Table of Contents

• Overview
• 1. Tools and BoM List
  • 1.1 Tools
  • 1.2 BoM List
• 2. Cable Length
• 3. Cable Strip
• 4. Cutting Cable Shield
• 5. Stripping the Wire Ends
• 6. Proper Usage of Crimpers
• 7. Preparing Grounding Cable
• 8. Hiding Shield Leftovers
• 9. References

Overview

This article shows how to prepare a shielded Rheonics sensor cable for the SME-DRM terminals, which accept wires of 0.2 - 1.5 mm² (AWG 24 - 16). It first lists the tools and parts you need, then goes step by step: cut the cable to length and strip the sheath 18 cm (7 inches) from the end, free the metal shield, strip each wire 9 mm and crimp an 8 mm ferrule on it, and turn the shield into a ground wire with a soldered eyelet, with heat shrink over every joint. Unused wires are neither stripped nor crimped. The mind map below shows the whole sequence.

1. Tools and BoM List

1.1 Tools

• Crimping Tool: Crimping tools are used to deform materials and create connections. To connect wires together or to other connectors, crimping is commonly used in electrical work.

Figure 1. Crimping Tool - 0.25-2.5 mm² (24-14 AWG). [1]

• Precision Micro Wire Cutter: A wire cutter or cable cutter is a tool that cuts wires and cables in a safe manner without damaging the insulation or conductors.

Figure 2. Precision Micro Wire Cutter. [2]

• Measuring Tape: A Measure Tape is a tool used to measure length.

Figure 3. Measuring Tape. [3]

• Stripping tool: Wire strippers are portable handheld tools used by workers, especially electricians, to remove the protective coating of electric wires for replacement or repair.

Figure 4. Stripping tool [4]

• Knife: A tool used to cut wires or cables.

Figure 5. Knife. [5]

• Soldering Equipment: A durable, permanent connection can be created by joining conductive metal elements with solder. Soldering machines are essential tools for building, modifying, and repairing electronics.

Figure 6. Soldering Equipment. [6]

• Hot air gun: Heat guns are devices that emit a jet of hot air toward a particular point or surface.

Figure 7. Hot air gun. [7]

1.2 BoM List

Table 1. BoM list

The terminals of the SME are rated for wires of 0.2 - 1.5 mm² i.e. AWG 24 - 16.

• Ferrule: Correct ferrule size must be selected based on the gauge of the wire, as a standard Rheonics uses ferrule with a pin length of 8mm and diameter of 1mm (cross-section 0.5mm²).

Figure 8. Insulated Ferrules (8mm Pin). [8]

• Solder wire: Solder wires are wires with a low melting point, used to create joints using a soldering iron.

Figure 9. Solder wire [9]

• Heat shrink tube: Heat shrink tubing is a common element in most electrical installations that protects wires from moisture, dust, abrasion, and sharp objects that might otherwise damage them.

Figure 10. Heat shrink tube [10]

• Eyelet: Eyelet fittings are used for mounting cable assemblies using screws, pins, rivets, and bolts.

Figure 11. Eyelet. [11]

2. Cable Length

Tools needed: Knife, Measurement tape

Take the cable and cut the required length for your application by measuring with tape. We recommend stripping out the cable sheath at 18 cm (7 inches) from the end as a suitable length to prepare the cables for attachment to SME-DRM.

Figure 12. Cutting cable to the correct length.

3. Cable Strip

Tools needed: Knife

Strip out the sheath with the help of the cutter and a previous cut.

Figure 13. Strip cable sheath.

4. Cutting Cable Shield

Tools needed: Knife, Cutter

1. Loosen the metal shield from the black cable cover and cut it out.

   
   

   

   Figure 14. Removing the cable shielding to get access to the internal wires.

   
   

2. With the help of the cutter, clean all the remnants from the shield and cable cover.

   
   

   

   Figure 15. Cleaning the cover remnants.

   
   

5. Stripping the Wire Ends

Tools needed: Cable stripper

Stripping the wire at 9mm from the end with the stripping tool.

Figure 16. Stripping wire end

6. Proper Usage of Crimpers

Tools needed: Crimping tool

Your crimping tool should have a nest for inserting the terminal. After inserting in the correct slot, squeeze the crimp tool firmly and release it to get a long-lasting, tight connection.

Twist the wire and crimp a ferrule on it using the Crimping Tool.

Figure 17. Crimping the wire end.

Final results after crimping all wires from the sensor cable.

Figure 18. Crimped wires.

7. Preparing Grounding Cable

Tools and parts needed: Soldering machine, Solder wire, Heat Shrink tube, Hot air gun

1. Now take the prepared sensor cable and the metal shield and put them together to one side.

   
   

   

   Figure 19. Metal shield thread prepared to be twisted.

   
   

2. Take a thin cable and strip both ends.

   
   

   

   Figure 20. Thin cable with both ends stripped.

   
   

3. Take the twisted metal shield of the prepared sensor cable and the stripped end of the thin wire and twist them together by adding some flux if necessary.

   
   

   

   Figure 21. Ground cable

   
   

4. Solder the joint obtained in the previous step using the soldering equipment and the solder wire.

   
   

   

   Figure 22. Soldering the joint from two wires.

   
   

5. Put a heat shrink and pull it back so it completely covers the solder joint. Apply heat with the air gun.

   
   

   

   Figure 23. Ground wire with Heat shrink

   
   

6. Soldering the ground wire in preparation for the eyelet.

   
   

   

   Figure 24. Applying soldering material to the ground wire cable end.

   
   

8. Hiding Shield Leftovers

Tools and parts needed: Heat Shrink, Hot air gun, Eyelet

1. Pull the shrink tube over the prepared sensor cable to cover the group of wires.

   
   

   

   Figure 25. Heat shrink tube pulled back in sensor cable cover

   
   

2. Blow hot air using the hot air gun at the shrink tube when oriented as instructed in the previous step.

   
   

   

   Figure 26. Hot air was applied to the heat shrink tube

   
   

3. Inserting the Heat Shrink tubing before soldering the eyelet.

   
   

   

   Figure 27. Inserting Heat Shrink tube

   
   

4. Soldering the eyelet with the ground wire.

   
   

   

   Figure 28. Soldering the eyelet with the ground wire.

   
   

5. Cover the eyelet with heat shrink and blow it with heat to secure the joint.

   
   

   

   Figure 29. Eyelet with heat shrink.

   
   

After all the steps are complete the final result for the SME-DRM sensor cable is as shown below:

Figure 30. Sensor cable assembly completed for use with SME-DRM.

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9. References

1. KNIPEX Tools, "5 3/4" Crimping Pliers for Wire Ferrules 97 62 145 A." [Online]. Available: https://www.knipex-tools.com/products/crimping-pliers/ferrules/crimping-pliers/9762145A. [Accessed: Sep. 29, 2026].
2. Ferrules Direct, "FD3101 - Precision Micro Cutters, Stainless Steel, Flush Cut Edges, Range: 28-14 AWG, 1 Piece." [Online]. Available: https://www.ferrulesdirect.com/products/fd3101. [Accessed: Sep. 29, 2026].
3. Civiconcepts, "How To Read Measuring Tape: Inches, Feet & Meters." [Online]. Available: https://civiconcepts.com/blog/how-to-read-measuring-tape. [Accessed: Sep. 29, 2026].
4. Ferrules Direct, "FD2810WS - Wire Cutting and Stripping Tool - 28AWG to 10AWG." [Online]. Available: https://www.ferrulesdirect.com/products/fd2810ws. [Accessed: Sep. 29, 2026].
5. Uline, "Uline Steel Utility Knife." [Online]. Available: https://www.uline.com/BL_1158/Uline-Steel-Utility-Knife. [Accessed: Sep. 29, 2026].
6. SCHOFIC Technologies, "SCHOFIC 937 SMD Rework Soldering Station." [Online]. Available: https://www.schofic.com/products/schofic-937-smd-rework-soldering-station. [Accessed: Sep. 29, 2026].
7. RS Components, "RS PRO EOT0202 500 °C max Corded 1.6 kW Heat Gun, Type C - EU (124-5159)." [Online]. Available: https://uk.rs-online.com/web/p/heat-guns/1245159. [Accessed: Sep. 29, 2026].
8. Distrelec, "RND 465-00566 - Bootlace Ferrule 0.5mm² White Pack of 100 pieces." [Online]. Available: https://www.distrelec.ch/en/bootlace-ferrule-5mm-white-pack-of-100-pieces-rnd-rnd-465-00566/p/30110345. [Accessed: Sep. 29, 2026].
9. RS Components, "RS PRO Wire, 0.71 mm Lead Solder, 183 °C Melting Point (800-7661)." [Online]. Available: https://uk.rs-online.com/web/p/solder/8007661. [Accessed: Sep. 29, 2026].
10. RS Components, "HellermannTyton Heat Shrink Tubing x 35mm Length 3:1 Ratio, ShrinKit 321 Series (380-03005)." [Online]. Available: https://uk.rs-online.com/web/p/heat-shrink-tubing/7114783. [Accessed: Sep. 29, 2026].
11. Vogt, "Solder Eyelet Tin-Plated Brass, 2007.68 (DIN 41496), datasheet." [Online]. Available: https://www.manualshelf.com/manual/vogt/2007-68/datasheet-german-english-french.html. [Accessed: Sep. 29, 2026].