Task

Our customer requires a fully shielded, pair-twisted cable. An 8-pin METZ CONNECT plug-in terminal with gold-plated contacts on both ends, and an interference-suppressing ferrite ring on one end, all protected by a mesh sleeve.

Technical challenge

Rapid design and production — the first 500 units within 2 weeks of receiving the plug-in terminals.

Solution

The raw cable is pre-assembled: S1 is stripped, the shield is removed, the pairs are slightly untwisted, and ferrule sleeves are crimped onto the wire ends. S2 ferrite threaded in, secured with a cable tie, and protected from damage—even during assembly and transport—with a protective tubing. Then stripped, the shield unraveled and twisted into a “pigtail,” covered with heat-shrink tubing, and crimped with a flat connector sleeve. Pairs lightly untwisted, wire end ferrules crimped. This allows us to install the components immediately after the terminal blocks are in place and perform a 100% electrical test right away using a test adapter. Even this seemingly simple assembly involves a significant amount of technical work and, above all, logistical effort.