How to Select and Apply the Correct Cable Ties for the Harness

With the increasing use of electrical and electronic components and subsystems, the correct fixing of wire harnesses is an important aspect of system design, but it is often ignored. Whether inside equipment or between systems, it is essential to ensure the safe, secure and efficient wiring of cables for the success of design and service life, especially in applications with high vibration and harsh environment.

For designers like us Kable-X, the challenge is to find cable ties that meet the application requirements in terms of tensile strength, life, flexibility, chemicals, vibration and ultraviolet (UV) radiation resistance, while not over-designing or damaging the insulation and internal structure of the integrity cable. This requires analyzing various types of cable ties and various materials available now, and distinguishing them, fearing that the final cost of choosing the wrong cable ties may be much higher than the purchase cost.

To alleviate these concerns, designers need to know the nuances of cable ties and how to make their choice consistent with the application requirements. This article will outline the precautions of cable ties, the advantages of each type, and how to apply them effectively using the corresponding practical examples.

1. Specifications of Cable Ties

Cable ties, commonly known as zip-tie or tiewrap, are available in a variety of lengths, widths, materials and colors. When tying the electric wire bundle, the lace or adhesive tape should surround the electric wire bundle, and the loose end should be completely pulled through the locking mechanism and tightened until the locking notch of the strap is firmly engaged.

The cable tie can be constructed as a single piece, in which the locking barb is molded as a part of the locking mechanism. In contrast, higher quality ties have a two-piece structure. In the two-piece design, anti-corrosion stainless steel barbs are embedded in the lock head to grasp the relatively smooth lace surface. It is designed to provide a firm lock that can be infinitely adjusted, because the barb does not need to fit into the locking groove.

The maximum diameter specification indicates the maximum diameter wiring harness that the cable tie can accommodate. The binding should be firmly fixed, and the wiring loom insulation should not be over-tightened, cut or worn. An extra point should be considered when using the length of the strap to engage the loose end in the locking mechanism.

The wrapping strength is defined as the ring tensile strength (LTS) measured in pounds, is the maximum force that can be applied after LTS locking mechanism is engaged. The most common ties are between 18 pounds and 250 pounds.

It depends on the size of LTS tie and the material used. The material selection is mainly influenced by the environmental operating conditions that the cable ties will experience. Factors to consider include:

1) Is it for internal or external use?

2) What is the expected temperature range?

3) Will it be exposed to water, oil, chemicals or vibration?

For example, PLT1.5M-M10 cable tie is a part of a company's cable tie series. This cable tie series is its largest and most comprehensive product series, offering ties of various colors, materials and structural types. The PL. M-M10 has a nominal length of 5.6 inches (inches), a rated maximum diameter of 1.25 inches and a tensile strength of 18 pounds. According to its cross-section integral, the lace is ultra-small, micro, or middle. PLT1.M-M10 is a miniature tie, which is designed with an integrated structure. It is made of nylon 6.6 and suitable for indoor use.

As mentioned earlier, another common cable tie design includes two pieces with a single stainless steel barb instead of the molded nylon barb in the one-piece design.

It is made of ethylene tetrafluoroethylene (ETFE) and is suitable for applications requiring chemical resistance, flame retardancy and radiation resistance. Its cable tie is BT4S-M0 of the above-mentioned company, which is a member of DOME-TOPBARB-TYBT series, and is made of individual barbs. In addition, this series of cable ties adopt round heads and round edges, which can minimize the wear of wire insulation. Black is achieved by adding carbon black to nylon, which improves the resistance to ultraviolet rays and makes this color more commonly used in outdoor applications.

Cable ties are made of a series of materials specific to their intended application environment. The lace is basically molded from nylon 6.6. 6.6 Nylon has high mechanical strength, rigidity, good heat resistance and reasonable chemical resistance. Variants include weather-resistant, heat-stable and flame-retardant nylon 6.6.

Various other materials are used to achieve specific tolerances. For example, DT8EH-Q0 is designed for high strength, impact resistance, chemical resistance, ultraviolet resistance and weather resistance. It uses acetal (polyoxymethylene, or POM), a series of materials including Delrin. It is 2.25 feet (ft.) long and has a tensile strength of 250 pounds. These cable ties are specially designed for harsh outdoor applications in the power and communication industries.

2. The Temperature Range

The temperature range that a cable tie can withstand mainly depends on the materials used in its structure. The rated operating temperature range of nylon 6.6 is-76 F to+185 F. Thermal nylon 6.6 extends the upper limit of the range to 212 F. PEEK has the highest temperature tolerance, with an upper temperature limit of 500°F.

3. Special Functions

CBR1M-M is a part of Contour-Ty series of a company, which has a unique design to prevent the damage of wire insulation or cable sheath. It adopts a low-key head design, uses parallel entrances to limit the exposure of sharp edges and reduce obstacles, and has locking dents on the outside of the strap.

HV9150-C0 in-line cable tie uses weather-resistant nylon 6.6. Mechanically, it adopts a locking mechanism with double wedge design, which can realize fixed locking and flexible locking.

The releasable head allows temporary binding before final locking. Indentations are molded on both sides of the strap, providing extra locking strength and greater flexibility. Its length is 1.721 feet, its bundle diameter is 5.92 inches, and its tensile strength is 160 pounds.

SST1.51-M cable ties are 5.3 inches long and have a tensile strength of 40 pounds. It is designed to have a small head height, and is suitable for common binding and through-panel applications. Its two-piece design has the lowest threading force in the industry and is 14% lighter than the one-piece design. In addition, before the final tightening, the lacing can be loosened.

The main body of ERT2M-C20 is designed to be flexible when the tensile capacity of most cable ties is low.

This type of cable tie is designed to conform to the wire or optical cable bundle to prevent over-tightening. It also has a high friction coefficient, which can clamp wires to prevent lateral movement. This detachable cable tie is 8.5 inches long and has a tensile strength of 18 pounds. Like other cable ties in this series, it has UL94V-0 flame retardant rating-meets the strict telecommunication flammability requirements-and is halogen-free and non-toxic.

SG100M-M0 is suitable for maintenance, repair and overhaul environments and rough installation practices in the construction industry.

It is made of weather-resistant nylon 6.6, which is very suitable for applications exposed to strong ultraviolet rays. It is 4.2 inches long and has a rated tensile strength of 18 pounds. Its thin and wide strap is designed to flexibly hold the cable bundle and reduce the lateral wire movement.

IV. Conclusion

Although cable ties are generally considered to be relatively simple, designers need to carefully consider many available options to ensure that the most suitable ties are used for the application. A good cable tie should range in length from inches to several feet, be compatible with various environments, and have many functions to meet the needs of various applications.