High Voltage Cable Assembly Design
Every high-voltage project presents unique challenges. At Caton, our expert design team collaborates closely with customers to develop custom high-voltage cable assemblies tailored to their requirements. Our specialized process ensures precision in high-voltage cable system design and cable assembly engineering, delivering reliable solutions for even the most demanding applications.
Our Approach:
- Collaborative Design Process: Partner with our team to achieve precision in every aspect of your custom high-voltage cable design.
- Advanced Prototyping and Machining: Benefit from cutting-edge prototyping and machining capabilities for faster iterations.
- Design Verification and Validation: Ensure every assembly meets stringent safety and performance benchmarks, ideal for custom cable solutions for high voltage systems.
High Voltage Cable Assembly Manufacturing
Caton manufactures high-voltage cable assemblies at our cutting-edge facility in Kingston, Massachusetts. Our experienced assemblers, certified to IPC-J-STD-001 and IPC-A-620 standards, ensure that each high-voltage assembly meets stringent quality benchmarks. From over-molded high-voltage connectors to advanced cable jacketing and shielding solutions, we deliver precision and durability in every product.
Our Capabilities:
- Cable Preparation: Advanced soldering, brazing, and welding techniques for optimal connectivity.
- Injection Over-Molding & Silicone Molding: Reliable solutions for defense-grade cable manufacturing.
- Silicone & Resin Encapsulation: Protective measures for high-stress environments.
- Automated Wire & Cable Cutting: High-speed precision processes tailored for industrial and aerospace needs.
- Cable Jacketing & Shielding Solutions: Robust insulation and shielding to meet application-specific requirements.
Testing and Quality Control for High-Voltage Cable Assemblies
At Caton, we prioritize uncompromising quality in high-voltage cable assembly testing. Every product undergoes thorough inspections and electrical testing to ensure reliability. Our high-voltage test lab offers state-of-the-art resources, including environmental and altitude testing for high-voltage systems, ensuring performance even under extreme conditions.
Our Testing Capabilities:
- Partial Discharge Testing: Essential for ensuring reliable high-voltage cable assembly insulation.
- Accelerated Life Testing: Simulates long-term use to reveal potential weaknesses.
- Altitude and Temperature Testing: Confirms durability in extreme environments.
- Cable Bend, Flex, Pullout, and Retention Testing: Verifies mechanical durability for high voltage systems.
- Connect/Disconnect Testing: Ensures connectors withstand repeated use without compromise.
- Immersion Testing: Validates resistance to environmental stressors, including water exposure.
In addition to testing our products, our test lab offers high-voltage testing services for customer equipment and hands-on training for customer field service technicians. This ensures systems operate seamlessly under real-world conditions.
Engineering Support
Expert Guidance for High Voltage Systems Design and Optimization
At Caton, we go beyond manufacturing to provide engineering support that helps you tackle even the most complex challenges. Our experienced team collaborates with you to ensure your high-voltage cable assemblies and connectors deliver maximum performance and reliability. With access to our M.E. Lab, you gain a resource equipped to handle advanced problem-solving and system optimization.
Our Engineering Support Includes:
- Collaborative Design Consultations: Partner with our engineering team to refine designs and align them with your project requirements.
- Connector Optimization Advice: Receive expert recommendations for enhancing the performance and reliability of your high-voltage connectors.
- Troubleshooting and Problem Solving: Overcome challenges with targeted solutions for your complex applications.
- Access to the M.E. Lab: Utilize cutting-edge tools and expertise for comprehensive testing and engineering support.
