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Wire Abrasion Protection
Spring-Fast® Wire Protection Grommet Edging
Cable Abrasion
When wires and cable harnesses exit from sheet metal architecture, they are often routed over and through sheet metal panel edges. Over time, there is potential for abrasion and failure as the wire insulation comes into contact with the sharp metal edges and begins to chafe. The typical industry solution for reducing abrasion is to apply grommet edging to burrs and sharp edges in close proximity to wires and cables. The two most common approaches are glued-on edging, and snap-on edging. “It is critical that design engineers understand the difference between these solutions” says Device Technologies Engineering Manager Steven O’Loughlin. Traditional adhesive-based (glued-on) grommet edging requires a five-step application process: First, the sharp edge must be cleaned with a solvent. Next, an adhesive must be mixed (in most cases, pre-mixed adhesives cannot be used for this type of application). The adhesive must be applied, followed by the grommet edging, which must be left to cure for up to 24 hours and often fixtured with devices and or tape. Clean up of the adhesives, solvents and removal of fixtures complete the process. Not only is this a lengthy, labor-intensive installation process, but the VOC's generated by the adhesives and solvents require adequate ventilation during and after installation.
Additional solutions such as plastic or rubber-based grommet edging typically have not been tested to the high performance qualification needs of a race car or tactical aircraft such as flammability, shock and vibration. In conclusion, it is also very critical for design engineers to understand cable reliability issues. Protection from external wear and abrasion is solved by the right grommet solution, and internal protection against data and electrical response destruction. Consideration of and planning for critical wire protection and management parameters, will help design engineers give their teammates a longer-lasting, more reliable equipment.
Reliability
The innovative reliable Spring-Fast wire abrasion protection grommet edging replaces various thermoplastic (nylon) grommets that breakdown, then crack and fall off, leaving wires exposed to sharp-edged metal surfaces, as well as those made in Polyolefin that require significant assembly time in manufacturing, requiring the use of adhesives.
Spring-Fast wire abrasion protection grommet edging is designed to protect critical wires and cable harnessed from wire chaffing, and simply snaps on and is easier to install than alternative products. It installs fast and has excellent holding ability, thereby improving productivity, and minimizing safety issues associated with the use of adhesives. The high performance Spring-Fast grommet edging, tests to high levels of shock and vibration, up to 41.7 g. Other ambient conditions tested for include flammability, salt spray, chemical immersion and tabor abrasion. Supporting its long term reliability, within critical equipment such as IT devices, medical imaging and aerospace equipment, which cannot have any electrical problems associated with wire breakdown.
“Spring-Fast is perfectly tailored for critical high-performance race cars; stock, Indy, formula…, whose wires and cable harnesses are subjected to significant aerodynamic loads throughout its operational life,” said Device Technologies Engineering Manager Steven O’Loughlin. “We are in full production of our BAP and SL Series Spring-Fast wire protection grommet edging for various race teams, and helmet and seat manufacturers, which also have to protect sharp edges.
The Spring-Fast SL Series grommets are made from RoHS compliant materials and DFARS compliant spring-loaded stainless steel, which is encapsulated in a protective polymer coating. Spring-Fast quickly mechanically locks into place, using only the pressure applied by the installer’s fingers or application roller. The product is delivered on reels, or pre-cut to length for the specific protective applications where wires contact sharp edges.
Spring-Fast originally was developed for the electronics industry, and is currently fitted on storage and server computers, aircraft, medical imaging, automobiles, gaming slot machines and other critical equipment. It is increasingly becoming a standard for the automotive, aerospace and defense industries because of the excellent performance, ease of installation and production cost effectiveness compared to old-style thermoplastic and rubber-based grommets. Spring-Fast is approved for use by the U.S. Department of Defense, as well as the U.S. Federal Aviation Administration civil aviation authority.
Steven O’Loughlin, Engineering Manager
Device Technologies, Inc.
155 Northboro Rd., Unit 8 Southborough, MA 01772-1033 USA
Toll Free: 1-800-669-9682
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