Finding the right connector or cable for your device has always been a challenge. You might encounter problems such as mismatched wire ends, unsatisfactory performance, and inefficient assembly, etc.
This Guide will help you determine the types of connectors and clearly understand how to choose the appropriate connectors for your device.
Types of Connectors (Classification by appearance)
Circular Connector
The circular Connector was initially applied in the military field and performed well in harsh working environments. The wide application range of the circular connector accounts for its convenience in signal manipulation.
In the aerospace, mining, electricity, and transportation industries, circular connectors can exhibit excellent performance, such as small volume, moisture resistance, corrosion resistance, signal transmission stability, and vibration resistance.
If your device has extreme durability requirements and your cost is limited, consider using integrated injection-molded circular connectors. This type of connector can reduce bulk procurement costs while maintaining high-quality levels, providing durable materials for your production line.
Rectangular Connector
The rectangular connector is designed as a rectangular pin array. Unlike circular connectors, it has more pins and more integration but is less water resistant. It’s more suitable for the interiors of your devices, such as in-car electrical modules.
Additionally, it can be used in onboard terminals, BMS battery systems, and various cable bundles in cars. For automotive manufacturers, it’s the most demanded type of connector in your field.
Types of Connectors (Classification by link)
Board-to-Board Connector
The board-to-board connector has a small volume and high density; it plays the role of linking device rails and metal cases. It’s usually composed of three parts: the Header, the Receptacle, and the auxiliary structures.
It’s widely used in consumer electronics (such as mobile phones, smart wearables), automobiles, and industrial communication. For instance, the RAM slot of IPC devices is a kind of board-to-board connector.
However, it requires a high standard of PCB alignment parity; you should replace the entire circuit board when failure occurs. So low-cost alternatives can be a good choice, helping you reduce costs and improve productivity.
Wire to Board Connector
The wire-to-board connector acts as a link between the cable bundle and the PCB circuit board.
Structurally, it’s similar to a board-to-board connector: the board end is the header; the cable end is the receptacle. The cable bundle can be connected directly to the PCB through this connector. In most cases, the wire-to-board connector is a rectangular connector rather than a circular one.
Additionally, the mold of this connector can be reused to support large-volume production orders, providing a safeguard for your device production.
Wire to Wire Connector
Unlike wire-to-board connectors, wire-to-wire connectors are mainly circular connectors, suitable for external connection scenarios that require waterproof performance.
Most wire-to-wire connectors are modular connectors. Their installation method is convenient. They can be installed by a compression method without welding, which reduces manual costs. Meanwhile, assembly-style components also ensure good device consistency, suitable for long-term use.
The number of pins of the wire-to-wire connector can be customized and has a wide range of applications. For instance, you can use the 4-pin connector for small appliances, and the 16-pin connector for car electronics. Whether you need to develop new products or mass-produce mature devices, a wire-to-wire connector is a wise choice.
Types of Connectors (Classification by function)
Plug and Play Connector
PnP (Plug-and-Play) connector does not require manual welding and debugging. They can be directly plugged in and unplugged during use. Wire-to-wire connectors and wire-to-board connectors mentioned above are both typical examples of PnP connectors.
Being different from traditional welding terminals, plug-and-play connectors perform better in mass production. They can reduce equipment failure rates and costs, improving your production efficiency.
Latch/Thread Locking Connector
The latch-locking connector consists of a plug, a socket, and a latch. The essential feature is having screws that can completely lock the header and the receptacle. This robust structure makes sure latch locking connectors have ultra-strong self-locking, loosening-resistant, and shock-resistant performance.
The external seal ring can achieve IP65/IP67/IP68, maintaining stable contact and repeatable plug-and-switch use. It’s more suitable for use in aerospace, industrial, military, and vibration equipment than normal plug-and-play connectors.
When your device is required to work in an outdoor, wet, or high-vibration industrial environment, a latch locking connector must be used. Of course, small appliances and indoor devices can use ordinary wire to connect to the board connectors.
DedicatedConnectors
Terminal Connector
A terminal connector is a component consisting of metal terminals and shells, supporting connection methods such as wire-to-wire or wire-to-board. It’s easy to disassemble, conducive to electricity reliability, and vibration-resistant.
Terminal connectors come in many shapes and specifications, such as ring terminals and bullet-shaped terminals. Different structures correspond to different equipment requirements, such as ring terminals that are not easily dislodged, making them suitable for high vibration environments such as cars and aerospace.
If you produce line bundles, new energy devices, and encounter problems such as unstable wiring, easy detachment, or installation difficulties, you can consider using terminal connectors to make your device reach a higher quality.
Coaxial Connector
The coaxial connector is specifically used for signal transmission. It has needles inside and is encased in shielding material. The shielding material is resistant to electromagnetic interference, ensuring the safety of high-frequency electrical signals. A coaxial connector can be waterproof, dustproof, or reinforced for outdoor and vehicle environments.
If your device has communication requirements such as wireless cameras, routers, or medical detection devices, coaxial connectors are the first choice.
Basic Principles of Choosing Connectors
There are several factors you need to know when selecting the type of connector.
Device performance:
Focusing on the versatility of the connectors, using more general models can reduce costs and material types.
Pay attention to the structural size of the connectors. Usually, there are space limitations in your device. Choose the right size and shape of connectors based on the production order and the installation part of your device to ensure productivity.
Pay attention to the connectors’ impedance and load to avoid signal transmission problems.
Scene:
Is your device mainly used outdoors or indoors? If outdoors, you need to consider water and dust resistance. Especially when the working condition is corrosive, you can choose a circular connector or a latch locking connector to ensure sufficient durability of your device.
If your device operates mainly indoors, consider using a regular plug-and-play connector, which can be easily and quickly plugged in and unplugged, saving manpower.
How to connect:
Which two parts do you need to connect? If you need a board-to-board connection, choose a board-to-board connector. Similarly, if you need a cable to board connection or any other type, choose the corresponding connector.
Application type:
What does your device need to transmit? If you need to transmit large currents, consider using circular or rectangular connectors; if you need to transmit high-frequency signals, use coaxial connectors.
Of course, selecting a connector should consider more. Please consult an experienced manufacturer for further information.
FAQs
Q1: What to do if the wire to the board connector shows an abnormality?
First, make sure the connector specs are selected correctly and the installation direction is correct. Second, check the contamination and deformation of terminals. In addition, the assembly workers should comply with specifications, and the equipment environment should be dustproof and waterproof as well. If there are metrics that exceed the recommended values, you need to replace the corresponding components as soon as possible to ensure your production line runs properly.
Q2: What is a self-aligned connector?
A self-aligned connector is not a specific type of connector, but rather a feature of a connector. For instance, a board-to-board connector can have self-aligned functionality.
Specifically, connectors with a self-alignment feature have a structurally oriented or inverted design that helps the worker align during plugging. Without this feature, delicate pins are prone to wear and deformation.
Q3: How to save thread removal to improve assembly efficiency and consistency?
In the production process, there are numerous problems of manual operation instability. Traditional wire bundle assembly requires manual removal of the insulation layer and then assembly. This method is very cumbersome, inefficient, and has a risk of damaging materials and causing poor contact.
In order to solve the problems above, you can use IDC (Insulation Displacement Connector). It has metal blades inside. This technology can complete the wire removal steps itself. And let IDC greatly improve core stability and production assembly efficiency. Provide reliable connectivity for your industrial, vehicle, and high-speed signal transmission devices.
Conclusion
In conclusion, there are many types of connectors. Choosing the appropriate connector can help you significantly avoid rework risks for your devices. Typically, it is best to consult experts in the manufacturing field.
ECOCABLES explores connectors in relevant fields and can accurately match connectors for you. Besides, ECOCABLES supports customization, solves connector selection and cable bundle problems in one place, taking your device to the next level with professional connectors and bundle services.
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