS. Coiled

Picture this: you’re in need of some power cords. You call Quail Electronics requesting a coiled cord. The sales representative asks you, “would you like a coiled cord or for your cords to be packaged in a coiled form?” Well, now you’re confused, thinking ‘what’s the difference?’ Today I will be explaining coiled vs. coiled.

First, we have coiled as in the way it’s packaged. For example, you can have your cords packaged in a form which can either be hanked (often described as a figure 8 wrapping) see Image 1,   hanked

OR you can have them coiled as a “loop,” as shown in Image 2. image 2

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Universal 3500 series is now Approved for China!

Universal Approved for China

Universal approvedUniversal 3500 series is now approved for China. We’re happy to announce the new CCC approval. At the moment, Quail Electronics offers the IEC-C14 to IEC-C13 jumpers on the market to be internationally and domestically approved. However, our 3500 series power cord now carries UL, C-UL, VDE and China’s CCC approval. That means you can take it all over North America, Europe and China without ever having to switch a thing. Travel the globe with our 3500 series!

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!

Electric Vehicle Part 1

EV plug 1

Electric vehicles have become a way of life. To prove that is true is the new Corporate Average Fuel Economy (CAFE) standard put into place by the Obama Administration. By 2025, every new vehicle sold in the United States will need to reach at least 54.5 mpg. In order to operate, the plug-in hybrid EVs that function on batteries need to be charged occasionally. No more trips to the over-populated, busy gas stations. You can fill up right at home overnight or at work during the day. The car simply plugs in while it is immobile for a given period of time. It can also charge while being driven – once the car is coming to a stop and the brakes are applied, kinetic energy is transformed into chemical energy in the battery.

In order to operate, the plug-in hybrid EVs that function on batteries need to be charged occasionally. No more trips to the over-populated, busy gas stations. You can fill up right at home overnight or at work during the day. The car simply plugs in while it is immobile for a given period of time. It can also charge while being driven – once the car is coming to a stop and the brakes are applied, kinetic energy is transformed into chemical energy in the battery.

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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.

Contact Quail Electronics, Inc. Today to Order Power Cables

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.

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

Understanding the Overall Rating of a Power Cord

electricity-1-1024x768When it comes to understanding the rating of a power cord, there are a handful of factors to consider directly related to the amperage and voltage of the cord. Each element of a power cord has a maximum rating as an individual component. The elements are the plug, the wire, and the connector.  The overall rating of a power cord is effectively the weakest link out of these ratings.  Here, we take our popular 2500.072 power cord as an example:

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MD&M West 2015 Preview

MDM_West_2013_4cFor our first trade show of 2015, Quail Electronics will head west to Southern California to demonstrate our top-of-the-line medical industry power products. Quail will be showcasing our industry-leading product line at the Medical Design & Manufacturers trade show exposition at the Anaheim Convention Center from February 10-12. MD&M West is hosted by MedTechWorld and is the largest OEM medical device and manufacturing event in the world. The event features over 2,000 exhibiting suppliers demonstrating leading edge technology in the medical field. This tradeshow offers a variety of informative expert insight, hands-on workshops, as well as networking events.

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CES 2015 Roundup

international-ces-2015-las-vegasAs the new year begins, it’s also time to roll out the fancy new gadgets. The 2015 Consumer Electronics Show (CES) roared through Las Vegas last week.  The weeklong showcases over 3,600 exhibitors and attracts over 160,000 attendees. Previous CES events have included high-profile introductions such as the world’s first VCR, camcorder, DVD player, household robots, and most recently, 3D printers and 4k televisions.

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