Choosing the best connectors and terminals for your application is important when customizing an electrical wire harness for your application to assure consistent and proper connectivity, data and power transmission.
Connectors (most often specified as UL Listed) connect similar electrical conductors (e.g. one wire to another) to create an electrical circuit while helping prevent exposure to hazardous environmental factors such as moisture, abrasion, and electromagnetic interference.
A terminal refers to a type of connector used at the point where a conductor comes to an end (e.g. fixed post, stud, chassis). It also can refer to the endpoint itself. All terminals are connectors, but not all connectors are terminals.
Because connectors and terminals come in a wide assortment of shapes, sizes and materials, it helps to know your options to pick the right ones for your wire harness.
For expert guidance when choosing the best connectors and terminals to choose for your custom wire harness, we’re here to help!
Connectors are typically one of two mating types: either male (plug) or female (socket/jack). To make a connection, the plug is inserted into the socket. An extension cord plug and electric socket are a good example of male and female connectors.
To determine the appropriate connector type to meet the performance needs and conditions your wire harnesses will be under, you’ll need to consider certain factors, such as:
Here are some of the most popular connector/terminal options, typically available in both insulated and non-insulated, that often are able to be either crimped or soldered to the conductor.
Ring Terminals
Round-ended ring terminals allow for easy, semi-permanent attachment to screws or studs, which won’t separate from the terminal block until the fastener is removed. That makes them the most secure type of tongue-style terminal available.
Fork Terminals
Ideal for wire harnesses with tight space limitations, fork terminals — also called spade tongue terminals — have an open-ended, fork-like head that allows for easy attachment and removal from screws and studs.
Hook Terminals
Offering similar convenience and ease-of-use to spade terminals, hook terminals’ open hook shape makes them slightly less reliable than ring terminals because it is detachable without removing the fastener.
Quick Disconnects
Designed for rapid mating/unmating, quick connects — also called tab terminals, slip-on, or fast-on connectors — are widely used in industrial and consumer applications which involve frequent repair or replacement, and are easily mated/unmated with a straight push/pull.
Flag Terminals
Featuring crimped barrels perpendicular to a tang/stud hole centerline that resemble a flag on a pole, these terminals offer a unique option for tight spaces and hard-to-reach angles.
Bullet Terminals
With a bullet-shaped male designed to connect with a hollow bodied socket-shaped female connector of the same size, bullet terminals snap together easily and maintain a tight hold.
Ferrule Terminals
Ferrule terminals have barrel-shaped caps that slip over and completely cover frayed wires, providing a more reliable connection to a terminal block.
Butt Terminals
Often used to extend wiring, butt connectors, which are also called crimp-type connectors, bring together two wires in a sheath-like tube allowing for easy crimping and added protection.
Not sure which connector and terminal options are best for your custom wire harness? Start a conversation with us today.
Plug connector is the core component of the wiring harness.The performance of the connector directly determines the overall performance of the wiring harness and plays a decisive role in the stability and safety of the whole vehicle.
Selecting the connector is very important as there are many features relating to it. During the selection, revise and ensure the following aspects:
· Anefficient contact with the electrical components
· The contact resistance to a minimum
· Improve reliability
· Preferred dual spring-loaded structure of the connector
According to the wire cross-sectional area and the size of the current through the rational choice of connectors.
Due to the cabin temperature, humidity and the existence of a large number of corrosive gases and liquids can get affected. For this reason, make sure to choose waterproof jacket.If it is the same harness with the same sheath, the color must be different.
Based on the overall coordination of the exterior of the vehicle, a black or dark jacket should be preferred in the engine compartment.
In order to reduce the type and quantity of the connected harnesses, the hybrid type is preferred because the assembly is easy to fix.
For the requirements of high performance airbags, ABS, ECU, etc. with the terminal connector, a preferred gold-plated pieces are preferred in order to ensure safety and reliability.
Battery connector (battery clip) is preferred for the internal cone, taper 1: 9; battery clip material is tin-plated copper, zinc-plated copper or lead antimony alloy.
Different series of connectors can carry the following current:
· 1 series,
· 10A or so; 2.2 or 3 series
· about 20A; 4.8 series,
· bout 30A; 6.3 series
· 45A; 7.8 or 9.5 series
· 60A or so.
1. Sheath material (plastic parts)
The most common sheath materials are:
· PA6
· PA66
· ABS
· PBT
· Pp
Among others.
Design plug-ins can be selected according to different needs of different materials, but also in accordance with the actual situation in the flame-retardant plastic materials or enhancements to achieve enhanced or flame retardant purposes, such as adding glass fiber reinforced.
2. Terminal material (copper)
Copper connectors are mainly made of brass and bronze. The hardness of brass is slightly lower than the hardness of bronze.Additionally, different coating can be chosen according to different requirements.
Automotive wiring harness consists of the general use of rubber pieces to transition regarding the wear-resistant play, waterproof, sealing and so on.
It occurs mainly in the following parts:
· The engine and the cab interface
· The front cabin and cab interface (about 2), four (or back door)
· The compartment interface
· The fuel tank entrance
Commonly used materials are:
· Generally natural rubber
· Neoprene
· Silicone rubber
· EPDM
Among others.
This material is very elastic and mechanically strong, with an excellent flex resistance. Some of the factors that make it very valuable are its higher tear strength and amazing cold resistance.
Disadvantages:
· Anti-aging hasn’t shown great results
· The absence of oil and ozone
· Flammable
Neoprene is ozone resistant, it has a heat aging, oil and other properties that function perfectly. It is flame retardant and self-extinguishing.
Disadvantage:
· Poor low temperature resistance
Silicone rubber is heat and cold resistant, which is very beneficial. The weather resistance is improved as well so these problems are easily avoided.
Disadvantage:
· The absence of oil
Being weather resistant, ozone resistant, heat resistant and corrosion resistant, EPDM already offers so much. Apart from the resistance, acid, alkali and other properties are of decent quality and a great strength and high rate of expansion are also provided.
Disadvantages:
· Poor adhesion
· No natural flexibility
· Poor oil resistance
In comparison, the overall performance of EPDM is the best. Therefore, the automotive wiring harness with rubber parts generally use EPDM material because of all the benefits mentioned above.