#Gear guage zigzag lines how to

This level of sophistication is what truly sets apart working with a custom manufacturer over relying on off-the-shelf cable assemblies. As a custom cable manufacturer, we examine all of the nuances of a design in order to produce the best utilization of our client’s budget, given the parameters of the intended application. You might simply think you should always just use a larger gauge wire and be done but this blanket approach can prove inefficient, especially from a materials-cost perspective. In our AWG size chart, you’ll see this expressed as a measure of ohms per 1,000 feet. A larger gauge wire can help to make sure that the signal or current is able to travel these long distances without becoming too degraded. Longer distances lead to more resistance which can degrade the signal. With longer wires, the signal or current has to simply travel further before reaching a termination. Wire gauges have to be exact in order to create the ideal resistance level in a given custom wire and cable harness.Īnother important consideration is the length of the wire. A very small gauge wire might not be able to handle a given electrical load, which could prove dangerous and even cause a fire. The larger a wire’s circumference is, the less resistance the signal or current will have. Wire Resistance & Wire LengthĪWG helps to provide consistency to resistance and wire length as well since different gauges will have known levels. Diameters are calculated with this formula – D(AWG) = 0.005♹2 ((36-AWG)/39) inch.įor those that want to dig more into the technical side of electronic formulas like this, we recommend a mainstay in the industry known as the “Handbook of Electronics Tables and Formulas” by Howard Sams. The actual formula for figuring out the diameter of wire gauge is a little complicated but one our engineers use in our designs every day to find the perfect wire to match the application.

Conversely, a 3 gauge decrease doubles the wire’s cross-sectional area. For example, with every 6 gauge of decrease, you’ll get a doubling of the wire’s diameter. This is important because it helps to qualify a constant multiple from which the entire system is based. With 40 different gauge sizes between 0000 and 36, there’s a consistent geometric step with each successive AWG number. The ratio between these matters is exactly 1 to 92. Looking at an AWG wire gauge chart, you’ll see 0000 on up to 36 and beyond. For the purpose of this wire gauge guide, we’ll stick with the AWG. However, the AWG isn’t the only gauge measurement around with most of the world relying on a metric-based system for gauge measure. As we discussed, the larger gauge numbers expressed in an AWG size chart correspond to lower wire diameters and smaller gauge numbers mean larger diameters.īefore the AWG, different manufacturers had their own unique sizes and systems, making any form of standardization difficult. To answer questions like, “how thick is 4 gauge wire?”, you need to understand how the AWG wire gauge system works. In the custom cable manufacturing industry, exactness matters which is why even the smallest degree of error needs to be corrected in a design before ever moving forward with production. This standardization helps our wire engineers start with materials with known electrical properties to provide the most effective designs possible. Wire diameter is critical in custom wire harness design as it helps to determine how much of an electrical load and the level of resistance, expressed in ohms (Ω). Non-ferrous metals, like aluminum and copper, make excellent conductors. It’s important to note that the AWG applies to round, solid, and non-ferrous wires. The AWG sets gauges in order to have a unifying system of measure with wires and conductors. The AWG sets corresponding numbers to different diameters of wire gauge.Ĭontrary to what you might think, the lower AWG numbers actually correspond to wires with higher diameters and the larger numbers in the AWG wire gauge size chart correspond to smaller diameters of wire. The diameter of a wire is expressed in a unit known as a gauge, as set by the American Wire Gauge (AWG).

#Gear guage zigzag lines how to

In today’s LiveWire spotlight, we’ll showcase a complete wire gauge guide focused on topics like wire gauge sizes, how to measure wire gauge, and how to choose the right wire gauge in custom cabling applications.įirst up, what does gauge mean in wire harness design? Wires are produced in a wide variety of widths in order to meet the needs of the project. That’s why our designers take such care when designing custom wiring harnesses to incorporate the perfect gauges to meet the needs of the project. Wire gauges help determine the effectiveness, as well as the costs of the overall design.