Hexapolar Diagnostic Cable Assembly for Utility Applications (PR034)

Safety-Critical Industrial Cable for Utility Applications (ENEL Italy)

Custom hexapolar (6-pole) diagnostic cable assembly developed for utility-grade applications.

Hexapolar Diagnostic Cable Assembly Technical Overview

This project involved the development and industrialization of a custom hexapolar (6-pole) diagnostic cable assembly intended for utility-grade field use.The final application is within ENEL infrastructure, 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:

• Custom 6-pole diagnostic connector

• High insulation margins between conductors and connector body

• Robust strain relief for repeated handling in the field

• Mechanical integrity over long service life

• 100% electrical and insulation testing

• Traceable conformity documentation per unit

In short: product + process + proof.

Integrated strain relief system designed to protect internal conductors from mechanical stress.

Controlled crimping and conductor identification to ensure electrical integrity and repeatability.

FR4 insulation layer used to increase dielectric safety margins inside the connector housing.

A. Custom Connector Development

Dedicated plastic components and tooling were developed to ensure:

• precise geometry

• stable insulation distances

• scalable production

B. Supplier Engineering (Key Success Factor)

We selected and validated:

• industrial-grade contact terminals (long-term stability)

• certified multi-core cable suitable for utility diagnostics

• 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:

• stripping lengths

• crimp profiles

• torque values for enclosure screws

• strain relief validation steps

This removed operator-dependent variability.

Documented manual assembly process under controlled industrial conditions.

Testing & Compliance

Electrical continuity, insulation resistance, and dielectric testing performed on final assemblies.

Every single cable is delivered with a conformity test package, including:

• Electrical continuity & pin mapping

• Insulation resistance verification

• Dielectric withstand testing

• Mechanical integrity checks

Testing is performed on the final assembled unit, not just components.

What Was Delivered

The customer received:

• Custom hexapolar diagnostic cable assembly

• Utility-grade connector architecture

• Validated tooling & industrialized process

• Controlled and repeatable assembly flow

• 100% tested products with traceable documentation

Integrated strain relief system designed to protect internal conductors from mechanical stress.

Multiple finished cable assemblies prepared for delivery after final inspection.

Multiple finished cable assemblies prepared for delivery after final inspection.

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:

• design for compliance, not just function

• control suppliers as part of the system

• deliver products ready for utility-level audits

Start a pilot run