Customer Challenge
A US industrial equipment customer required a custom power harness for a fixed installation application.
The solution needed to integrate:
- 25m outdoor AC input cable
- 54V industrial AC/DC power supply
- 1m CAT6A cable
- Custom RJ45 power output
The challenge was not only cable assembly, but also ensuring long-term reliability in a permanent installation environment.
Engineering Solution
During the design review, Alvin’s Cables worked with the customer to confirm key specifications, including:
- Wire gauge requirements
- RJ45 connector configuration
- Custom power pinout
- Cable connection method
Because the system would remain fixed after installation, the customer preferred a permanent splice solution instead of additional inline connectors.
This reduced unnecessary connection points while improving long-term reliability.
Manufacturing Approach
The final cable assembly included:
- Industrial 54V power supply integration
- Outdoor-rated AC cable
- Custom RJ45 power cable assembly
- Sealed splice protection
- Additional strain relief
Each harness was inspected before shipment to ensure correct wiring, polarity, and assembly quality.
Fast Prototype & Low-Volume Production
The customer required an accelerated production schedule:
- Initial 5 units for early deployment
- Additional 15 units for follow-up production
Alvin’s Cables supported the project with rapid engineering confirmation, production coordination, and small-batch manufacturing.
Custom Cable Assembly Capability
This project demonstrates Alvin’s ability to support industrial customers with:
- Custom power harnesses
- AC/DC cable assemblies
- Custom connector solutions
- Low-volume production
- Cable assemblies based on customer drawings
From prototype development to production batches, Alvin’s Cables helps engineers turn cable requirements into reliable production-ready solutions.
