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A PGF Cable Machine Run-Down
May 30, 2023 3:36 pm Leave a Comment
Edge of Technology

PGF Technology Group is a manufacturing company that continues to improve processes while integrating the newest cutting-edge technology. The range of capabilities and services include cable assembly, printed circuit board assembly, wire harness assembly, box build assembly, and prototype services. With each PGF project, workers have the proper tools and skillset to effectively assemble and test each product. Additionally, for cable assembly, a variety of cable machines are utilized to guarantee high-quality and time-efficient projects. All in all, PGF continues to automate processes from crimping to stripping wires for ultimate customer satisfaction.

Cable Machines

Whether it be the initial cutting of a wire or the sleeving of a cable jacket, cable machines advance manufacturing processes immensely. Additionally, integrated throughout PGF cable assembly are the Schleuniger automating wire processing machines. Each of the machines carries a distinct function in either assembly or testing procedures. Overall, the cable machines highlighted include a multitude of benefits and innovative outlets for cable assembly procedures.

Crimp Center 36S
- Automatic wire cut/strip/terminate/tin
- Benefits
  - compact modular design
  - touchscreen (easy function)
  - product flexibility with 6 processing stations
  - basic network integration
Coax Strip 5300
- Coax semi-automatic wire stripper
- Benefits
  - fast processing speed
  - precise rotary stripping for thin wires with up to 9 steps
  - programmable functionality
  - user-friendly graphical displays
Rotary Strip 2400
- Coax/fine gauge semi-automatic wire stripper
- Benefits
  - can strip insulated wires
    - such as Kapton, Fiberglass, Teflon
  - includes function for the twisting of inner wire strands
  - programmable machine with a colored touch screen
Unit Strip 2300
- Semi-automatic standard wire stripper
- Benefits
  - color touch screen user interface
  - able to strip the inner conductors of jacketed cables with a small break-out length
  - sensitive trigger sensor for small flexible wires
  - no mechanical adjustments are required for different wire sizes
OmniStrip 9450
- Automatic wire cut and strip
- Benefits
  - graphically enhanced display with high resolution
  - simple tooling change
  - cables and processing libraries are through system demand
OmniStrip 9400
- Automatic wire cut and strip
- Benefits
  - high productivity
  - can process multiple wires simultaneously
  - graphical screen allowing easy navigation and programming
JS 8300
- Cable jacket scorer
- Benefits
  - even cuts in depth for each cable jacket
  - high precision standards
  - options of radial or axial wire cuts
Multistrip 9480
- Automatic wire cut and strip
- Benefits
  - easy processing of high precision coaxial and multilayer application
  - programmable system
  - versatile in cut and strip platform
The PGF Advantage

PGF prides itself on integrating the newest generation of trusted technology while following a hands-on approach for all project assemblies. Continuously progressing through the years, PGF removes tedious and time-consuming tasks with automated machines. The cable machines mentioned above are only some of the technologies that continue improving PGF quality standards and timely delivery expectations. However, to ensure only the highest quality products, quality personnel perform quality checks mechanically and with the help of trusted machinery. All in all, before the delivery of any project, employees utilize their skill set, as well as machine focus for the ultimate hands-on yet effective approach.
Equal Resources for PCBA & Cable Assembly
May 24, 2023 2:30 pm Leave a Comment
Equal Resources for PCB and Cable Assembly

PGF Technology Group is a leading contract manufacturing company that specializes in providing high-quality printed circuit board (PCB) and cable assembly services to businesses of all sizes. One of the company’s most notable strengths is its equal resources for both types of assembly, providing a significant advantage to customers who require both products for their projects.

Working with a contract manufacturing company that has equal resources for both PCB and cable assembly can offer several advantages for businesses. Here are some of the benefits of working with PGF Technology Group:
1. Single Point of Contact
One of the most significant benefits of working with a contract manufacturing company that provides both PCB and cable assembly services is the convenience of having a single point of contact for both types of assembly. This eliminates the need to work with multiple vendors, reducing the complexity of the project and minimizing the risk of communication errors.
1. Streamlined Project Management
By working with a single vendor for both PCB and cable assembly, businesses can streamline their project management process. This allows for greater control over timelines, budgets, and resources, as the vendor can manage all aspects of the project and ensure that it is delivered on time and within budget.
1. Improved Quality Control
When working with a single vendor for both PCB and cable assembly, businesses can benefit from improved quality control. The vendor is responsible for ensuring that all products meet the necessary quality standards, reducing the risk of errors or defects. This can help to minimize the risk of product recalls or returns, and ultimately improve customer satisfaction.
1. Cost Savings
Another advantage of working with a contract manufacturing company that provides both PCB and cable assembly is cost savings. By consolidating both types of assembly with a single vendor, businesses can often negotiate better pricing and terms, ultimately reducing their overall manufacturing costs.
1. Technical Expertise
PGF Technology Group is a contract manufacturing company that has significant technical expertise in both PCB and cable assembly. The company uses state-of-the-art equipment and techniques to produce high-quality products that meet or exceed industry standards. By working with a vendor that has expertise in both types of assembly, businesses can benefit from this technical knowledge and experience, ultimately improving the quality and reliability of their products.

How PGF Can Help

Overall, working with a contract manufacturing company that provides equal resources for both PCB and cable assembly can offer significant advantages for businesses. From improved quality control and cost savings to technical expertise and streamlined project management, there are many benefits to consolidating both types of assembly with a single vendor. PGF Technology Group is a contract manufacturing company that offers these advantages and more, making it an ideal partner for businesses in need of high-quality manufacturing services.
Box Build Assembly
September 27, 2022 1:51 pm Leave a Comment
What is a Box Build Assembly?

A box build assembly incorporates the manufacturing of both cables and printed circuit boards. Box builds consist of a single enclosure holding various complex electromechanical components. The combination of PCB and cable manufacturing involves a process involving intricate design, production, and construction for each unit. Additionally, box builds include an immense opportunity for customization in size, wiring specifications, and enclosure fabrication. PGF Technology Group offers a wide selection of enclosure types ranging from weatherproof to plastic materials. PGF dedicates itself to ensuring high-quality services and proper assemblies for each project and partner!

Box Build Applications

Box build assemblies are utilized in a variety of different industries and for a multitude of purposes. In practice, box builds have many integral applications in the advancing world of technology and electronics. Whether the box build is large or small, its importance to growing fields and daily conveniences continues to increase exponentially. From computers to industrial machines, each application demonstrates an industry seeking the capabilities of box-build assemblies for critical purposes.

Computer

The growing dependency on computers increases the demand for box builds. Complex software requires immense wiring connections and electrical systems for the highest performance quality.

Aerospace and Defense

The highly critical aerospace field requires error-free and trustworthy devices such as design-specific box builds. To ensure the utmost safety, the aerospace industry requires proper box build enclosures and reliable electronic processes.

Industrial Machinery

The necessity for high productivity and performance distinguishes the need for box build industrial electronic devices. For protection purposes, the addition of PCBAs and wiring guarantees smooth operation in environmentally stressful conditions.

Data Cable

A data cable box build is a common assembly that greatly varies from project to project. With the immense selection in size, such assemblies are customized based on their intended location. Typically, larger data cable assemblies are found in sizeable buildings. For example, skyscrapers, hotels, and even substantial homes generally hold data cable box builds.

Environmental Protection

The box build structure differs from traditional assemblies in that the cables and printed circuit boards are protected through a physical barrier. Additionally, the entirety of the box build can be found within the external box aiding in the assembly process. Yet, in some instances, the barrier safely protects its components from extreme weather conditions, abrasion, physical destruction, and oil.

PGF Excellence

PGF’s cross-trained and qualified personnel provide efficient and high-quality box build assemblies. A PGF partnership benefits customers in the vast opportunity for customization as well as simplifying the supply chain assembly. With professional knowledge in box build assembly, PGF can lower production costs by accessing lower-priced components. Additionally, with both cable and PCB expertise PGF can provide box build services under a single warehouse, decreasing overhead costs. As for a simplified supply chain, PGF assembles box builds entirely in-house, thus removing potential conflict points for customers. PGF is a solutions provider relieving customers of the unnecessary stress of logistics and manufacturing. Request a quote today and learn more about the ways PGF can assist in all box build assembly needs!
Terminals Basics
August 11, 2022 2:09 pm Leave a Comment
What is a Terminal?

Terminals are crucial components to any cable assembly process. By definition, a terminal is part of a class of electrical connectors used for the transfer of electrical currents from a grounding source or power. The terminal of a wire also indicates the point at which the conductor, from a component, device, or network, comes to an end. The multitude of cable applications introduces a wide selection of terminal variations and types. Each project consists of specified requirements that lead to the use of some terminals over others. PGF supplies customers will all kinds of terminals, effectively integrating the necessary parts for a successful cable assembly!

Variations

There are two main variations amongst cable terminals: insulated and non-insulated. Depending on the designated project, either one of the two variations is preferred for high quality product performance. Insulated provide an additional protective cover to avoid water and other moisture from getting to the wire. The insulation can be found in nylon, heat shrink, or vinyl material to act as a non-conductor wire. On the other hand, non-insulated are typically used in the instances in which the extra wire protection is not necessary. Additionally, the non-insulated wires are cheaper to manufacture, thus proving to be more economically valuable.

Terminal Types

Ring

a round-ended terminal that easily allows a screw or stud to be attached. Ring Terminals are either crimped or soldered to the wire. Available in insulated or non-insulated.

Common Applications: Ring terminals are typically utilized within the automotive industry. The shape is ideal for connecting various contactors or mechanical relays to car engines and circuits.

Spade (Fork)

an open-ended spade terminal that is convenient to use allowing easy attachment or removal from the screw. Available in insulated or non-insulated.

Common Applications: Wire harness assembly projects commonly consist of tightly spaced installation spaces, thus mostly utilizing spade terminals. The spade provides reliable and quick electrical connections that are solderless.

Hook

a terminal convenient to use with an open end. Produced insulated or non-insulated, hook structures offer a simplistic yet durable connection for a variety of projects.

Common Applications: The simplistic hook design allows for easy-to use terminals that are durable and efficient. Thus, instances in need of electrical wire connectors are the most common hook terminal applications.

Quick-Disconnect

A quick-disconnect terminal provides convenient and reliable use offering an easy connect and disconnect for two wires. Produced insulated or non-insulated.

Common Applications: Quick-disconnect terminals can be found in a multitude of auto, industrial, and consumer products. As one of the fastest ways to connect and disconnect two wires, such terminals are easily reusable and highly efficient.

Bullet

Bullet terminals connect with the male and open-ended round female connectors creating a high-quality connection. The connection with bullet terminals helps prevent corrosion and other potentially harmful materials from entering a wire harness.

Common Applications: The automotive industry utilizes bullet terminals for quick and simple wiring connections. The bullet design provides durable connections that can be easily assembled and disassembled during manufacturing.

Butt

a Butt Terminal connects or terminates single or multiple wires. They help prevent abrasion and cutting. This extra protection helps keep out moisture, corrosion, and other negative elements. Butt Terminals serve as a simple solution to extend wires due to the ability to mate and connect wires.

Common Applications: Amongst various industries, butt terminals safely terminate any given wire. Additionally, another common use is to connect one wire to another.

Flag

terminals that offer a convenient and secure connection. Flag terminals work well in tight spaces as well as when a quick-disconnect is too large. Provides a quick and easy connection and disconnect. Also available in insulated and non-insulated.

Common Applications: Flag terminals reliability promote their use for applications that require frequent connections.

PGF Terminal Services

Through the variety of industries and applications, PGF Technology Group, Inc. adheres to all customer project specifications and requirement. The company’s devotion to supreme quality, on-time delivery, and competitive industry pricing allows customers to trust PGF with all terminal needs. The wide range of manufacturing diversity within the company guarantees proper product assembly from highest expertise. Learn more about PGF capabilities and request a quote today!
Cables and Wire Harnesses: What’s the Difference?
June 8, 2022 10:06 pm Leave a Comment
What Is the Difference Between a Cable Harness Assembly and a Wire Harness Assembly?

Cables and wire harnesses are both responsible for supplying electrical components with power, organizing cables and wires to optimize space, and providing them with some manner of protection from environmental conditions. Despite their functional similarities, however, these assemblies are not interchangeable. Each has its unique advantages and optimal applications. At PGF Technology Group, Inc., our team can assist you in finding the right assembly for your project.

Just as these assembly types are two different products, the same is true of wires and cables. A wire is a strand of electrically conductive metal like copper or aluminum that can transmit power as well as information. A cable, then, is made up of multiple wires that are usually joined in a braided or bonded configuration.

The key variation between the two assemblies has to do with how protected their cables or wires are from chemicals, moisture, dust, extreme temperatures, and friction.

Cable Assemblies

Cable assemblies bundle wires or cables together for organization and efficient electrical system operation. Of the two assembly types, cable assemblies are best suited to outdoor applications. They are superior for withstanding environmental stress because they utilize a durable cover of materials such as vinyl, thermoplastic rubber, or shrink-wrapped thermoplastic. This robust insulating sheath safeguards internal cables from high heat, dirt, or other contaminants, detrimental weather, compressive force, abrasion, and more.

Wire Harnesses

Wire harnesses work well as cable system organizers, particularly in grouping smaller internal wires or cables for added connectivity. However, while these assemblies do include a protective casing to prevent short-circuiting in the wiring, it is far less rugged than a cable assembly cover. Instead, the grouped cables and wires in wire harnesses typically have their outer coverings already for that protection. While the assembly does group them in one harness, their sheaths still make it easy to see individual cables. Additionally, these individual sub-assemblies allow for highly complex projects that are adaptable for many unique uses. The harness’ simple outer sheath of thermoset materials or thermoplastic helps protect the wires and cables from their environment for indoor applications.

Looking for a prototype cable or wire harness solution? Make sure to download our free eBook.

Cable Assembly and Wire Harness Advantages

Cable assemblies and wire harnesses increase organizational and spatial efficiency. They also improve operational safety by preventing electrical fires and taming loose wires. However, each assembly type has its advantageous qualities. The covers that jacket cable assemblies are durable and strong, enabling more versatile applications as they can withstand a wider variety of environmental conditions. Also, as the internal bundled wires are all contained within a single outer sheath, it makes them more accessible for threading within smaller areas.

Wire harnesses are ideal for their ease of installation and simplified maintenance, resulting in reduced labor time. Providing less protection, wire harnesses work best indoors. This characteristic, added to their simplistic design, typically makes them more affordable. Also, the outer covering will still safeguard against moisture or chemical solvents.

Applications of Cable and Wire Harness Assemblies

Given the assemblies’ strengths, wire harness and cable assembly applications are varied, spreading across diverse industries.

Cable Assembly Applications

Cable assemblies organize or facilitate safe wiring in the following applications:

Military
- Flight Simulators
- Ground Equipment
- In-Flight Medical Systems
- Links for Field Communication
- Remote Control Weaponry
- Navigation Systems
- Rugged Computers
Aircraft
- Cockpit Instruments
- Drones and Unmanned Aerial Vehicles (UAVs)
- Electronic Systems for In-Flight Entertainment
Automotive and Transportation
- Data Transmission Systems
- High-Voltage Current Transmissions
- Navigation Systems
Electronics
- Audio Systems
- Communication Systems
- Flat-Panel Displays
Wire Harness Applications

Wire harnesses allow for orderly wire organization in:

Aerospace
- Aircraft Power Transmission
- Airplane Engines
- Communications Systems
- Drones
- Satellites
Automotive
- Dashboards
- Lighting and Turn Signals
- Navigation Systems
- Engine Bays
Healthcare
- Crash Carts
- Dental Equipment
- Diagnostic Equipment
- Imaging Equipment
Robotics and Automation
- Assembly Line Systems
- Automated Computer Numerical Control (CNC) Machines
- Computerized Systems, Servers, and Electronics
- Data Transmission
- Power Distribution
Cable and Wire Harness Solutions from PGF Technology Group

At PGF Technology, we pride ourselves on providing high-quality, cost-effective wire harnesses and cable assemblies for industry compliance in some of the most demanding electrical applications. Backed by over 50 years of ISO-certified design and manufacturing experience, our team can work with you to determine your installation requirements, space limitations, power needs, and environmental challenges to develop a reliable assembly solution tailored to your specifications.

Our comprehensive capabilities for residential, industrial, and commercial applications include:
- Product development
- Prototyping
- Design and Inspection Support
- Fabrication and Manufacturing
- Turnkey Component Assembly
Partner with PGF Technology

Determining the appropriate cable and wire harness assembly for your application will keep your systems and workspace organized, compliant, and functioning efficiently. PGF Technology specializes in assembly creation, with capabilities for C-Track cables, D-Subminiature cables, motor cables, sensor cables, data link assemblies, potting, and more. Contact us to learn about our electronic manufacturing solutions, or request a quote today.
“EV”erything to Know About EV Power Cables
April 21, 2022 2:01 pm Leave a Comment
Charging Up

Electric Vehicles (EVs) are quickly charging up in the ranks as one of the most important innovations to watch in the coming years. Presently, the push to pump the breaks on CO2 emissions starts with determining the most significant contributing factor: gas-powered automobiles. Therefore, this “rEVolution” means assembling powerful components to ensure performance, longevity, and safety in an immediate timeframe. With this in mind, EV Power Cables drive forward with innovation to adhere to strict guidelines and certify proper conditions.

Here is a breakdown to amp up your knowledge about the top considerations for EV Power Cables during these changing times:

Critical Factors of the EV Power Cable

Seeing that the Electric Vehicle itself is on the cutting edge of technology, it would only make sense for the components involved to caravan behind. Hence, the regulations for EV Power Cables must reflect the industry’s future with added adaptability for the fast-changing times. By and large, these cable assemblies must be:

Extremely Flexible

Coupled with the Battery Management System (BMS) and various charging components, EV Power Cables must mold into different spaces to maintain balance in the vehicle and not obstruct any necessary operations.

UL-Listed

Underwriters’ Laboratories (UL) evaluates components for nationally recognized safety requirements for component manufacturing. At length, in a growing industry with many fresh ideas, increased testing shows responsibility for the drivers and manufacturers.

Compliant with RoHS

Similarly, if a product is certified by the Restriction of Certain Hazardous Substances (RoHS), its hard-to-dispose substances are limited to a set amount. Especially with the push for renewable energy sources, minimizing hazardous substances remains a top priority for each piece of the product.

Temperature-Controlled

When dealing with high-power electronics and batteries, heat becomes a central awareness topic. Cables must withstand heat to protect the inner layers and maintain the processes of the vehicle without becoming a hot mess.

Resistant to Chemicals, Cuts, Abrasion, and Crushing

Equally to heat resistance, the ability to withstand unwanted impacts or leaks marks a well-made EV Power Cable. When you enter your electric vehicle into the Monster Truck Rally, you need to know that the cables will last!

Supportive of Different Charging Modes

As stated above, adaptability for EV Cables must be the main factor for their assembly. With this in mind, EMS Providers must manufacture cable assemblies for every charging mode to power the vehicles correctly. Imagine how frustrating it is when your phone runs out of battery mid-call during an interview; now imagine your car in the middle of a snowstorm. Thus, assembling cables with these different charging modes is critical for safety and mental health:
- 1-phase AC charging for domestic connection
- 3-phase AC charging for domestic connection and public charging station
- DC charging for quick charging
Design Dilemma

Now that the requirements are established, another critical point becomes the design of this adaptable cable. Engineers must design cables to fit wherever needed while still providing the proper power. This design dilemma calls for:

Smaller Diameter

Reducing the size and weight of the power cable is always a requirement to downsize the drive train and trim vehicle weight. Besides reducing carbon emissions, the vehicle’s weight is another draw for prospective drivers who desire a change of pace.

Thick Outer-Layer

EV Power Cables must withstand road travel accidents, battery leakage, and user error. Indeed, the idea of having thick skin applies in a more literal sense to this electrical assembly.

Copper

Chiefly, copper electrical wires are safer to use than wires made of most other conductive metals because they are resistant to heat.

Copper is the preferred metal for electrical wires because of its high electrical conductivity, inexpensive, malleable, and thermally resistant properties. These details make it the universally accepted standard for manufacturing electrical wires.

Assembly Process

Tooling for Heavy Gauge Cables

We process our wiring for cables by using both automated and manual methods. This combination guarantees accurate work and checkpoints for assembly finalization.

At PGF, our Wire Processing Center and Cable Assembly Work Stations turn a grouping of wires and jackets into a functioning EV Power Cable. To learn more about our distinct processes, visit our PCBA and Cable Assemblies in EV Applications page.

Automated Assembly

Whenever possible, Schleuniger’s Manufacturing Machines assist in the automated operation of processes, mainly the following functions: Cutting, Stripping, and Terminating. For further uses, they are also handy (or should I say machine-y) for crimping and wire twisting.

Manual Assembly

In the next steps for projects, manual assembly is necessary for connector layout and visual inspection. Trained personnel can take a hands-on approach to finalizing and testing the assembly for the highest quality output.

Quality Testing

PGF goes through multiple rounds of testing to provide customers with durable, long-lasting cable assemblies. Our team utilizes:
- Pull-Testing Machines
- Schleuniger’s Inspection Machines
- UL Standard Inspection
- IPC 610 Class 2 and 3 Trained Personnel
Field Applications

EV Power Cables are essential for in-vehicle function and performance. Their applications range across many avenues, but ultimately, they connect and transfer power to crucial components of whichever vehicle they are implemented. Overall, they create a network of intelligence that allows the completed project to function correctly.

Power cables connect the inverter with two three-phase alternating currents (AC) motors, one for driving and generating electricity.

Many updated industries:
- Automotive
- Automatic Guided Vehicles (AGVs)
- High-Lows
- Helicopters
- Public Transportation
- School Buses
- Aerospace
- Battery Charging
Above all, noticing the constant updates to this industry as a whole, knowing that influential minds are innovating every component, is reassuring for electric manufacturing and should amp up solutions providers who have the opportunity to grow.