5 Must-Have Features in a connector industry

14 Apr.,2024

 

At some point during the design of your machine or equipment, you will need to join two or more electrical components together. This could be in order to enable communication; transmit a signal or distribute power these are all needed for the proper functioning of your system or electronic devices. This is where industrial connectors come in. Industrial connectors are devices that are used to join electric circuits, the duration of this connection can be temporary or stay connected for almost the entire service life of a machine. Mostly we use connectors for things that need to be plug and unplugged often. When these connections are temporary it is best if they can be disconnected manually, but some do require the use of special tools.

Industrial connectors make it easier to assemble and manufacture machines. They are widely used for communication signals and power connections in machines, computers, and many electronic and industrial devices. Generally, there are six levels of "interconnection" - level 0 through 5. The 6 classifications start at the chip level (0) and go all the way up to connecting systems together (5) like your PC and monitor.

Ref: Connector Basics: Three Types of Electrical Connectors Article|March 2, 2021

We will quickly talk about the 4 most important levels for industrial equipment, control panel and machine building. Based on their termination ends, these connectors are classified into three areas:

1. Board-to-Board connectors: When you need to connect printed circuit boards (PCB) together without a cable, a board-to-board connector is ideal. Board-to-Board connectors can connect one PCB to another PCB and thus eliminate cables, and because of this, they are ideal for systems with limited space. 


 2. Cable-to-Cable/Wire-to-Wire connectors: Simply put, cable-to-cable connectors are used in connections where two wires or cables need to be connected together. In this case, one end of the connector is permanently fixed to the wire and the connector forms a separable interface. Now your wire can be plugged and unplugged whenever necessary. 

3. Wire-to-Board connectors: The wire-to-board connector is ideal in situations where a cable/wire is to be connected to a PCB. In most cases, the wire connections are like those used for wire-to-wire connection, but the PC board connections will press-in or soldered two-piece connectors.

4. Panel Feed-through (connector and receptacle): Also called panel mount connectors and bulkhead connectors, this connection type is for feeding a wire or cable through a panel that will need the ability to be disconnected later. One of the important features of a connector like this is that they are typically going to have an environmental seal. Since these are usually found on an enclosed electrical or electronic cabinet the seal will usually carry an IP rating. Some are even potted so they remain sealed even if the mating connector is not plugged in.  

 

Since industrial connectors are bound for harsh and rugged environments, they can be susceptible to failure and you need to look out for device damage, cracking, wearing, and fretting fatigue. In order to avoid a machine disaster, it is important that you are aware of the factors to consider when choosing an industrial connector. This is exactly what you will get by the time you're done reading this article - the ability and confidence to choose the right connectors for your devices.

Quickly educating yourself, or asking the following questions, before connector selection will put you on the path to success.

 

1. Wire gauge

A wire gauge measures a wire’s cross-sectional area, and it determines the resistance, weight, and amount of safe electrical current a wire can carry. Usually, the larger the cross-sectional area, the lower the resistance and the greater the amount of current the wire can carry. Therefore, a wire with a smaller gauge (has a larger cross-section) can carry more power than one with a larger gauge number. It is important to take this into account and use the proper gauge wires that match your connector and electrical parameters.

Quick Note on Wire Gauge - North America and other parts of the world use the AWG (American Wire Gauge). In Britain, it is measured in SWG (Standard Wire Gauge), while Europe and some other parts of the world use mm² (IEC 60228) which is a reference to the wire cross section, the amount of copper that can carry current, as opposed to a "wire diameter" that includes the insulation.

2. Current rating

Current rating is the level of current that an appliance or other device can carry continuously, with complete safety. Ensure that the connector’s current rating matches the current-carrying capabilities of the individual terminals being connected. You may also want to make sure your device has the proper safety approvals for the jurisdiction (location) your machine will be used in, such as UL, NFPA, and CE.

3. Environment

When selecting a connector type, it is very important to consider the environmental conditions because not all connectors can function effectively under certain conditions such as extreme temperature, submersion in water, and other unusual environmental conditions. Industrial connectors can be ruggedly designed with metal housings, special exterior coatings and innovative materials for sealing and anti-mold. Connectors should also be able to protect the signal from electromagnetic interference, not add to EMC complications. Connectors with plated metal shells or conductive gasket help in this regard to protect components from radiated Electromagnetic Interference (EMI). Electromagnetic compatibility (released energy) from surrounding devices is also a consideration of the equipment you are building, if it is a power connector you may also need a shield to make sure you are building an EMC compliant machine.  

 

4. Standards approval

Try to ensure that the electrical connector system has been tested to meet the standard requirements of the local governing approval agency. In North America it is UL approval and NFPA that you will be answering to. In other parts of the world you will find IEC, CEE, and CENELEC are the standards you want to follow. There are also industry specific connector standards for the automotive industry like SAE, or the semiconductor industry, SEMI agency. Examples of standard tests performed on connectors include:

  • UL 1977 - C

    omponent Connectors for use in data, signal, control, and power applications

  • NFPA 70 NEC Article 110.3 - A device that establishes a connection between two or more conductors w/o the use of solder

  • EIA-364 - Electrical Connector Performance Test Standards

  • GMW 3191 – Automotive connector test and validation specification

  • IEC 60512 - Connectors for electrical and electronic equipment - Tests and Measurements

  • MIL-STD-1344A – Military standard, test methods for electrical connectors

  • SAE USCAR2 - Performance specification for automotive electrical connector systems

  • SAE USCAR21 - Performance specification for Cable-To-Terminal electrical crimps 

A Cat.6A connector with zinc die-cast housing, suitable for application in the railway industry

 

5. IP Rating

An IP Rating describes the level of protection provided by a connector against the intrusion of solid objects and liquids. An IP Rating usually has two numbers: The first number represents the level of protection from solid materials and the second number represents the level of protection from liquids. A third letter describing other information such as impact resistance, can be used, but is often omitted.

When choosing exposed external connectors that could allow water or particles to enter the equipment, the connector selection should include an IP rating. You will need to review the applications environmental conditions to ensure a high enough IP rating is considered. This is referred to as the required minimum protection based on the application's intended use. The higher the IP number, the more it is sealed from the outside environment. 

 

 

6. Engagement force

The effort needed to mate, join, or engage the two populated electrical connection sides is referred to as engagement force. Total engagement forces for some connection families in high circuit count applications can reach 50 pounds or more, which may be too much for some assembly operators or in situations where the electrical connectors are hard to access. In contrast, a high engagement force may be preferred in heavy-duty applications so that the connection can endure frequent jostling and vibrations in the field.

 

TL; DR

In too much of a hurry to read it all? Here's a summary:

- Industrial connectors are devices that are used to join electric circuits to enable communication, signal transmission and power distribution that are required for the proper functioning of your machine.

- Generally, there are six levels of interconnection within industrial connectors - level 0 through level 5, each situated in one or more closed paths to perform a desired electrical or electronic function.

- Industrial connectors are classified into four types based on their termination ends: board-to-board connectors, cable-to-cable connectors, wire-to-board connectors, and panel feed-through.

- The 6 important factors that you should review next time you choose an industrial connector are wire gauge, current rating, environment, standards approval, IP rating, and engagement force.

 

When selected properly, industrial connectors drastically reduce the time, effort and manpower needed for the manufacturing, assembling and installation of your devices, components, and wiring.

If you find our article on Choosing the right connectors useful, you may also want to check the various types, components, and applications of industrial connectors.  We would love to have you join other machine and electrical control panel builders on LinkedIn where we share insights and stories that are helping engineers build awesome products and get those products to the market faster. 

Should you need help in any way for your industrial connectors needs or other electrical control components, feel free to reach out to us.

 

 

We usually never give the electrical connector a second thought. They sit at the end of the product, and we mostly ignore their importance.


Electronic equipment will not work without electrical connectors! You have to count in several factors while choosing a connector- what will be the cost factor? Where will be the connectors used? What should be the spacing and pin count?

Surely, there’s a lot of things to process. To help you out, we are going to take an in-depth look at electrical connectors in this article. By the end of the guide, you will know all you need to make an informed decision and choose the best product. 

Table of Contents

Chapter 1: Electrical connector

What is a Connector

Electrical connectors allow you to join various components of an electrical circuit like wires and cables. The connectors create a continuous path for the electrical current to flow through the connection or circuit.

Connectors can come with male-end plugs or female-end jacks. You can join them together to form a temporary or permanent connection based on your needs.

Electrical connectors facilitate manufacture, assembly and installation of electrical devices by cutting down labor, time and effort. Electrical connectors are widely used in electronic devices, domestic appliances, telecommunication, industrial machinery, computers, and automobiles.

Here’s a video of how connector blocks work-

Electrical connector–Basic Composition

Electrical connectors consist of mainly two parts- the housing and terminal.

Housing:

The housing is the case which contains the terminals. Housing stabilizes the connection and keeps the electrical contacts safe from environmental hazards and short-circuits.

Generally, manufacturers use molded plastic for the housing, but you can also use other insulating materials like ceramics.

Terminals:

Terminals refer to the pins on the connector that establish the electrical connection. The Terminals are mostly made of metals, but you can also use other conductive materials like silicon or carbon.

Features of Connectors

You will need connectors with different features for some specific applications. Here are a few important features-

Keyed Connector:

Keyed connectors can only be connected when they are in the proper orientation. The design helps you connect in the right direction preventing damage to the pins.

Lock Connector:

Locked connectors come with a locking mechanism to hold the connectors in place. They prevent the connectors from dislodging or breaking away accidentally during movements or vibrations.

Sealed Connector:

Sealed connectors are used for applications that need to withstand water and water pressure. They can be used underwater up to certain depths.

Waterproof Connector:

As the name implies, the connectors are resistant to water splashed or dampness. But you can’t use them under water.

Moisture-Proof/Oil-Proof Connector:

The connectors are designed to protect the connections from oil or moisture damage.

Filter Connector:

Filter connectors protect the electrical connection from interfering electrical signals like electromagnetic interference (EMI) or radio frequency interference (RFI).

Shield Connector:

Shielded connectors protect the wiring and components from electrostatic discharge.

Now we will take a look at the different types of connectors. 


Chapter 2: Electrical connector–Types of Connectors

Electrical connectors come in all sizes and shapes. You can divide individual connectors into various types based on levels, application, and nature of terminals.

Connector Level

Electrical connectors can be classified into one or more categories, known as levels in the professional realm. The levels were put forward by various companies with the guidance of the National Electrical Distributors Association (NEDA). The levels include-

  • Wire-to-board or subassembly-to-subassembly level
  • Box-to-box or input/output level
  • IC chip or chip-to-package level
  • IC package or package-to-board level
  • PC board-to-board level

Main Connector Types

Let’s discuss some of the main types of connectors based on use.

1. Electrical connector–Audio and Video Connectors

Audio connectors connect cables to audio equipment for carrying electronic signals. You can use them to connect telephones, microphones, and speakers. Video connectors establish connections carrying analog or digital video signals. You can use them at the end of cables, connect electronic devices and other devices with video input or output.

The connectors have a male or female plug with shielded cables.

2. Electrical connector–Automotive Electrical Connectors

Connectors are an integral part of modern automobiles using microprocessors and extensive wiring. The connectors enable connections with different interfaces required for the proper functioning of the automobile. Many vehicle systems like sensors, power windows, doors, and ignition system, need electrical connectors.

Automotive connectors can be of different types like power connectors, audio connectors, B-group connectors, C-group connectors, and D-group connectors.

3. Board Mount Connectors

Board mounted connectors are also known as circuit board connectors and used to connect components on a computer board. The connectors are embedded on the boards, and you can customize them to meet various applications.

Board mounted connectors take help of pins to establish a connection between boards. You can also use them to connect USB or audio wires to the board.

4. Board to Board Connectors

Board to Board connectors are ideal for connecting printed circuit boards or PCBs. Each terminal of the connector links with separate PCBs to create a continuous connection. 

The biggest advantage of the board to board connectors is that you don’t need to use wires. The connectors are generally made of plastic and have metal pins or connectors.

5. Circular Connectors

Circular connectors come with multi-pin connectors and applicable for external interfacing. The connectors are useful for transferring data, the transmission of electrical signals and relaying power to devices.

Circular connectors are also called power and control connector as they can carry mixed signals. In industrial applications, the housing is either made of plastic or metal and fulfill the needs of a reliable and secure connection.

6. Coaxial Connectors

Coaxial connectors or coax are used to transmit radio frequency (RF) signals for CATV applications. The connectors have an insulated conductive inner wire covered in a shielding conductor. On top of that, you can find another insulating or protective layer.

Coaxial connectors are designed to carry a huge amount of information. They are also common connectors used in most home video installations.

7. DIN Connectors

DIN connectors follow the standards created by the DeutschesInstitutfürNormung (DIN), a German organization for establishing national standards. The DIN connectors are commonly used in various applications like network, microphone, audio, video, data, and telephone.

DIN connectors can be both male and female and can carry high-frequency signals through multiple pins. Computers also use DIN connectors to connect microprocessors and RAM.

8. DB Connectors

DB connectors are officially known as D-subminiature connectors and used in data, computer and audio/video applications. The name comes from the “D” shape of the connector which houses two rows of pins. You can find DB connectors like DB9 and DB25 in serial and parallel port connections in PCs.

DB connectors may also have thumbscrews to secure them in place.

9. Edge Connectors

Edge connectors or edge card connectors form an external electrical connection by pairing with single-sided or double-sided PCBs. They are embedded on the board and follow industry standard power specifications like power requirements, pin locations, and voltage levels.

The housing is made of plastic while the contacts use metal and come plated with a metallic coating for improved conductivity.

10. IC Interconnect Components

IC Interconnect connectors create a connection between PCBs and microelectronic semiconductor chips. The device closes the gap between two conductors allowing the transmission of current or light waves between the conductors. The package comes with an integrated circuit (IC) on a metal die along with an enclosure made of metal or plastic.

IC Interconnect components are an important part of many present-day electronic systems.

11. Instrument and Computer Power Connectors

Instrument and computer power connectors connect the power supply from the SMPS to various devices such as hard disks, CD and DVD drives, cooling accessories such as fans and thermal coolers and more.

The connectors use a plastic housing with four wires that carry 5V and 12V power and two grounds. They often have different features based on the application.

12. Medical Electronic Connectors

Medical electronic connectors are used in various medical equipment and devices found in clinics, hospitals, and other healthcare facilities. They can be of various types based on application and include circular connectors, coaxial connectors, micro connectors, and heavy-duty rectangular connectors.

Medical connectors can be both male and female.

13. RF and Microwave Connectors

RF and microwave connectors connect the end of cables of devices that use radio frequency or microwave spectrum. The connectors are used to transfer electromagnetic energy and RF signals in case of wireless broadcasting or communication.

The connectors are also commonly found in transmission systems and can couple and uncouple system components.

14. Solar Connectors

Solar connectors are quite common in solar energy systems. The connectors can establish a connection between the solar modules and set up a complete electrical system for your property.

You will mostly see the MC4 (multiple contacts, 4 mm pin) connectors which match with most models of solar modules. The male and female ends can be easily connected using hands, though you will need a tool to detach them.

15. Solenoid Valve Connectors

Solenoid valve connectors are used to form a connection between pressure switches and solenoid valves. The valves also serve the purpose of environment-proof junction boxes and can work with AC or DC voltages. The security boxes can function with pressure switches or solenoid valves.

Solenoid valve connectors have various standard specifications and feature options.

16. Terminal Blocks

Terminal blocks small insulated blocks that connect two or more wires. You can use terminal connectors to fix or terminate wires, and they come with multiple individual terminals. Terminal blocks are often used to secure wiring to ground, or connecting switches to the mains.

You can purchase terminal blocks with a different number of terminals and wire sizes.

17. USB Connectors

The USB connectors can connect devices using the Universal Serial Bus (USB) standard ports. USB has high data transfer speeds of 12 Mbps in the 1.1 version. Different computer devices and peripherals use USB connectors to connect with the PC, and even smartphone chargers need them.

USB connectors are available in USB-A, USB-B, UBS-C, and mini/micro-categories. USB comes with hot plugging and plug-and-play feature.

18. Wire to Board Connectors

Wire to board connectors are connectors attached with wires which interconnect PCBs. The terminals are placed in individual housing to establish connectivity between circuits. The connectors feature a locking technology to secure them in place.

You can find a wide variety of wire to board connectors including FFC connectors, IDC connectors and RMC connectors. FFC connectors are ideal for connecting a bunch of wires to carry data from the board to board or from one part of a board to another

19. Wire to Wire Connectors

Two wire-terminated connectors can be connected using wire to wire connectors. They can serve as electrical connectors, electronic connectors or computer connectors. Male wire to wire connectors plugs into the female wire to connectors to form a connection

Chapter 3: Material of Connector

Electronic or electrical connectors are made up of insulating and conductor materials. The common materials used to make connectors include plastic and metal, though you can also use other materials. The conducting material is of importance as they impact the electrical contacts such as mechanical durability, conductivity, resilience, and formability.

Some common terminal materials you can use are-

Brass

Brass is the cheapest metal you can use in terms of weight. Generally, the zinc content in brass can range between 5% to 40% based on the application. Brass offers considerable strength, good spring and adequate electrical properties.

Brass connectors are mainly used for KK terminals.

Phosphor Bronze

Phosphor bronze is tough and offers increased strength compared to brass. It comes with impressive conductibility and superior fatigue resistance. Phosphor bronze also has excellent elasticity making it suitable for use in electrical contact springs.

Beryllium Copper

Beryllium copper is the best type of copper alloy for spring terminals. It contains around 0.5% to 3% beryllium with other elements. The alloy offers high strength and is cheaper than phosphor bronze.

High Copper Alloy

High copper alloys contain a high percentage of copper (more than 96%) and are suitable for demanding applications. The alloys have high strength coupled with excellent thermal and electrical properties. You can also use them in high-temperature settings as they don’t soften easily.

High copper alloys are mostly used in automotive applications.

n the next chapter, we will cover the considerations when choosing electronic connectors.

Chapter 4: Factors to Consider When Purchasing Electrical Connector

You have to consider many factors to choose the right connector for your application. Many types of connectors are available in the market, so make sure you choose wisely. Here are a few factors worth considering-

Cost

Cost is usually an important consideration for many engineers and manufacturers. After all, you want to have the best at the lowest price possible, right?

Even that is your goal, don’t make the mistake of choosing your connectors based on the only cost. You may end up with cheap products which don’t do their job and lead to the failure of your project.

So always look for quality and try to strike a balance with cost to enjoy the maximum cost-effectiveness.

Electrical connector–Environment

The environment where you will use the connectors is also crucial. Will the connectors be used on bare ground or in the water? Or in a boat? Will the connectors encounter extreme weather? Will the project involve vibrations and shocks?

Select the best connectors based on your use environment. You should go for connectors with environmental sealing if you need protection against dust, vapor, liquids or combustible gases.

Determine the level of safety you require and then choose the connectors. Also, keep the operating temperature range in mind while making your selection.

Signal Type

You will need to choose the connectors based on the signal they transmit. Signals can be analog, digital, or a combination of both. If the signal is analog, then what is the frequency? Does it involve audio or RF? What is the bit rate or clock speed for analog signals?

The type of signal decides the type of connector, pinout, and wiring you will need.

Remember that you cannot use certain signal combinations in the same connector. You will need to consider clearance distances and creepage for high-voltage pins. You can also go for a custom solution based on your unique needs and design specifications.

Power Level

The level of current passing through your connector will also influence your choice. For high current paths, you will need multiple larger and thicker pins. If you are dealing with high voltage, then go for a connector with more insulation. For high voltage pins, you may also need to consider clearance distances and creepage.

Electrical connector–Ruggedness

The frequency of your terminals determines the strength of the connectors you need. Will the terminal be often plugged in and plugged out? Choose a connector with appropriate ruggedness based on your application.

Conclusion

The electrical connector is important for the smooth operation of any electronic equipment. It’s always wise to go for reliable and quality terminals which ensure the success of your project. Get in touch with us today to get more information on electrical connectors and custom solutions.

5 Must-Have Features in a connector industry

Electrical Connector — Everything You Need to Know