License Number: 91441900MA4WN5MJ8Y
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Hexapolar Diagnostic Cable Assembly for Utility Applications (PR034)
Safety-critical industrial cable for utility applications (ENEL Italy).
Hexapolar Diagnostic Cable Assembly Technical Overview
This project involved the development and industrialization of a custom hexapolar (6-pole) diagnostic cable assembly designed for utility-grade field applications, where electrical safety, mechanical robustness and full traceability are mandatory.
This was not a standard cable supply. The customer required a fully controlled assembly, capable of withstanding repeated connection cycles, harsh industrial environments, and strict internal compliance audits.
This hexapolar diagnostic cable assembly was engineered as a safety-critical solution for utility-grade applications.
Customer Requirements (Utility-Grade)
The brief specified:
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Custom 6-pole diagnostic connector
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High insulation margins between conductors and connector body
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Robust strain relief for repeated handling in the field
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Mechanical integrity over long service life
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100% electrical and insulation testing
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Traceable conformity documentation per unit
In short: product + process + proof.
A. Custom Connector Development
Dedicated plastic components and tooling were developed to ensure:
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precise geometry
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stable insulation distances
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scalable production
B. Supplier Engineering (Key Success Factor)
We selected and validated:
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industrial-grade contact terminals (long-term stability)
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certified multi-core cable suitable for utility diagnostics
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an assembly partner capable of process discipline, not craft assembly
Supplier quality was treated as an engineering variable, not procurement.
C. Assembly Process Control
Defined parameters included:
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stripping lengths
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crimp profiles
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torque values for enclosure screws
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strain relief validation steps
This removed operator-dependent variability.
Testing & Compliance
Every single cable is delivered with a conformity test package, including:
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Electrical continuity & pin mapping
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Insulation resistance verification
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Dielectric withstand testing
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Mechanical integrity checks
Testing is performed on the final assembled unit, not just components.
What Was Delivered
The customer received:
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Custom hexapolar diagnostic cable assembly
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Utility-grade connector architecture
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Validated tooling & industrialized process
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Controlled and repeatable assembly flow
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100% tested products with traceable documentation
Why This Case Study Matters
This hexapolar diagnostic cable assembly was developed as a safety-critical solution for utility-grade applications.
This project shows the difference between:
“supplying a cable” and engineering a safety-critical industrial solution
It demonstrates SHAMANA’s ability to:
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design for compliance, not just function
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control suppliers as part of the system
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deliver products ready for utility-level audits
