What Are Twin Axial High Speed IO Cables - Miracle Electronics

Copper twin axial raw wires have been developed for more than five decades now, and are yet being used in all kinds of diverse applications. Today, these wires, after receiving much trust and authority, are being used for several new generation I/O interface standard and custom wire assemblies. They are being used for both internal and external assembly applications within enterprise infrastructures, high performing computer systems, commercial data centers, and many other consumer applications.

However, these wires are yet quite expensive, which poses a challenge for manufacturers to produce budget-friendly ones, and for users to pay a little extra for the extra performance that they expect. But, in spite of the price, these wires are yet used preferably in expensive test equipment for 56 Gbps per lane circuits, and for handling 100W power closely adjacent to sensitive high-speed digital signaling per interface specifications like USB 3.1 and the latest power over Ethernet IEEE-802.3 specifications.

Here are some tips on how a wire assembly manufacturer can overcome these challenges, by considering these guidelines as part of the component engineering process. Although it is easy to cut down costs while designing a quality wire harness , but it could be a little challenging in the case of twin axial high speed I/O cables.

• Having relationships with strong suppliers can address any and all material, quality, process, performance, and testing variations details.
• The raw wire from one reel should be used for I/O link assemblies because of slight, but critical performance variations from one reel to another. That’s because it depends on how tight the wire is reeled up, and the difficulty of maintaining structure symmetry. Generally, each reel of the raw wire is individually measured, characterized, and documented for use by the wire assembly supplier, and the traceability by the OEM or end user.
• The wire conductor gauge size versus electrical signaling reach should be carefully considered. The dielectric material properties that will achieve needed signaling performance ranges must be looked out for. This may include evaluating solid, air, and foam types. Also, the process variation tolerance and control of bubble size, symmetry, density, and distribution must be looked at.
• Pure copper conductor elements with very low oxygen content, when used, can optimize conductivity. The conductor silver-plating smoothness and purity must be considered, enabling best electrical skin effect relative to signal launch path, insertion loss, jitter, and reflection loss.
• Twin axial differential pair elements need to be layered within the bundle for optimized element fan out and prepping, relative to the termination zone. The pair shields need to hold tight geometries when processing and wire termination prepping, and also for wire bundle shields and fillers. In addition, the bundle diameters and bend radius need to be designed relative to the wire routing.
• Wire termination to contacts or PCB pads must be watchfully done for both signal and ground conductors and wire bundle shield termination. The best technologies must be used for every process right from wire termination shaping and smoothness to welding or soldering.

All in all, you need to find a manufacturer that is up to the mark and perfect at producing nothing but only the best for your application. And, Miracle Electronics is one such name that tops the list of the most reliable wire harness manufacturers from India, where you can get high performing wire harnesses, especially customized to your needs.