The Importance of Wire Harness Connectors

26 Aug.,2024

 

The Importance of Wire Harness Connectors

A wire harness is a specially-designed bundling system used to keep numerous wires or cables organized. Rather than manually routing and connecting every individual strand, wires are cut to length, bundled and clamped to terminal or connector housings to form a single piece. This compact, organized arrangement allows for drop-in installation to reduce labor time and human error, and enable technicians to fit complex wiring assemblies into small or hard-to-reach spaces.

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Wire harnesses involve dozens of individually-overmolded wires that branch off into different directions and junction points. Due to their often-complex design, low-quality wire harnesses can have several serious issues, especially at termination joints. No connector, no electricity. This is why high-quality wire harness connectors are the hallmark of a reliable, well-manufactured product.

Common Wire Harness Connector Issues

When selecting high-quality connectors for your wire harness, function should dictate design features. Herein lies the problem. Without a working knowledge of how every connector component contributes to performance, developers often end up with a poorly-designed product.

Wire Harness Connector Issue - Contacts

Contacts are one of the most common points of failure in wire harness connectors. Contacts are tiny metal pins and parts that touch to form an electrical connection. If the connector is not properly protected, contacts can become grimy or corroded, which will affect the flow of electricity. Additionally, the contacts within wire harness connectors have a finite life span. If contacts are not designed for the number of mating cycles required, they can lose their springiness over time, causing the connector to fail prematurely.

Wire Harness Connector Issue - Crimping

Most wire harnesses use a crimping technique to adjoin wires to connectors or terminals. Crimping involves the use of a specialized tool to create a gas-tight fusion between the two parts. However, if the incorrect technique is applied, loose crimps can allow moisture to penetrate the joint and cause corrosion. As a result, wire harnesses can experience short circuits, open circuits or total electrical failure.

Wire Harness Connector Issue - Strain Relief

Strain relief is another issue common in low-quality wire harness connectors. Strain relief is a design feature that allows for the transfer of force in any direction to enhance the mechanical strength of the connection. If a connector doesn&#;t possess enough strain relief for the application, the wiring can pull apart from adjoining terminals.

Wire Harness Connector Issue - Overmolding

The overmolding material used to protect the connector will also significantly influence the life span of a wire harness system. Material selections are based on environmental conditions and the mechanical demands of the application. This chart breaks down the pros and cons of the most common overmolding materials as they relate to specific environmental and mechanical demands.

Given the complexity and importance of wire harnesses connectors, this is one electrical component in which you do not want to be frugal. You may find off-the-shelf options that work well for your application. However, we recommend choosing a connector engineer that can also customize products based on the demands of the application. iCONN Systems offers numerous tools and services to ensure you receive a high-quality connector that fulfills every application requirement.

Learn more about our standard and customized connectors.

What Are The Types Of Wire Harness Connectors And ...

Wire Harness Connectors And Terminals

Wiring harness connectors and terminals are crucial in joining the ends of wires or cable assembly within a harness. They facilitate secure and reliable connections between wire assemblies and electrical components like switches, sensors, connectors, or electrical circuit boards. These connectors come in various sizes, the wire-to-wire and the board-to-wire configuration, to cater to different applications, environmental conditions, and connection requirements.

Wire harness manufacturers prioritize thorough testing of the final product during the manufacturing process to ensure compliance with safety standards, assess functionality, and guarantee overall quality.

If you are looking for more details, kindly visit Suntex Electronics.

Conversely, wire harness terminals are specific components within a humble wire harness connector that interface with the wire ends. They are designed to hold the wire and establish electrical conductivity securely. Terminals can be metal pins, blades, sockets, or lugs integrated into the connector body. The weather-resistant connectors and termination methods determine the appropriate connection type, like crimp barrels, insulation displacement slots, solder cups, or screw terminals.

Wire harnesses provide protection against extreme temperatures, dirt, contaminants, dust, constant vibration, and moisture. They are classified as male and female, with plugs typically serving as male connectors and jacks as female wire harness connectors.

Backshells are commonly used with circular connectors in industrial and high-reliability applications to protect from environmental factors, mechanical stress, and electromagnetic interference. Military and aerospace backshells adhere to regulations like SAE AS in the USA.

Types Of Wire Harness Terminals

1. Crimp Terminals: Crimp terminals are the most widely used single or multiple wire harness terminals. They consist of a metal barrel or sleeve that is crimped onto the stripped end of a wire. Crimp terminals come in various designs, such as butt connectors, ring terminals, spade terminals, hook terminals, bullet terminals, and pin terminals. They provide a secure mechanical and electrical system by compressing the metal barrel around the wire, ensuring good conductivity and preventing wire pullout.

2. Insulated terminals: Insulated terminals have plastic or rubber insulation covering the metal barrel or sleeve. The insulation provides electrical insulation and protection against moisture, dust, and vibration. Insulated terminals are commonly used in automotive and industrial applications where environmental factors are a concern.

3. Heat-shrink terminals: Heat-shrink terminals are similar to crimp terminals but feature a heat-shrinkable insulation sleeve. When heated, the insulation sleeve shrinks and conforms tightly around the wire and terminal, providing excellent insulation and protection. Heat-shrink terminals are often used in applications requiring a waterproof or sealed connection.

4. Solder terminals:  Solder terminals have a metal barrel or lug soldered to the wire. The solder forms a strong and permanent connection, ensuring electrical conductivity and mechanical strength. Solder terminals are commonly used in applications where a high level of reliability is required.

5. IDC (Insulation Displacement Connector) butt terminals: IDC butt terminals allow for quick and easy connection of wires without stripping or crimping. They feature sharp metal contacts or blades that penetrate the insulation of the wire when pressed, making a connection with the conductor inside. IDC terminals are commonly used in modern technology like telecommunications, data communications, and computer applications.

6. Screw terminals: Screw terminals have a metal terminal block with a screw that clamps down on the wire, creating a secure connection. Screw terminals are often used in applications that require frequent connection and disconnection, as they offer easy and reliable wire termination.

7. Push-on terminals:  Push-on wire harness terminals, also known as quick-disconnect terminals, feature female connectors with tabs or blades that provide a secure connection when pushed onto a corresponding male terminal. They are widely used in automotive and appliance applications.

It&#;s important to select the appropriate types of wire harness fork terminals based on factors such as wire gauge, current carrying capacity, environmental conditions, and the specific connection requirements of the application. Proper installation techniques, including crimping or soldering, should be followed to ensure reliable and durable connections within the wire harness.

For more information, please visit Automotive Electrical Harness Connectors.