Performance Optimization Strategies and Process Improvement Path for High-Speed Cable Assemblies

In modern high-speed data transmission systems, the electrical performance of high-speed cable components directly affects signal integrity and system reliability. In order to enhance the transmission performance of high-speed cables and harness assemblies, reduce insertion loss, return loss, and signal crosstalk, it is necessary to carry out systematic optimization in aspects such as material selection, structural design, wiring layout, welding technology, and automated assembly.

Optimize cable material and structural design

Optimize cable materials
• Insulating materials with low dielectric constant (Dk) and low loss tangent (Df) can effectively reduce dielectric loss and improve the quality of high-frequency signal transmission.
• Using high-purity silver or tin-coated conductors can reduce transmission attenuation caused by high-frequency skin effect and improve conductivity efficiency.
Reasonably design the cable structure
Control the conductor diameter within an appropriate range to avoid increased insertion loss due to an overly thin central conductor.
• Adopt high-density woven shielding structure or multi-layer shielding design to enhance anti- electromagnetic interference ability and reduce external crosstalk and signal reflection.

Optimization of Wire Harness Wiring and Connection Technology

Control cable length and routing
Minimize the signal path length and reduce unnecessary cable redundancy and reflections.
Maintain parallel and consistent spacing of wires within the harness, avoid sharp bends, crossings, or excessive twists, and reduce signal crosstalk and mode conversion from the source.
Optimize welding and connection technology
Ensure that the solder joints are flat and the solder is evenly distributed, eliminate potential hazards such as cold joints and bridging, and ensure the reliability of the connections.
Design an impedance matching structure between connectors and cables to avoid reflections and return loss caused by impedance discontinuity.


 

Three, enhance consistency and reliability through automated processes

In the manufacturing of high-speed interconnect components, automated assembly and precise welding technology are critical to ensuring consistency and batch reliability.



|| Suzhou Huichengyuan Electronic Technology || produces micro coaxial cables and dual-axis cable components, which are all made using automated termination and testing processes. This effectively ensures the structural consistency, low loss, and high stability of mass-produced products. Through the collaborative optimization of material optimization, structural design, wiring control, process improvement, and automated assembly, the overall electrical performance of the cable harness can be significantly improved, providing a stable, low-loss, and mass-produced interconnection solution for high-speed data transmission systems.

I amSuzhou Huichengyuan Electronic Technology,Long-term focus on the design and customization of high-speed signal cable harnesses and ultra-fine coaxial cable harnesses, committed to providing stable and reliable high-speed interconnection solutions. If you have any related needs or wish to learn more, please feel free to contact:Manager Yin 18913280527 (WeChat same number)。