Broken Wires
Sometimes it happens that measuring equipment gets damaged and it is necessary to go to the field for repair. If a complete spare part is not available or the sensor itself is, for example, a non-replaceable integral part of the monitored structure, all is not lost. The entire delicate situation can in many cases be saved on the spot with the help of skilled hands. If you prefer professionals who are able to provide complete maintenance and repairs of your measuring devices, the Automatic Sensing team is always ready to provide its services.
Main Causes
One of the most common problems we encounter is mechanically broken cables from sensors or antennas. This happens very often inadvertently at ongoing construction sites, where workers carelessly cut the cable. On the periphery or in nature, cables are sometimes bitten through by farm or wild animals.
What needs to be ensured?
For a quality repair of a broken wire, 3 main goals must be achieved: conductive connection of broken wires and shielding, prevention of short circuits and corrosion of exposed wires, ensuring mechanical resistance of the entire joint and the immediate surroundings at least at the level of the rest of the undamaged cable.
Available Methods
There are several available methods and each requires different tools. Methods of conductive connection can be divided into hot / cold repairs and cable insulation into dry / wet ways.
By far the most productive method of repair uses a crimp connector which typically also includes insulation. In this case, two exposed wires are connected by deformation of the connector itself and subsequently insulated with integrated heat-shrink insulation. Many people do not trust mechanical connectors for current transmission and prefer soldering. However, this method is very reliable and proven, for example, by its abundant use in the automotive industry. For example, a large number of connectors in computers also use crimping techniques. The problem for the average person, however, is the need to use special pliers.
The best-known method of repair is probably classic soldering and then insulating individual wires using heat-shrink tubing. In this case, it is necessary to have a portable soldering iron (gas or battery) and have some skill in soldering. The disadvantage in some cases can be handling a very hot tool, which can damage the surroundings of the soldered place and melt plastic components.
A special category of the hot repair variant are solder sleeves with heat-shrink tubing, hot melt adhesive and solder. This all-in-one repair method has a huge advantage in that it requires only a common heat source such as a lighter as a tool. The disadvantages are similar to normal soldering and, moreover, with greater use, this method is probably a bit more expensive.
Sufficient mechanical and weather resistance of the entire joint can best be achieved using self-amalgamating tape or by sleeving the joint with a tube and filling the gap with glue or sealing putty.