From custom cable design to the motor production line

For a motor manufacturer, choosing the right cable involves more than its electrical specification. The cable also needs to fit the product, suit its operating environment and arrive in a format that works for the production team.

HB Cables supported a customer through each of these stages, taking a jointly developed cable design through to manufacture and direct supply onto the customer’s production line.

Developed with the customer

The project began with a specific requirement for a custom cable. Working with the customer, we developed a construction that combined different conductor sizes within one outer sheath.

The finished design incorporated four 25 mm² copper conductors and five 1 mm² tinned copper conductors. This brought the larger and smaller conductors together in a single nine-core cable, rather than requiring separate cable runs.

Polyurethane insulation and a black polyurethane outer sheath formed part of the agreed construction. The cable had a nominal outside diameter of 24.2 mm and a specified operating voltage of up to 1,000 V.

These details gave the project a defined specification against which the cable could be manufactured, while keeping the design focused on the customer’s application.

From specification to manufacture

Once the design had been agreed, HB Cables arranged production of the bespoke cable.

Our role connected the customer’s requirements with the manufacturing process, carrying the agreed construction through from design to finished cable. This gave the customer one point of contact for both the cable itself and the way it would be supplied.

For custom cable projects, that continuity matters. Conductor sizes, materials and overall dimensions are only part of the requirement; the delivery format also needs to be considered before the cable reaches the factory.

Coiled to exact lengths

For this project, we arranged for the manufactured cable to be prepared and coiled to the customer’s exact required lengths.

The supply format was therefore built around the production requirement. Instead of leaving the customer to measure and cut each length from bulk reels, the cable arrived in the specified lengths, ready for the next stage of the customer’s process.

Length preparation and coiling were part of the service from the outset, alongside the cable design and manufacture.

Supplied directly onto the production line

The finished coils were supplied directly onto the motor manufacturer’s production line.

The result was a complete supply arrangement: a bespoke cable developed with the customer, manufactured to the agreed specification and delivered in the required format.

This project demonstrates how HB Cables can support customers beyond selecting a cable from a catalogue. We can help bring together custom design, manufacture and length preparation to suit a specific production process.