Custom Cables, Leads, Pinouts, and Cable Management
Cable Management, Custom Cables, and More
Cables are one of the most overlooked components in industrial automation. That is, until something goes wrong. Whether they’re being used to connect motion systems, sensors, vision equipment, or even control panels, cables keep your facility running. And when they stop, so does production.
At Cross Company, we understand how critical it is for manufacturers to have reliable connectivity. That’s why we offer to design, source, and assemble custom cables, leads, pinouts, and cable management systems built specifically for your application. We help manufacturers reduce downtime, simplify maintenance, and enhance performance without the guesswork (or risk) of using less-ideal cables.
Why Your Operation Needs Custom Cables From Cross
Even though much of the equipment you order comes with cords included, those cords do not typically meet the standards required for automation applications. One of the prime examples in automation is flex rated cables. The cables that come standard are typically not made for the repeated flexing or bending that will occur during the course of regular use. If a cable is not flex rated, it will likely fail leading to costly and unplanned downtime.
Another common reason to order custom cables is if your application requires very long or non-standard length cables. Many servo motor manufacturers only offer cables up to 10 meters or 50 feet. If you happen to need 100-foot motor cables, then a custom cable solution would be right for you.
The need for special connectors is another great reason to purchase custom cabling. For example, if you need your connection to go through a bulkhead assembly, standard cabling will not work. We can also help with custom pinouts or cable harnesses to make assembly go smoothly. Putting thought into the design of your wiring ahead of time can save you lots of time and headaches when starting up and commissioning your equipment.
Finally, special environments have unique cord needs to ensure they are safe and operate as intended for years to come. Some examples of special environmental considerations include vacuum, high temperature, chemical contact, UV, and water resistant for submerged applications.
Meet automation standards
Prevent cables failing
Get non-standard length cable
Meet compliance for special connectors
Trustworthy cables for extreme environments
Increase optimized throughput
When A Custom Cable Solution Makes Sense
If you’re wrestling with deciding if custom cables are worth it, consider how often your operation experiences unplanned downtime or difficult startups due to damaged cords (or even cords that aren’t behaving like they should). Custom cables and wiring assemblies are a practical means of eliminating those difficulties.
You may benefit from a Cross custom cable, lead, pinout, or cable management if
- You’re dealing with frequent cable fatigue or failure due to motion or flexing
- Your setup requires longer or nonstandard cable runs
- You need specific connectors for through-panel or sealed environments
- Your environment involves heat, vacuum, moisture, oil, or chemical exposure
- You want to reduce wiring complexity and streamline commissioning
Custom Cable Solutions Designed For Your Operation
At Cross, we offer end-to-end custom cable services specifically designed for industrial and automation applications. Whether you need a single specialized cable or a complete harness and management system for a new production line, our team can help.
Our cable capabilities include
Custom Cable Design
We spec and design from the ground up, considering voltage, signal type, stress, bend radius, and even environmental exposure
Custom Wire Harnesses
For more complex systems needing multiple signal and power lines, we can design and assemble wire harnesses that simplify installation, reduce clutter, and protect cables
Custom Pinouts and Connectors
We provide accurate pinout configurations to match your control systems, motors, or sensors, eliminating wiring confusion during installation
Custom Leads and Extensions
When your layout calls for nonstandard cable lengths or split leads, we can produce reliable extension cables and jumpers that meet automation-grade requirements
Cable Management Systems
Our engineers can design and integrate cable carriers, guides, and strain-relief systems that keep your cabling organized and protected
Is Automation Right for Your Process?
Answer a few simple questions and find out! We’ll send a copy of your inputs to help build the case for automation, and determine ROI for automating parts of your operation.
Why Cross Custom Cables, Leads, Pinouts, and Cable Management?
Whether you need a single custom lead or a plant-wide cable management overhaul, Cross Company provides the engineering expertise, quality standards, and customer support to make it happen. Every custom cable or harness we build is the result of collaboration between our automation engineers, sourcing specialists, and your production team. Together, we ensure that each assembly delivers measurable improvements in performance and maintainability.
Don’t let cable issues slow down your automation efforts. If you’re ready to improve reliability, simplify maintenance, and protect your investment in automation equipment, talk with a Cross engineer today. We’ll help you design, specify, and deliver a cable solution that keeps your production moving.
