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Wire Gauge

Tips for Choosing the Correct Gauge of Wire for the Job

Have you been looking into a wiring project? Do you know what gauge of wire is best suited for your needs? Our tips can help you in the choosing process of wires!

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**

1: What type of project are you doing?

There are many different types of wiring projects. Depending on whether you are working on home wiring or building your own robot, there is a difference of what type of wire is required. For example, some projects include:

  • Home wiring
  • Robotics
  • Computers
  • Vehicles

2: How much space do you need for wiring?

To begin with different housings for different projects will vary in size. Due to the wire size, the space needed to house them will vary. If you think about a light switch, some have a single switch and therefore only need enough room for the wires of that one switch. However, there are light switches that have multiple switches. Therefore, the space required for the wiring of a multi-switch receptacle is larger than that of a single switch receptacle. In order to do a job properly, you need to be aware of how much space you have to work with and really need. If you are working on home wiring that requires a larger current as opposed to a robot that requires less current the space needed is different because the wire size will be different.

3: How are wire gauges calculated?

Especially relevant is the fact that as wire increases in physical width, the gauge of that wire will decrease in numerical value. While this does seem backward it’s really not. Due to the wire drawing process, the number of operations that it takes to get it to that physical size is the numerical gauge of a wire. As a result, gauges are larger or smaller than the physical size.

Wire Gauge

4: What are large and small gauged wires used for?

There are also many different gauges of wire. Consequently, they have many different uses.

Uses for some smaller gauges (larger physical sizes) of wire:

  • Electrical lines (like those you see outside attached to power lines)
  • Heavy duty automobiles like trains, larger armored trucks
  • Home wiring

Uses for some larger gauges (smaller physical sizes of wire):

  • Computers
  • Radios
  • Phones
  • GPS
  • Mp3 player
5: How much amperage do you require?

There are different factors that determine the required amount of amperage:

  • Amperage= Wattage/Volts
  • What current do you need for your project
  • Where the wire is going
  • Where the wire is coming from

In addition to these tips you can learn more about wire gauges by looking back to our previous blog Why Do Wire Gauge Sizes Seem To Work Backwards?

In conclusion, the chart below will be helpful in deciding which wire is appropriate for your specific job.

AWG Cable/ Conductor Size Chart

AWG Diameter 
[inches]
 Diameter 
[mm]
Area
[mm2]
Resistance
[Ohms / 1000 ft]
Resistance
[Ohms / km]
 Max Current 
[Amperes]
Max Frequency
for 100% skin depth
 0000 (4/0)0.4611.6841070.0490.16072302125 Hz
000 (3/0)0.409610.40384850.06180.202704239160 Hz
00 (2/0)0.36489.2659267.40.07790.255512190200 Hz
0 (1/0)0.32498.2524653.50.09830.322424150250 Hz
10.28937.3482242.40.12390.406392119325 Hz
20.25766.5430433.60.15630.51266494410 Hz
30.22945.8267626.70.1970.6461675500 Hz
40.20435.1892221.20.24850.8150860650 Hz
50.18194.6202616.80.31331.02762447810 Hz
60.1624.114813.30.39511.295928371100 Hz
70.14433.6652210.50.49821.634096301300 Hz
80.12853.26398.370.62822.060496241650 Hz
90.11442.905766.630.79212.598088192050 Hz
100.10192.588265.260.99893.276392152600 Hz
110.09072.303784.171.264.1328123200 Hz
120.08082.052323.311.5885.208649.34150 Hz
130.0721.82882.622.0036.569847.45300 Hz
140.06411.628142.082.5258.2825.96700 Hz
150.05711.450341.653.18410.443524.78250 Hz
160.05081.290321.314.01613.172483.711 k Hz
170.04531.150621.045.06416.609922.913 k Hz
180.04031.023620.8236.38520.94282.317 kHz
190.03590.911860.6538.05126.407281.821 kHz
200.0320.81280.51810.1533.2921.527 kHz
210.02850.72390.4112.841.9841.233 kHz
220.02540.645160.32616.1452.93920.9242 kHz
230.02260.574040.25820.3666.78080.72953 kHz
240.02010.510540.20525.6784.19760.57768 kHz
250.01790.454660.16232.37106.17360.45785 kHz
260.01590.403860.12940.81133.85680.361107 kHz
270.01420.360680.10251.47168.82160.288130 kHz
280.01260.320040.08164.9212.8720.226170 kHz
290.01130.287020.064281.83268.40240.182210 kHz
300.010.2540.0509103.2338.4960.142270 kHz
310.00890.226060.0404130.1426.7280.113340 kHz
320.0080.20320.032164.1538.2480.091430 kHz
330.00710.180340.0254206.9678.6320.072540 kHz
340.00630.160020.0201260.9855.7520.056690 kHz
350.00560.142240.0163291079.120.044870 kHz
360.0050.1270.0127414.813600.0351100 kHz
370.00450.11430.01523.117150.02891350 kHz
380.0040.10160.00797659.621630.02281750 kHz
390.00350.08890.00632831.827280.01752250 kHz
400.00310.07874 0.00501104934400.01372900 kHz

If you are interested in designing your own wire harnesses check out our new Wire Harness Estimator to get a quote!

If you need more information before you get started check out our blog on The Wire Harness Estimator Components Defined

You can also learn more about our pre-designed wire harnesses by checking out our Wire Harness Page!

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**   

Wire Harness Estimate

Do You Need a Wire Harness Estimate, Pronto?

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Need a price on a Wire Harness Assembly, like RIGHT NOW?! Traditionally, receiving a Wire Harness Estimate could take hours or even days. Well, thanks to some hard work and innovation that problem is now solved. You can now receive a Wire Harness Estimate within minutes (or even seconds depending on how fast you type). Stop by and check out the brand new Falconer Electronics Wire Harness Estimator.

Wire Harness Estimate in 6 Simple Steps 

The Wire Harness Estimator offers you a simple 6 step process. With each step, you can easily enter product information. Once complete, you hit submit. Within seconds your Wire Harness Estimate will be waiting for you in your email box.

Wire Harness Estimate

  1. Select your wire
  2. Enter the number of wires
  3. Select your terminals
  4. Choose add-ons – such as sleeving, heat shrink, labels, or wire ties
  5. Don’t see an item you need – this step you can type in a request
  6. Submit

At any time you are also free to submit a drawing.

Creating a prototype?

Testing a new product?

Need a Wire Harness Estimate quick? No problem. You can breeze through the Wire Harness Estimator completely free of charge and no obligations.

Questions on Wire Harness Components? Click here.

Custom Wire Harness Assembly 

What type of industries do we serve? Our wire harnesses can be found in the healthcare industry, auto and truck lighting, heating systems, locomotive products and much more.  

Commercial Power Strips

Commercial Power Strips manufactured by Falconer Electronics can be found working relentlessly at numerous major brick and mortar retail stores at product displays. We produce our own wire harnesses for all of our power strips.

Portable Work Lights 

We even produce wire harnesses for our own proprietary product line of portable work lights. This line includes magnetic trouble lights and magnetic spotlights.

MLC-50-C3 Trouble Light

 

Thank you for reading this post on Wire Harness Estimate. For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

Supplies Components

Who Supplies Components When Outsourcing Production? – Part 7

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Supply or not supply? That is the question for today.

When outsourcing to a custom manufacturer, a common question occurs, “Who Supplies Components When Outsourcing Production?” Do you supply your own parts and materials or is it more cost-effective for the custom manufacturer to purchase materials? We will address this topic from the perspective of a Wire Harness Manufacturer

This is our continued series on Outsourcing Wire Harness Manufacturing. Below includes links to previous topics on this discussion: 

Outsource Your Wire Harness Assembly Process – Part 1

Selecting a Wire Harness Manufacturer – Part 2

How to Find a New Wire Harness Manufacturer – Part 3 

Interviewing a Wire Harness Manufacturer – Part 4

Discreet Questions to Determine Character Compatibility and Financial Viability – Part 5

Touring a Wire Harness Manufacturer – Part 6

What if I want to supply my own products such as wire, connectors and other components to save money? 

Supplying your own products to a custom manufacturer offers several positives and negatives. It works best to communicate clearly with the manufacturer on the pros and cons of either option. 

The question is do you really save money?  One-size fits all does not apply here. There are many variables to consider which option makes the most sense (or more importantly – make the most CENTS). 

Pros and Cons 

Let’s take a look at the Pros and Cons of supplying your own parts and components: 

Positives 

Several benefits fall in your favor by taking the initiative to order and supply your own parts when outsourcing: 

  1. You control the ordering process and supply chain. 
  2. Ordering your own parts allows you to have full disclosure of pricing on the cost of goods. 
  3. First-hand knowledge of availability or stock-outs on your product. 
  4. Better control over delivery times. 
  5. Negotiate your own discounts with the vendor. 

Negatives 

Ordering or supplying your own parts may be welcomed by the manufacturer. On the other hand, this approach could be disruptive to the manufacturer. Here are a few negatives to consider: 

  1. The time you spend ordering parts. 
  2. The time you spend coordinating deliveries. 
  3. Lost opportunity of volume discounts available to the manufacturer due to their purchasing power.
  4. Product knowledge and expertise that the manufacturer possesses.
  5. The variety of shipments arriving at manufacturer at different times throws off their production schedule for your product. 
  6. The receiving department at the manufacturer must be informed of delivery. This communication is crucial for the manufacturer in order to properly schedule production of your products. 
  7. The manufacturer must implement a means to monetize the receipt of your goods that you order. It is in neither parties interest to not account for labor, handling, and the overhead expense of receiving and storing goods. 

Supplies Components

An important question to ask yourself: Is your time better spent focusing on other areas of the business? Did you partner with a company that you trust enough to delegate the purchases to the custom manufacturer? 

You partnered or hired the custom manufacturer due to their proficiency, expertise, and ability to deliver a quality product on time. Is it worth your time, hassle and energy to locate new vendors and product in areas that are either new to you or where you are lacking purchasing power and strong vendor relationships?

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.

Magnetic 8" Reflector Spot Light

Heavy Duty Magnet Base Spot Lights

Falconer Electronics prides itself in manufacturing superior electrical products for its amazing customers. Over the past two years, Falconer Electronics served as a contract manufacturer of Magnet Base Spot Lights for industrial work light manufacturer, Standard Portable.

Things went so well that the companies decided to join forces and become one business. Falconer Electronics purchased Standard Portable to create an opportunity for businesses and consumers to purchase directly from the manufacturer at low prices. 

As a Wire Harness Manufacturer since 1985, this partnership brings tremendous energy and excitement. Expanding from a manufacturer of Commercial Outlet Strips, PCB, LED Lighting and Wire Harnesses, adding the line of Industrial Work Lights is just……well…..deLIGHTful! (Sorry, we couldn’t help ourselves). 

Magnet Base Spot Lights

Magnetic Spot Lights at Falconer Electronics come equipped with a sturdy ceramic or neodymium magnetic base that creates either a 30 or 45 lb pull. This durable Magnet Based Spot Light provides you the flexibility to attach to any ferrous metal surface allowing you to work hands-free. Each spot light is produced with an aluminum reflector delivering ideal lighting wherever maximum illumination is required. 

You can now purchase our Portable Work Lights direct as well as Industrial Magnets on our brand new ecommerce store. We offer Magnet Base Spot Lights for industrial, office, and residential use. 

Industrial Magnet Base Spot Lights 

The Spot Lights can be purchased with a 3 prong grounded cord that works perfectly for industrial settings. These rugged and durable cords provide long-lasting use. Plus the grounded cord delivers the additional safety feature necessary in warehouses, factories or a garage. 

MLC-200-25-C3 and MLC-200-50-C3

Magnetic 9" Spot Light with 25' Cord

 

MLC-231-25-C3 and MLC-231-50-C3

Magnetic 5-1/2" Spot Light w/50' Cord

ML-200-25-C3 and ML-200-50-C3

Magnetic 9" Reflector Light w/25' Cord

ML-231-25-C3 and ML-231-50-C3

Magnetic 5-1/2" Spot Light w/50' Cord

 

WSL-8-3

Magnetic Work Light w/ 8ft Cord

Magnet Base Spot Light with Cord Reel 

Also a perfect fit for industrial use, the Magnet Base Spot Light with Cord Reel is built to tackle challenging projects. 

C200-20R
Magnetic 9" Spot Light with 20' Retractable Cord Reel

C200-50R 

Magnetic 9" Spot Light with 50' Retractable Cord Reel

Magnet Base Spot Lights for Office and Residential Use 

Lastly, you can take advantage of low prices with a line of two prong spot lights that work great for office and residential use.

WSL-51/2-2C8

Magnet Base Spot Lights

WSL-8-2C8

Magnetic 8" Reflector Spot Light

 

WSL-2C8

Magnetic Spot Light

Thank you for reading our post on Magnet Base Spot Lights. 

We would love to hear from you. Please connect on FacebookTwitterGoogle+, and  LinkedIn for more electronic info.

Touring a Wire Harness Manufacturer – Part 6

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Part 6! We almost feel like the Harry Potter Series (my daughter would be proud of that analogy). Each week we have been addressing the due diligence and selection process when deciding to outsource wire harness manufacturing. Today we will explore taking a tour of a custom manufacturer. In particular, Touring a Wire Harness Manufacturer.

Below includes previous topics on this discussion: 

Outsource Your Wire Harness Assembly Process – Part 1

Selecting a Wire Harness Manufacturer – Part 2

How to Find a New Wire Harness Manufacturer – Part 3 

Interviewing a Wire Harness Manufacturer – Part 4

Discreet Questions to Determine Character Compatibility and Financial Viability – Part 5

It is Now Time to Plan a Visit and Take a Tour

So you continue plunging through the due diligence process to select a custom manufacturer. 

You have performed dozens of Google searches to narrow down the field.

You have evaluated plenty of websites and social media pages until they all start to blend together.

Hopefully, several companies are standing out from the crowd. 

Emails have been exchanged and phone calls have been made to break the ice.

There may be one or two that really seem like head and shoulders above the rest.

You are feeling good. 

It is now time to plan a visit and tour each facility. 

A physical visit to top candidates in person is vital with your decision. You might even want to consider a surprise visit (“Hey, I was in the neighborhood” – even if 500 miles away). 

Here is an excellent article from the Harvard Business Review regarding plant tours (Even though this was written 20 years ago): https://hbr.org/1997/05/why-and-how-to-take-a-plant-tour

Eyes Wide Open and the Attitude of a Harsh Critic

It is extremely important to go into the tour with eyes wide open and the attitude of a harsh critic.

(Actually, this was just a great excuse to get Judge Judy into one of our blogs).

What to Look for When Touring a Wire Harness Manufacturer

Below is a list to consider when Touring a Wire Harness Manufacturer: 

  1. Do you find the building and property presentable or unkempt? (Unmowed grass, disheveled parking lot, garbage, broken windows, etc…) 
  2. Office presentable or unkempt? (Top of the line everything or dated to the 1960’s) 
  3. Are you warmly greeted?
  4. Management, staff, and employees pleasant and welcoming?
  5. Do employees look happy and hustling?
  6. Are tools and equipment organized and well maintained?
  7. Are the warehouse and inventory efficiently organized?
  8. Is the Shipping dock clear of clutter?
  9. Are you impressed or underwhelmed with the team and operation? 
  10. Are there any red flags that make you uneasy?
  11. Do employees have cell phones out?
  12. Check kitchen area – is it clean or organized and dirty? 
  13. Are restrooms clean?
  14. Are there any key employees that do not come out to meet you? 
  15. Evaluating the quantity and quality of staff, does the company seem to be top heavy? 
  16. What are the years of service of the management team?
  17. Be prepared with tough questions regarding your product and process to determine if they are indeed experts in their field.
  18. Is the management team short and brief with you? Is this a good sign that they are focused and busy or are they rude and distracted? 
  19. On the other hand, if they meet with you for a long period are they too lackadaisical or not busy? 
  20. Do they seem eager to earn your business or desperate? 

Outsourcing your product production to a custom manufacturer is similar to finding quality daycare for your child. You need to find a company that you Trust, Trust, Trust! 

There is a saying that if something is not a “HELL YAH” then it is simply a “No”. 

Check back next week for Part 7 of our series on Outsourcing. 

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.