Custom Wire Harness for Slip Rings

Posted on Monday, August 29, 2011 in UEA Blog

One of the available options that sets UEA slip rings apart from most other slip ring manufacturers are custom wiring harnesses.   These harnesses are built in-house to attach to either or both the center leads from the center core stack and/or the brush leads or outer portion of the slip ring assembly.   With plugs or connectors added to the outer ends of the harnesses the slip ring assembly becomes a 'plug and play' component of the customer's complete electrical wiring system.

The assembly of the harnesses begins with discrete wires of the correct AWG size, voltage rating, environmental rating, etc. that are often color-coded to meet a customer's specifications.  The harnesses may also include or be composed of one or more jacketed cables of the required size and ratings.   Any discrete wires in the harnesses are ink-jet marked with the circuit number to match the correct circuit in the slip ring and also often a customer specified function for that circuit.  These markings are spaced approximately every 2.00” along the full length of the wire to make the circuit easily identifiable at any position along the full length of the harness.  The wires and cables are cut to a length to meet customer specified overall lengths when attached to the slip ring, bundled for use in either the brush or center harness and supplied to the Harness Layout Department.  If any one of a vast variety of connector types or brands is to be attached to the harnesses the insulation is stripped from one end of the individual wires and terminals are attached or the wires are soldered to the connectors.  At that point the individual wires from the connector, or connectors if the harness includes more than one, are put through individual holes in a 'die' which puts the wires in the correct order to match the center core leads from the core stack of rings and insulators or to provide a more orderly 'break-out' of the leads to the brushes.   As the wires are pulled back through the die they are taped to keep the wires in the correct order and often a twist is added to the harness, retained by the tape, which adds flexibility to the harness.  Some harnesses are supplied with only the taped covering but many also add a heat shrink tubing jacket for better sealing or an over-braided nylon thread covering for increased abrasion resistance.  Once the harnesses are completed they are attached to the slip ring assemblies and then attached to one of the test stands for a complete continuity, shorting, and etc. test.  It is at this point that the harnesses which include connectors becomes an advantage to UEA as the assemblies with connectors are more easily attached to the test stands using mating harnesses than the assemblies with only the individual wires on the ends of the harnesses.

Custom wiring harnesses are just another of the advantages provided by UEA slip ring assemblies.

Brent Jensen, Director of Engineering