Sep. 23, 2024
As someone who builds a lot of electrical things, one of the perhaps most unexciting yet fundamental subject areas is connectors. The range of connectors available and in-use today is trully astonishing. Big sellers like Digi-key/Farnell/Mouser literally have tens of thousands of product lines in their connectors category!
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With so many different types of connectors available, it&#;s often difficult to know what to buy, especially when you&#;re buying for general use and/or personal stock. On this page I&#;ll cover some of the most common connectors in use today, and detail crimping/tooling considerations.
Every connector system ever conceived has its own official crimp tool, in most cases the cost of these is over and above what any hobbyist could and would want to pay for a crimp tool.
I personally own many of the official tools but for cost reasons don&#;t necessarily recommend them.
Engineer PA-09 and PA-21For the past 5 years this page has been focused on comparisons with the above tools. Note that I do not recommend buying these. They are expensive, poorly finished, causing contacts to stick in the jaw, and the scissor type action makes it difficult to get sufficient force on the conductor part.
Several readers have written to me about this tool over the years &#; it&#;s generally well spoken of. I recently obtained a sample myself and can confirm that it&#;s a good option for those happy to spend a bit more. It tends to cost around $70-80 and has to be ordered from Japan.
It has two features which many generic tools lack:
It&#;s not a clear-cut winner however as it is more effort to use than the IWISS ratcheting tools and gets less consistent results, owing to the fact that crimping force is controlled by your hand.
IWISS have added an exact copy of this tool to their catalogue &#; IWS-L. Don&#;t expect it to be made to the same standard as the Hozan. Personally I would prefer they spent their efforts improving the mediocre results of their own designed crimp tools, rather than copying others.
Do your own research too. There are thousands of generic crimp tools out there. I cannot test them all.
These are four main differences:
Before I get started, let&#;s cover this one briefly with a simple diagram:
Correctly crimped contactWhen crimped properly, the strands remain individual even upon entering the insulation crimp, making the chances of strands breaking low.
Soldered contactWhen soldering, there is a very high chance that the solder will wick up the conductor, beyond the insulation crimp, making it very vulnerable to mechanical damage. In this situation, it only takes a small amount of movement to start snapping the strands at the invisible weak point.
Soldering doesn&#;t have any disadvantage in electrical terms, only mechanical. That make this method non-viable for production use; except under very controlled conditions with connectors that are designed for soldering. This having been said, I would recommend soldering in scenarios where connectors are carrying significant current, and the manufacturer tool is unavailable (see below).
Below is an interesting graphic from TE, from this video. On the left a cross section of a &#;gas tight&#; crimp, typical from a manufacturer original tool. The graphic on the right is the typical result of an off-brand tool. It&#;s important to put this into context however &#; gas tight crimps are only needed where contacts are used near their current rating, are expected to last a very long time, and/or the consequences of failure are serious.
Source: TE ConnectivityBack when I first started using crimp connectors, almost everything I built made use of cheap no-brand contacts with no particular care as to what they were plated with (not that it was ever specified anyway). Why waste money on name brand contacts when no-brand contacts work just fine?
Fast forward a few years, and I find that some of that equipment I built 3-5 years ago begins to malfunction. The problem was that I had mated contacts from two different eBay sellers with differing plating. The dissimilar metals in use corroded over the years ending in failure.
Attempts to save a few quid back then have now resulted in hours of profanities as all of those connectors have had to be re-crimped with name brand gold contacts.
If you are not on a tight budget, and building something that has to be reliable, and last &#; go straight for manufacturer original gold plated contacts . If buying Molex: 0.38µm &#;Selective&#; plated contacts are good enough (unless your creation is a life support system, or going to the moon).
Alternatively, if you don&#;t want to stump up for gold plated contacts &#; Tin plated contacts from known brands i.e. Molex / TE/ Amphenol / JST will last a lot longer than no-brand contacts.
Phosphor bronze and brass are both alloys of copper, however with different ingredients. Phosphor bronze contacts are generally regarded as superior as they are harder and retain their tension for significantly longer. Smaller brass contacts may need to be re-tensioned after 5-10 mating cycles. If a contacts material is not specified (i.e. it&#;s a cheap no-brand type) assume it&#;s brass.
There are other exotic materials used in contacts i.e. beryllium alloy however these tend to only be found in very expensive contacts (for example genuine Mini-PV).
These (and look-a-likes) are the most commonly used type by hobbyists. I have a separate page with a lot of detail relating to these.
Another range of common types used by hobbyists. There are quite a few to cover. I&#;ve detailed them on a separate page.
Connectors resembling these are produced by many manufacturers, most of whom are anonymous factories in mainland China, whose product is sold under a plethora of different brand names. For the most part, headers and housings mate and latch fairly well across brands.
As explained in the caption above, Molex/TE&#;s housing design is different to most no-name types of this connector. I&#;ve not been able to identify a well-known manufacturer who produces these with the longer (superior) polarising ribs.
Despite my dislike of Molex&#;s polarisation design &#; I don&#;t use the more common no-brand types anymore as several years ago I had a bunch of them fail after 18 months due to corrosion on the mating surface. I have since replaced all them with Molex Gold plated types which have now been running for 4 years without incident.
Numbers in bold can be changed to order connectors with a different number of positions.
Contact AWG 22-30 (Tin plated)08-50-Contact AWG 22-30 (Selective gold plated, mating surface only)08-55-Housing 3 position22-01-2035Housing 4 position (PC fan style polarisation)-Header 3 position (Tin)22-27-2031Header 3 position (Gold plated)22-29-2031Header 4 position (Tin plated, PC fan style polarisation)-Header right angle 3 position (Gold plated)22-12-4032Header right angle 3 position (Tin plated)22-05-7038Hand crimp tool AWG 22-- Molex KK100 crimp tool (mfg&#;d by Pressmaster Sweden)Crimped KK 254 contacts. Left: Contact crimped with PA-09, Right: Contact crimped with Original molex tool.Unfortunately there is no standard male connector in the KK 254 family, but this hasn&#;t stopped a slew of unofficial connectors from being produced. These connectors bear and extraordinary resemblance to the Molex SPOX series (SPOX is a similar, but incompatible type, which does have a wire-to-wire male).
Compatible KK 254 male connectorsAbove is a variety of Chinese manufactured connectors I&#;ve purchased off eBay and Alibaba which are designed to mate with KK 254 female connectors. They are only found in 2, 3 and 4 positions, because, these are the variants used for PC fans.
The quality of these is not comparable to that of the mating connectors, but perhaps this is not so surprising, given the intended market of these connectors.
A common 0.1&#; (2.54mm) pitch connector which is similar in appearance to Mini-PV / &#;DuPont&#; types, even mates with them but is quite different in design, in that the retention mechanism is part of the contacts, where as with Mini-PV it is part of the housing. It is manufactured by both TE and Molex with some minor differences. Chinese reproductions of this type are common.
If I were to start over, I would probably use these connectors in place of several others I commonly use, this is because it is truly a &#;do-it-all&#; connector family.
With 2.54mm pitch, they&#;re good for breadboard, strip board and anything else like it, they have a reliable and practical wire-to-wire male connector, they&#;re polarised, latching and contact positioning is very good i.e. in male housings they don&#;t flop around risking bending on mating. There&#;s even panel mounting options!
They&#;re not particularly cheap, but if not on a budget, well worth considering.
The downside is that PCB headers have a large footprint. Mini-PV is a connector family with comparable versatility including polarised PCB headers of significantly smaller footprint, and better quality contacts, however at slightly higher cost.
Numbers in bold can be changed to order connectors with a different number of positions. Non latched, and dual row types are also available.
Female contact AWG 24-30 (Gold plated)16-02-Female contact AWG 24-30 (Tin plated)16-02-Male contact AWG 24-30 (Gold plated)16-02-Male contact AWG 24-30 (Tin plated)16-02-Housing 4×1 position female (with latch)50-57-9404Housing 2×1 position male (with latch)-0001Housing 4×1 position male (with latch)-0003PCB Header 2 position (Gold plated, with latch)-0001PCB Header 4 position (Gold plated, with latch)-0003PCB Header 2 position (Tin plated, with latch)-0036PCB Header 4 position (Tin plated, with latch)-0038Hand crimp tool AWG 24, AWG 26, AWG 28, AWG -Hand crimp tool AWG 22, AWG 32, AWG 34, AWG -Hand crimp tool AWG 24-30 (Historic)11-01-Hand crimp tool AWG 22-24, AWG 30-36 (Historic)11-01- Current Molex SL crimp tools. Left: - (Pressmaster), right - (Wezag). Older tools exist and are likely to be found inexpensively on eBay.Left: SL contact crimped by -. Right: SL contact crimped by Engineer PA-09Unlike Mini-PV which almost no generic tools can crimp properly &#; SL Contacts crimp pretty well with off-brand tools.
As we can see from the picture above we have a familiar problem of not being able to apply the same kind of force. The original tool is designed in such a way that a large amount of pressure can be applied to a small area, but on the Engineer tool this just isn&#;t possible short of jamming the jaw into a vice every time, which&#;d be a little time consuming.
A common 2.0mm pitch grid type connector. Available in single and dual row configurations. Similar types are made by both Harwin and Molex. Harwin&#;s type is cloned by Chinese manufacturers and is significantly more common.
Numbers in bold can be changed to order connectors with a different number of positions.
Contact AWG 24-30M22-Blank polarising plugM22-Housing 4×1 positionM22-3010400Housing 4×2 positionM22-3020400PCB Header 4×1 positionM22-2010405PCB Header 4×2 positionM22-2020446Hand crimp toolZ22-020 Left: Harwin M22 housing and contacts. Right: Molex Mill-Grid housing and contacts. The housings and contacts are slightly different &#; Both are 4.0mm thick at the mating end however Molex&#;s are fatter (4.75mm) at the wire entry. Contacts and housings aren&#;t interchangeable. M22 Crimp tool Z22-020. Made by Pressmaster in Sweden. It crimps Molex Milli-Grid contacts perfectly too. This tool also crimps &#;M22-308&#; contacts which are for a completely different type of connector.M22 and Milli-Grid contacts crimp easily and cleanly with tools like the Engineer PAD-11, however with the usual problem of significantly less force on the conductor part, which means cable assembles have to be pulled from the connector body (not the wire) to avoid wire pulling from the contacts.
A exceptionally rare example of a two row wire-to-wire connector system. In total I have only ever identified two such types of connector, other other being dual row Mini-PV. If you come across any more, please let me know!
Very similar to the SL series mentioned above, except cheaper, lower quality and lacking latching options. These are an option for those looking for something in the form of &#;DuPont&#; style connectors, but better quality, and cheaper than genuine Mini-PV connectors.
The design of the contacts is distinctly different to SL. They crimp more like Mini-PV contacts with an &#;O&#; crimp on the insulation.
If seeking a CGrid III crimp tool &#; the old version (-, mfg&#;d by pressmaster) is a better bet for hobbyist use as it often seen cheap on eBay and covers both contact sizes in a single tool. With the current offering two different tools are required.Tired of reading about 0.1&#; wire to board connectors yet? AMPMODU MOD IV is yet another example, but one from the ark. The newest equipment I&#;ve ever found one in was manufactured in . They remain in full production to this day, for some reason or other.
The housings are quite a bit thicker than most other types. The two row housing has the same thickness as a 0.1&#; IDC connector. To me the only interesting thing about this family is the housing on the left. It&#;s got the exact dimensions and polarisation of an IDC connector. Quite handy when in situations when mating a non-IDC cable assembly to a shrouded IDC header. Agreed, an unlikely use-case. Beyond this, these are an expensive relic.
The old tool for AMPMODU MOD IV contactsEffectively a jumbo version of the KK .100 connector, this is another very common wire-to-board connector of which compatible connectors are made by a large number of manufacturers. Pitch spacing is 0.156&#; (3.96mm). The most likely place you will encounter them is inside of switching power supplies, almost certainly on the primary side, and possibly on the secondary side too.
As with KK .100/.254, connectors with this same 0.156&#; pitch, which mate with these are available from many other manufacturers.
There are two varieties of contact: basic and &#;trifurcon&#; &#; a special variant which contacts the pin on three surfaces for increased current carrying capability.
As expected, the original tool is effortless to use and gets absolutely perfect results. The IWISS SN-025 is a tool I found crimps these very well despite it not being inteded for this purpose.
Used for 20 and 24-pin ATX power supply connectors, and for the 4, 6 and 8 pin +12V connections found in modern PCs.
All of the part numbers specified below are for the &#;natural&#; colour types as pictured above. They are also available in black and white (left, above).
If supplied by Molex, black housings are for &#;glow wire&#; compatibility (they don&#;t spontaneously ignite in the event of a connection overloaded to glowing point). White housings are for UL94-0 fire safety compliance, i.e. they&#;re less flammable than the &#;natural&#; coloured types, however more expensive.
No-brand (non Molex) types are often coloured black for aesthetic reasons typically for use in PCs, and are made of low quality plastics which do not feature the improved fire safety ratings of Molex types.
Contact and header part numbers are for the most common Tin plated types. Gold plated types are also available however these should not be used unless both mating sides are gold plated.
Numbers in bold can be changed to order connectors with a different number of positions.
Female contact AWG 18--00-Male contact AWG 18--00-Female contact AWG 22--00-Male contact AWG 22--00-Housing 2×1 position (female receptacle)39-01-4020Housing 4×1 position (female receptacle)39-01-4040Housing 1×2 position (female receptacle)39-01-2020Housing 2×2 position (female receptacle)39-01-2040Housing 2×1 position (male plug, no panel mount)-Housing 2×1 position (male plug, panel mount)-Housing 2×2 position (male plug, no panel mount)39-01-3043Housing 2×2 position (male plug, panel mount)39-01-2041PCB Header 3×1 position (with mounting peg)39-30-1039PCB Header 4×1 position (with mounting peg)39-30-1049PCB Header 2×1 position (no mounting peg)39-28-1023PCB Header 2×2 position (no mounting peg)39-28-1043PCB Header 2×2 position (with mounting peg)39-29-9023PCB Header 4×2 position (with mounting peg)39-29-9043Budget hand crimp tool AWG 16--Premium hand crimp tool AWG 16-24 (Historic)-Premium hand crimp tool AWG 18-24 (Historic)11-01-Premium hand crimp tool AWG 18-24 (Current)-Premium hand crimp tool AWG 16 (Current)-Premium hand crimp tool AWG 22-28 (Current)-Contact extractor11-03-Sold separately. If you&#;ve ever found yourself trying to remove already inserted contacts, you&#;ll appreciate one. Instead of potentially hours of uttering profanities attempting to extract contacts with sewing needles, the contacts will pop straight out with one of these.
Above is a selection of crimps by various tools, including Molex original and some others which do a fairly decent job, with the exception of the IWISS SN-28B on AWG16, which is too loose for serious use.
For AWG24+ wire sizes, smaller contacts i.e. 39-00- are used. Note that both -/ and - both support AWG 24 but in each case, contacts for appropriately sized for the tool must be used.
There are of course many other possible combinations. I cannot cover them all. I wrote a bit more about Mini-Fit Jr on this page.
Molex Mini-Fit Jr crimp tools - and - (mfg&#;d by Pressmaster Sweden) with extraction tool.Also known as Universal Mate-n-Lok. At 600V it is the highest voltage rated connector I cover here. Contact rating is 19A.
Its contacts are remarkably similar to the 5.08mm pitch Mate-n-Lok connectors mentioned below, but not quite the same. They&#;re not interchangeable. As you may have predicted, officially there&#;s a different tool for them too, so that&#;s another months spending money if you aren&#;t keen to crimp them with off-brand tools.
I keep a small stock of these for high voltage applications, as they safely handle a 230V 13A load (UK max socket outlet) without breaking a sweat. They crimp perfectly with the -1 tool mentioned below, despite it not being intended for this purpose.
This tool is well made and effective. Extracting contacts from receptacles (pictured above on the left) is tremendously difficult without one. Unfortunately at $60 it&#;s not cheap. I got mine off eBay for a song. It also works with 5.08mm pitch Mate-n-Lok connectors pictured later on this page.
I went through all my cheap eBay tools on these. The one that came out on top is labelled SN-48B. The engineer tools aren&#;t suitable for contacts this large.
Top: Crimped with -1 tool. Bottom: Crimped with SN-48B tool. Wire size: AWG 16 / 1.5mmNot too bad of a result, however not quite enough force on the conductor part, this is a bit of an issue under heavy load as the thermal camera image at the top of this article shows.
These connectors come in an unadvertised variation which increases the contact rating to 31A with wire sizes up to a massive AWG 10. Contacts are incompatible with regular types. PCB headers are loaded with large female contacts which look distinctly different. They also require different housings and a different crimp tool (Daniels M310).
&#;High Current&#; male contact AWG 12--1&#;High Current&#; female contact AWG 12--1&#;High Current&#; 2 position housing-1&#;High Current&#; 2 position PCB header-1Also known as Commercial Mate-n-Lok. Not a particularly popular connector family anymore but notable as the 4 position variety of these were used on 5.25&#; floppy disks as far back as , they were also adopted on 5.25&#; PC hard drives, CD-ROM drives and 3.5&#; parallel ATA hard disk drives, plus a veritable arseload of other PC related applications. The two and three position varieties are sometimes found on very old computer equipment in design specific applications only.
This connector family includes a rather uncommon member: A single position housing. The contact&#;s circular mating surface allows them to swivel 360°
There is a hoard of different tools for Commercial Mate-n-Lok, Pictured below are -1 and -1 which crimp sizes AWG14 to AWG24.
Mate-n-Lok crimp tools -1 and -1. There are a few unlikely-to-be-used others too.¹ Although the singe wire die states AWG 14-20, it&#;s more like an AWG 14-16 in practice.
² Special contacts with longer tabs are required when crimping two wires into a single contact.
Is a piece of rubbish made of some kind of brittle metal. It broke about 10 minutes after I received it. I&#;m normally a sucker for a good contact extractor but this was a waste of $20. The Universial Mate-n-Lok (6.35mm pitch) extractor pictured earlier is significantly better quality, and works perfectly on these connectors.
Molex introduced a compatible connector (for the 4 position variety only) in imaginatively named &#;Disk Drive Power Connection System&#;, making them a second supplier of what was by then a very popular connector in the PC industry. Despite (somehow?) their name becoming the vernacular term for this type of connector, they have since exited this market, with all parts either discontinued or near end of life.
In practice it is unlikely that one would ever encounter a Molex branded connector. Where quality parts are utilised; Mate-n-Lok is the more common choice given AMP&#;s long term commitment to this family.
Molex original Disk Drive Power Connection System crimp tool, housings and contacts. Molex&#;s distinct &#;four eyed sunglasses&#; design can be seen here on the female housing. Male contacts and housings were discontinued 20 or more years ago, were eye-wateringly expensive when they were made, and are almost never seen in the wild.Molex contacts have a special retention feature for the locator in the tool, which makes both the tool and the contacts incompatible with anything else. Male Molex contacts are larger at the throat than other makes, meaning they fit very tightly in the housing, so one does not have to manually line up the pins before mating, however because of this they do not interchange with other branded parts. Unless like me you have a propensity for collecting crimp tools and connectors I would not recommend attempting to obtain any of the above.
There was a predecessor to the - tool show above with the part number 11-01- &#; in the unlikely event you are seeking a tool for these connectors.
The IWISS SN-58B does a good job of crimping Mate-n-Lok.
A commonly used heavy (50 amp) power connector. It has no frequent consumer uses, but is often used industrially for battery connectors, chargers, large motor controllers, DC power supplies etc.
Despite the similarity of the name to Mini-Fit Jr, that&#;s about where it ends &#; these connectors are big. They would make a very a reliable replacement for cigar plugs in marine/automotive applications.
There are three official crimp tools for this family:
Given the amount of force required to crimp these, I&#;m doubtful there is much in the way of good unofficial crimp tools. Even with - &#; large enough to bludgeon someone to death with, crimping requires significant elbow grease.
Half measures aren&#;t generally a good idea when you&#;re dealing with something that carries the kind of power these are designed for. If you don&#;t have the tool, I would suggest carefully soldering contacts &#; unless you&#;re looking to start a fire. Mini-Fit Sr contacts are near impossible to reliably manually crimp with pliers.
Mini-Fit Sr crimp tools - (top) - (middle) and - (bottom). All mfg&#;d by Wezag Germany.Mini-FIt Sr in recent years has become my go-to for big DC power connections. The one gripe I have is that in the case of the AWG8 contacts &#; Molex appeared to have forgone the possibility of an insulation crimp. Instead those larger contacts are crimped entirely onto the conductor, leaving nothing restraining the insulation, which isn&#;t as robust as what we end up with on AWG10+ sized contacts.
The AWG 14/16 tool understandably requires smaller contacts. I find it a little difficult to insert the contacts into the tool, so not so great for usability, In any case, these wire sizes are far too puny for the monster size and carrying capacity of these connectors. If you are using AWG 14/16, it&#;s because everything else in your system uses a bigger size, and you want something smaller on this one particular occasion. That can make splashing out on this tool hard to justify.
AWG 10/12 are the optimum wire sizes for Mini-Fit Sr.
Crimped Mini-Fit Sr contactsMini-Fit Sr Extraction toolThese look similar to Mini-Fit Jr, but scaled down. Not often seen in consumer products but has occasional use in small &#;DC&#; / ITX / Automotive PC power supply applications. I&#;ve also seen them in other unusual applications such as the connector on the DC end of the plug pack for HP Printers and Cisco routers.
Molex have recently added an AWG 18 option to Micro-Fit, which I very much welcome however note that a new tool, and different contacts is required. The AWG 18 tool also has a 0.75mm² die with barely a fag paper of difference.
Similar in appearance to the Mini-Fit Jr extraction tool, but used quite differently. Read the manual.
Microfit 3.0 contacts crimp fairly well with generic tools:
Left: Crimped with Engineer PA-09 Right: Crimped with original toolLeft: Crimped with Engineer PA-09 Right: Crimped with original toolAs always when using generic tools, results are usable but not entirely ideal. The insulation crimp has clearly pierced the insulation, meaning it would be at risk of tearing under mechanical stress. Another issue I noticed is that the contact ends up bent vertically a little too, due to the awkward un-crimped shape of the contact. This means that you&#;ll have to bend each contact straight again before insertion into the housing.
Due to their small size and high current capacity, these have become one of my favourite connectors.
PIDG terminals a bit too cheap for you? Fear not&#;
FASTON is a proper connector family, yielding very professional looking terminations, with a proper $ tool to match. They crimp OK in common tools like the SN-48B tools for wire sizes AWG18+.
Annoyingly (and predictably) there is a brace of different tools for FASTON contacts, for example, there are at least four tools for .250 contacts, and .187 contacts have a different tool too. The IWISS SN- crimps these very nicely. Male &#;tab&#; contacts require the massive AWG 10-14 tool due to the material thickness. I use my Mini-Fit Sr - tool for these.
A variety of FASTON Crimp tools. -1 is the old crimp tool for .187 terminals. Also shown is an older example the current $ -1 .250 tool.E.I. is most commonly known by its 4 position variant which became the de-facto standard power connection for PC 3 ½&#; floppy drives, and various other peripherals which installed into 3 ½&#; drive bays.
Despite its ostensible obsolescence by its original floppy drive use-case, this type of connector lives on as a sundry power connection for a variety of items which people install into their PCs requiring only a small amount of power. Contemporary power supplies still also include this type of connector and adapters to it from other types of connector are still sold in reasonable quantities. Unless some kind of new standardised power connection surfaces which meets this need, it isn&#;t going away. Clearly someone is still using the other types for some unknown purpose as well, as this product line and all its variants remain in full production.
Economical Interconnect crimp tool -1There is a swag of different tools for E.I. as one would expect for an AMP connector family, but the one most commonly used is -1 which crimps AWG 20-26 wire, with the corresponding sized contacts.
The IBM PC was the first type of computer to use a connector compatible with these for the power supply connection to the mainboard, and also internally inside the power supply &#; but from a different manufacturer. It may have been Berg who originally introduced this type but considerable research efforts by myself have failed to confirm this.
They were used for the power supply to mainboard connection for PCs up to the Pentium I era. Starting around they were gradually replaced by Mini-Fit Jr connectors, which are specified in the ATX standard. They made a brief re-appearance in the early s with AMD&#;s supplementary CPU power connector however this was quickly supplanted by Intel&#;s 4-position 12V CPU power connector.
The original series came in a number of different positions. On this page I show an obscure 4 position example from the original mystery manufacturer &#; &#;P4&#; which was used for the AC Fan.
Molex only ever produced a 6 position variety of this connector, as this was the only one which came to be incorporated into the XT/AT standard.
The most useful housing is - which comes with all polarising ribs attached, allowing one to snip off the remainder to achieve the desired polarisation. Unfortunately for anyone needing them, they&#;re now rather difficult to come by.
There are quite a few manufacturers of crimp D-Sub connectors. I ended up with the tools for these from a job lot, so that&#;s what I&#;ve mentioned here. D-Sub&#;s are normally soldered, however there are some scenarios where it is desirable to crimp them:
There is a plenitude of current and former crimp tools for these connectors, supporting various different wire sizes, as well as contacts with and without insulation support.
Two of the many AMPLIMITE hand crimp tools. I have others too, which I&#;ll probably never use.Unsurprisingly the current tools are very expensive. eBay is awash with the older tools for reasonable prices. Unless working with large wire sizes, -1 is probably the only one worth bothering with. The -1 tool I&#;ve pictured is for contacts which don&#;t have an insulation support. I am unsure why anyone would choose such an arrangement.
In terms of crimping these with budget tools, there&#;s nothing particularly special about them. Tools like the Hozan P-707 or Engineer PAD-11 will suffice for hobbyist applications.
A very small (1.25mm) pitch connector.
Old Picoblade crimp tool -. Manufactured by Pressmaster Sweden. This tool has been replaced with a newer version (-).Picoblade is a type connector whose contacts are so tiny that they are quite difficult to crimp with generic tools. The Engineer PAD-11 does well with these.
IWS-02B and SN-B. Two handy tools I don&#;t use for their intended purposePictured above are the only two generic tools I that I still use (since I have the manufacturer tools for everything else).
I use the SN-B for &#;fixing&#; insulation crimps which I&#;m not happy with, for example, all of the FASTON tools crimp the insulation too lightly on smaller wire sizes, so I re-crimp those with this tool afterwards if needed. It&#;s not designed for this, but having a set of single large dies, it works well for it.
The IWS-02B is designed for &#;buckle&#; crimps (un-insulated wire joiners), but I found it does very nice crimps on pre-insulated contacts:
Top: &#;Yellow&#; fork contact crimped in the IWS-02B (insulation has to be removed first). Bottom: Crimped in the &#;yellow&#; die of a generic pre-insulated terminal crimp tool (insulation removed after crimping).Above two crimps, cut openThe above image demonstrates why I&#;ve abandoned my pre-insulated crimp terminal tool. When I cut open the contact crimped with the IWS-02B, contact and conductor are crimped nicely into a solid mass of copper. I then finish this with a layer of glue-lined heat-shrink, making an inexpensive but excellent termination.
When I cut open the contact crimped with the recommended tool, all of the conductor strands fell out. Hardly a termination I feel I could trust.
Over the years I have received hundreds of emails from people asking me to identify obscure connectors. I didn&#;t know what any of them were. In summary: If it&#;s not here, I don&#;t know what it is. I would have to spend hours looking through thousands of pictures of connectors on re-sellers websites to identify it. I do not have time for this!
From time to time I come across obscure rarely used connectors too. Because we live in a world where there are tens of thousands of different types if connectors, it can take (even me) days to identify these. My general approach is to measure the pitch between the contacts with calipers. You should be able to work out its spacing i.e. 1.0mm 1.5mm 0.1&#; 0.2&#; (2.54mm, 5.08mm) etc. Enter this measurement as well as the number of contacts (any other visibly obvious features) into either Mouser or Digi-key&#;s parametric search on their connectors category. You may just find it.
Molex have a good web page with pictures summing up their wire-to-board connector products.
The most likely bet however are JST who have a very large range of products. They have reasonable product listing too.
Electrical Connector circuitry comprises various components, including cables and wires, to achieve a set goal. It is worthy of note that the entire circuitry would be useless without the help of connectors.
In today&#;s article, we&#;ll be looking at several things about connectors ranging from their composition to gender and more.
Before we nose dive into the article, let&#;s answer the question What is a Wire Connector?
1. Electrical Connector&#; What is a Wire Connector?
Wire connectors are electro-mechanical devices that combine various circuits. Depending on the function they are to perform, they possess different features. Some of these features are their mating type, materials of terminals, etc. In general, in an emergency or dangerous event, the connector makes it easy to connect and quick disconnect.
1.1 Electrical Connector
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Basic Composition
The electrical connector housing is simply a case in which the terminal stays. This housing protects against electrical shock or(short-circuiting) and ensures connections are firm and stable. The materials used in the making of connector housing are insulators (Plastics, ceramics, etc.)
These are the pins that carry electric current from the source to its destination. They are fundamentally conductors, made of metals, and while some are of other conducting material.
1.2 Electrical Connector
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Gender
Many electrical connectors have male and female types. This gender differentiation is primarily due to the shape and function of the ends of the connector. Male-end connectors are called plugs, and female-ends as sockets/jacks. The pins (plugs) connect to the sockets forming a temporal or permanent coupling.
It is a connector attached to either a cable or a piece of equipment with exposed terminals. They can be inserted into a receptacle to form a couple. This type of connector is also known as a plug.
Inside of the holes is conductive terminals to complete the circuit when in contact with the male connector. They are usually attached to either wire, cable, or equipment, similar to the male connectors.
1.3 Electrical Connector
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Geometry
The geometry of electrical connectors is mainly about the shape of the connectors. We can have a particular type of electrical connector having different forms or where its connection point faces. This geometry allows for easy connection and reduces the strain on the connector when installed in an area.
We can categorize the geometry of electric connectors into three;
1.4 Electrical Connector
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Features of Connectors
Connectors possess different qualities, and their characteristics determine their use. The following are features of electrical connectors:
Suitable for use when the coupling is in the correct direction. This concept prevents the wrong insertion, in turn damaging the terminals.
The locked connector feature prevents unexpected disconnection due to an external force and holds the connection tightly in place.
These are connectors built to withstand underwater pressure (to a certain depth) and still functioning properly.
They shield the connection from water splashes and dampness. However, they are different from Sealed connectors as they cannot withstand underwater pressure.
They prevent electrical damage from oil or moisture.
They filter electromagnetic interference away from interfering with electrical signals in connectors.
Protects against electrostatic discharge from damaging the cables and components of an electrical device.
2. Electrical Connector&#; Types of Wire Connectors
2.1 Electrical Connector
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Connector Level
Wire-to-board or subassembly-to-subassembly level: Here, connectors join the various components to PCBs of the computer.
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
2.2 Electrical Connector
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Main Connector Types
1. Audio and Video Connectors
Audio and video connectors are electrical connectors designed to deliver audio and optical signals from source to destination. The audio connectors are cables connected to audio equipment to carry signals. Part of its build is a ground (Earth) to prevent stray charges from damaging its equipment. Applications for this connector type are in various fields where sound waves are involved, including the military.
Male and Female Audio and Video Connectors
2. Electrical Connector
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Automotive Electrical Connectors
These types of connectors find applications used in vehicles. As innovation continues into electric cars and automated vehicles, the need for these connectors is inevitable. Many vehicle systems (Sensors, car diagnosis, etc.) are currently more compatible with Automotive electrical connectors.
Automotive Electrical Connectors come in various types too:
Vehicle Power Cable Outlet
3. Electrical Connector
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Board Mount Connectors
Board Mounted Connectors connect components on a PC board, and they are mounted on the boards and use pins to connect devices to their board.
4. Electrical Connector
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Board to Board Connectors
These are best suited for printed circuit boards. Here no wire/cable is required for connection. Two or more panels connected with the aid of metal pins in plastic cases, all embedded on the board.
5. Electrical Connector
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Centronics Connectors
These are 36-pin connectors used to connect printers and other devices compatible with computers such as CD-Players.
6. Electrical Connector
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Circular Connectors
These are multi-pin connectors fundamentally designed for transmitting both power and signal, and they are external interfacing components of an electrical device. However, these connectors carry mixed signals (power and data) based on the design in some cases.
7. Electrical Connector
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Coaxial Connectors
In a way similar to optical fiber cables, Coaxial connectors have insulated conductive inner parts, and they have on them overlaid with an outer cylindrical conductor acting as a shield. Their protection layer is to prevent information loss during transfer, as this phenomenon is consistent with thermodynamics. Because of these layers, Coaxial connectors carry signals or data long distances without any information loss during transmission.
Applications include Radiofrequency transmission and CATV applications.
8. Electrical Connector
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DIN ConnectorsIn line with Deutsches Institut für Normung, the national organization for standardization in Germany. As can be seen in telecommunications, microphone, internet connection, etc. Applications of these connectors are in computers, connecting their microprocessors and RAMs. Many of these will be discussed later in this article.
9. Electrical Connector
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D-Subminiature Connectors
D-sub connectors are electrical connectors having a D-shape metal shield, used as network ports, game controller ports, etc. They have a male and female type.
10. Electrical Connector
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Edge Connectors
These onboard embedded devices form an external connection by having to pair with single-sided or double-sided PCBs. They have industry-standard power specifications such as voltage level, power, etc.
11. Electrical Connector
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Fiber Channel Connectors
These are high-speed connectors used in Fiber Channel systems.
12. Electrical Connector
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FireWire Connectors
IEEE is another name for Firewire connectors. Apple developed them around the s to transfer data at a fast rate. However, these connectors are expensive.
13. Electrical Connector
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Heavy Duty Rectangular Connectors
As the name implies, they find application in transmitting high voltage power signals. They are to withstand large electrical loads, and they find their applications in industries where heavy-duty power transmission is needed.
14. Electrical Connector
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IC Interconnect Components
Used in low current devices, IC interconnect connects PCBs with microelectronic semiconductor chips. With fragile connector pins and the best suited to connecting ICs to boards. Either made of metals, plastics, or ceramic, but their pins are good conducting material.
15. Electrical Connector
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Instrument and Computer Power Connectors
It connects disk drives to the power supply. They have varying features depending on their applications. In general, they are cables that carry power to the various industries in the computer.
16. Medical Electronic Connectors
Medical electronics connectors find their applications in clinics, hospitals, and other healthcare facilities for connecting medical devices. Some Medical connectors are against electromagnetic signals interference during transmission.
17. Micro Connectors and Nano Connectors
They possess different features depending on their applications. Some micro connectors resist shocks or vibrations, while some, like coaxial cables, shields EM interference.
18. Military (MIL-SPEC) Connectors
Military (MIL-SPEC) connectors are for the military with Military Standard, &#;MIL-STD,&#; or &#;MIL-SPEC.&#; They function effectively under harsh environmental conditions.
19. Modular Connectors and RJ Connectors
There is no significant difference between Modular connectors and RJ connectors. They are connectors used for telephones and Ethernet.
20. Panel Interface Connectors
Panel interface connectors (PICs) provide the ability to interact with a device&#;s components without opening the doors. This connector type avoids potential safety hazards. In some panels, you can rectify faults using an external port, and it is through this external interface you can use the Panel Interface Connector.
21. PC Card Connectors
It is used to connect PC cards and other devices to the computer.
22. RF and Microwave Connectors
Radiofrequency (RF) is the rate at which wave signals oscillate. These oscillations provide the right EM field that fosters wireless transmission of signals. RF and microwave connectors effectively transmit high frequencies signals, and they find applications in Broadcast industries.
23. Solar Connectors
Solar connectors are used in solar energy systems to link various panels electrically. These solar connectors are gender-based &#; as explained earlier in this article.
These connectors come in various types (PV, MC3, MC4, etc.) and shapes (Y-joint, X-joint, U-joint).
24. The Solenoid Valve Connectors
The connect solenoid valves (hydraulic), pumps, pressure switches, and motors. They often serve as environmentally resistant junction boxes, and these connectors have a protective feature against environmental hazards.
25. Terminal Blocks
Simply put, Terminal blocks are blocks with partitions where two or more connectors connect. They have insulated bodies to prevent electric shock from the current-carrying conductors. These blocks hold various terminals together with the help of a screw. They can also be used to terminate an exposed terminal end, such as ground wires.
Isolated Terminal Blocks
26. Thermocouple Connectors
With thermocouple connectors, temperature signals reach a destination point, either to a monitor or a control unit.
In another sense, it serves as an extension of a thermocouple sensor.
27. USB Connectors
Suitable for devices using the USB standard port. They connect USB-compatible devices.
28. Wire to Board Connectors
Wire-to-board connectors interconnect printed circuit boards (PCBs) using connectors attached to wires.
29. Wire to Wire Connectors
They are electrical connectors linking two wire-terminated connectors together. The male and female wire-to-wire connectors are designed to couple firmly.
3. Electrical Connector&#; Materials of Wire Connector
It is vital to consider the various materials used in building these electrical or electronic connectors. The choice of connector materials determines signal transfer rate, temperature tolerance, and flexibility, and Connectors are insulating and conductive materials.
The insulating materials make up the housing of the connectors. Depending on the application of the connectors, materials like plastics, ceramics, etc., are used. Conductive materials are for the terminals, and they include metals, silicon, etc.
Here are some common terminal materials one can use.
Brass
Brass is the least expensive for the weight of the three metals, and they have excellent properties suitable for conducting electrical signals.
However, Brass metals have low yield strength. Metal&#;s ability to return to its original shape when stretched or distorted. This property implies that sockets made of Brass metal will become loose after a series of insertions. This loose grip will, in turn, yield what is called Partial contact with the connection. KK terminals have Brass as a making consistent.
Four Pin Brand Electrical Connector
RHT contains other products and information you need, so please check it out.
Phosphor Bronze
Phosphor bronze constitutes 0.2% phosphorus, 5% tin, and 94.8% copper. It is better in yield strength compared to Brass. As Brass, they have good electrical properties. Phosphor Bronze-made connectors have a low thermal conductivity, making them useful in devices operating at low temperatures. This property also reduces heat generation during transmission. They are fair in price too.
Beryllium Copper
Beryllium copper is a copper-based alloy with 0.5% &#; 3% of Beryllium and other contents. It has a combination of high yield strength with non-sparking and non-magnetic properties. With high thermal conductivity, Beryllium Copper can withstand high-temperature zones. The price is relatively fair compared to Phosphor Bronze.
High Copper Alloy
This alloy contains more than 96% copper. It has excellent thermal, electrical, and physical properties, making it useful in the Automobile industry and other industries operating in high-temperature regions.
4. Electrical Connector&#; Factors to Consider When Purchasing Electrical Connectors
Having gone through the details above, one might just be confused about which electrical connector to get. In this section, we walk you through the various factors to consider when purchasing electrical connectors.
Electrical requirement
The electrical need is the first factor to consider before purchasing a connector. You will have to know the required voltage and current capacity. Suppose the conductors would be carrying high voltage and current. In that case, the connectors will have to withstand such power and be resistant to temperature. As terminals, overtime may heat up, thereby heating the connector in contact with it. Connectors with thicker pins and high insulation will be best for high-power devices or cables.
Environment
Where will the connectors be used? Underwater, underground, bare ground, or in airplanes? The environment matters as the electrical requirement does. For example, you will be looking for connectors resistant to vibrations if the climate is prone to mechanical vibrations.
Generally, connectors with environmental sealing are best suitable for liquids, moisture, dust, or combustible gas.
Reliability/Durability
The mating cycle tells of the connector&#;s durability. If you plan on using a connector in areas with a high mating cycle, you should consider this factor. Connectors with a firm grip over time can withstand a high mating cycle, and this feature is so to prevent partial contact.
Signal Type
What type of signals will be transmitted? Analog or digital, high-frequency signals? Coaxial connectors have high insulating features to prevent the loss of information during transmission over a long distance.
A Coaxial Cable and Connector
Cost
It is no news that people want the best and at the lowest price. However, reality has it that, to some extent, the best products come with a prize.
It is your responsibility as an engineer or manufacturer to strike a balance between profitability and functionality.
5. Electrical Connector- 6 Common Issues About Connectors in Custom Wire Harness
Having looked at connectors so far, we have established that connectors do not work independently, and they function as a unit, which is called a Wire/Cable harness.
Wire harness brings with it lots of benefits, and some include ease, troubleshooting, and flame-retardant.
Woman Performing Quality Check on the Various Parts of A Wire Harness
However, there are some common mistakes observed in a custom wire harness. These mistakes may be familiar, but their impact on a project could be fatal. We will reveal six common issues about connectors in a custom wire harness.
The ability for electrical signals and power to be transferred from one point to another is dependent on the contact. If there is no contact between the cable and connector, the call will break. This feature place touches as a vital join to protect. However, we see unprotected connections in the wire harness due to mistakes. An unprotected contact exposes the contact pins to the risk of attack from corrosion, moisture, and other external factors.
Corroded contacts have their conductivity reduced, which in turn can cut-short power supply.
These are enough reasons not to make the mistake of purchasing or manufacturing wire harnesses with unprotected contacts, and they should have adequate protection with layered coatings.
Crimping, which joins wires with connectors using a crimp, creates a firm connection between cables and connectors. Nonetheless, if done wrongly or with a faulty tool, it can affect the relationship, like a short circuit.
Man Crimping An Automotive Terminal to A Cable
After crimping, it is essential to ensure the device is in good working condition and fits the cable&#;s size.
At CLOOM Tech, we ensure to follow industry-standard procedures in manufacturing wire harnesses. We employ a high level of precision and caution to deliver value to our clients globally.
Every manufacturer knows about Strain relief, but sadly some do not consider it when designing wire harnesses. Strain relief merely allows some additional length of cables to make room for mechanical movement.
If not considered, it can lead to a breakdown of the wire harness, resulting in a total power failure.
At CLOOM Tech, our certified engineers and technicians will serve you best in customizing your wire harness.
We are putting into consideration all factors, including strain relief, during manufacturing. Value is what we serve.
Owing to the benefits of custom wire harnesses, applications for this type of connection spans many industries. The vehicle industry seems to be the most use of the cable harness /wire harness. The manufacturer of any custom wire harness considers every layout and design before production. However, the increase in demand for more custom wire harnesses puts producers on edge.
Sometimes they fail to do a proper layout and design as they have deadlines to meet up. This act, in turn, gives rise to continuous alterations in electrical connectors. These frequent alterations weaken or eventually damage the contact. These are the result of poor wire harness layout. Producers and manufacturers with poor wire harness layout may tend not to follow project specifications.
As part of the modus operandi at CLOOM Tech, our team takes the design process seriously. It is a vital stage in making a custom wire harness, and we are accurate and precise when it comes to wire harness layout and design.
There have been situations where a custom wire harness has wires with some missing terminal connectors. This missing hardware is a mistake from the manufacturers. Sadly, some manufacturers fail to double-check the custom wire harness before shipping it to clients.
If technicians double-check work is done and crosscheck it with the layout design, this mistake is invalid.
The moment a connector joins with a terminal, it should fit and stay firm. Sometimes, this is not the case. The contact retention failure makes contact loose and can experience a push-back effect, affecting electric current flow.
Hence, it is something to be taken seriously. Here are a few methods you can apply to contact retention failure for a custom wire harness.
This method is simple. It involves inserting the connector into the terminal until the retaining mechanism clicks. After this, you pull the connector a little to check how taut it has become.
This method is a basic form of testing, and it requires no tool or equipment for testing. However, it is most prone to human error, as there is no specific amount of force to apply.
In this method, tools verify the retention of contact. To check how taut it is during the pull, the same force can be measured and recorded. There will be little or no interference from human error.
However, it costs more to practice.
Also, verification takes so much time as it requires testing every pin one after the other. This testing also may contribute to the fault of the nails. After assembly, you may discover some errors due to the use of those hand tools for testing.
The Cirris&#; Pin-Sight tool guides technicians to correctly insert wires into the right cavity. It does have the ability to determine a specified force with which the technician can pull. Until you met that specified pull force, the tool would not move to the next wire. This tool is easy to use as it integrates into the assembly process. It also provides a specified force when using for contact retention verification.
Unlike the Hand tool method, the electric testing method uses an electric current to analyze the connectors&#; contact retention. This analysis the electric tool does together without having to test them one after the other. This feature makes it the fastest and most trusted method when it comes to contact retention.
6. Electrical Connector&#; 8 Reasons Waterproof Connectors Can Help You Power in Advance
In this part of our article, we will consider eight reasons waterproof connectors can help you.
By definition, waterproof connectors are electrical connectors explicitly designed to resist liquids, damp and dust. They have insulating materials like rubber and plastics, and they also come alongside screws. These screws help ensure that a watertight connection prevents water or oil from seeping into the joint.
Using a waterproof connector can protect the assembly from moisture though not made for a particular environment. As said, water can attack the connectors, causing them to decay and get damaged.
A waterproof connector for the custom wire harness is necessary with much rainfall, dust, hurricanes, and high humidity.
Contact pins decay, wear out and become less conductive when exposed to warm temperature, water, or moisture.
It becomes loose when connected and, in turn, affects the connection.
A Male Connector with Exposed Pins
The protective feature of waterproof connectors affords the prevention of corrosion on the contact pins.
This excessive temperature is another reason we recommend using waterproof connectors in your custom wire harness. It will protect the connectors against extreme temperature or cold, expose the environment, and prevent cable insulation from damage over time.
Owing to frequent insertions, high temperature, and others, the mating grip of connectors fails. This failure allows for moisture build-up and, in turn, damages the custom cable.
But with a waterproof custom harness, there will be no reason to panic or make frequent changes to damaged connectors. They provide good durability and workability in extreme conditions to serve you better.
Waterproof connectors come with screw features that ensure that connections are air and watertight. Failure to do this allows water to seep into vital parts of the assembly and damage the contact and devices. With waterproof connectors, you are safe.
Moisture in electric circuits does not go along. Hence, using waterproof connectors will be the best solution in high humid areas. We&#;re sure you do not want a frequent change of custom cable assembly weekly because of damaging moisture connections.
Contact resistance comes alongside the corrosion of metals, making it challenging to transfer electric current. Over time, this resistance to the current flow leads to the heating up of connectors and cables.
You can avoid all of this stress and drama when using waterproof connectors in your custom wire assembly. We offer quality and at the best price.
Distinctively from corrosion, oxidation occurs when air naturally reacts with metals. Using waterproof connectors will shield your connections, contact point, and custom wire assembly from oxidation.
Group of Electrical Connectors
We believe the above reasons are more than enough for you to make the right decision.
Another thing we will let you know about electrical connectors is DB connectors. In the next section of this article, we will be looking at that.
7. D-Sub Connector &#; Everything You Need to Know
1. D-sub Connector
D-sub connectors are also called D-subminiature. They are one of the main types of electrical connectors, and they perform the function of interfacing a cable with a device. Their main goal is to create a connection between devices, just as other connectors do.
D-sub connector derived its name from the D shape of its metallic shield. Using D-sub connectors ensures that you do not miss its orientation. The shape of the metal shield will prevent mating if the direction is wrong.
A Typical Picture of A DB-15 connector with Blue Colored Insulation
Also, D-sub connectors have screws on both ends to secure firm connections against mechanical movement or vibrations. D-sub connectors are gender-based. By that we mean, it has both a male and female type of connectors. Its male connectors have two or more parallel rows of pins, while the female type has holes.
The number of pins denotes the type of D-sub connector it is. D-sub connectors with nine pins are DB9, the ones with 25 pins are called DB25, etc.
2. The Applications of DB Connector
As old as D-sub connectors have been in existence (), they are still relevant and used in
today&#;s world. They find their applications in printers, monitors, video games, controllers, etc.
Some applications include;
Electronic Office Systems
Some years back, the D-sub connectors connected most office equipment and computer peripherals to the desktop. They connect printers, mice, and other office equipment. For example, the DB25 (having 25 pins) connects printers to the computer.
A Blue VGA Connected to A Monitor
Medical Equipment
Medical equipment requires an uninterrupted supply of power and signal, especially during use. For this reason, D-sub connectors are the best connectors to use, and they have screws to secure the connection against any mechanical movement or strain to disconnect it.
D-sub connectors in medicinal equipment can prevent interference from the surroundings. These connectors&#; shielding effects can help keep display readings (in electrical signals) unaltered.
Some of the medical equipment where DB connectors are proper are imaging machines, Electrocardiography, ultrasonic diagnostic equipment, etc.
Data Communications
Transferring data among devices, either from a printer to a computer or vice versa, becomes possible with D-sub connectors.
Precisely, RS-232 has the most comprehensive application in communications. It functions to transfer data from computers to printers.
Another application of D-sub connectors in data communication is with modems. Some devices have installed the male type on them, while the female modem connects to it.
Business Equipment
Business equipment Includes various devices like computers, communication devices, other office equipment used primarily for business. They utilize DB connectors to transfer data and power to their different equipment.
Security control rooms in airports, big stores, train stations, and others use D-sub connectors for surveillance devices.
They do this because D-sub cables are suitable for fast transferring data signals undistorted by stray EM signals.
Mobile Communications
D-sub connectors find their application in mobile networks. Their ability to transfer signals efficiently makes them preferable. They also possess a connection securing feature that ensures the relationship stays in place without easily being disconnected.
Consumer Electronics
Consumer electronics are simply the electronics you can get from a store, especially for household use. They are either for entertainment, recreation, or communication, including video games, Telephones, TV sets, etc.
Some of these household electronics make use of D-sub connectors to function. For example, video games require a DB9 connector for their game controller.
3. The Types of D-sub Connectors
We can classify D-sub connectors based on their connection method, connection duration, and number of pins and jacks;
Connection Methods
D-sub connectors have a locking technology feature with them. Not only that, but the D shape of the metal shield also ensures proper orientation during connection. It also has threaded screws on both ends. These screws ensure that every relationship is held in place without tampering and jostling, unlike HDMI or USB ports.
Connection Duration
D-sub ports also allow you to connect in different styles. For example, Crimping is suitable for temporal connection and soldering when you want a permanent relationship.
Number of Pins or Jacks
If you noticed, we have been consistent with the word D-sub. This consistency is because D-subminiature is a series with different types, but they all belong to the D-series. Of course, the D comes from the shape of the metal shield on their connectors.
A numbering and lettering system differentiates the various D-sub connectors. The letters span from A to E, depending on the metal shell size. Also, you could tell the type by counting the number of pins on a D-sub male connector. The connector name with either &#;P&#; or &#;S&#; stands for plug and socket. For example, DB-25P shows a D-sub connector with 25 pins, and it is a plug, and DE-9S says this is a nine socket (holes).
Letters A to E standard pin configurations are A=15 pin, B=25 pin, C=37 pin, D=50 pin, E=9 pin.
Another thing to note is that some D-sub connectors have labels like &#;HD,&#; meaning High density. D-sub connector density is a measure of how closely packed the pins or jacks are in a shell. Connectors ending with HD imply a high density of plugs or jacks in its body.
4. DB Style Connectors
We have spoken about D-sub connectors classified by their number of pins and jacks. In this part of the article, we will be focusing on the various DB-style connectors.
This connector style has only nine pins in its male and female shell arranged in two rows. At the top row, there are five terminals and four terminals at the bottom row.
Two-dimensional Diagram of A DB-9 Connector
The DB-9 connectors are compatible with the ETA/TIA serial interface standard.
DB-15 connector has 15 pins arranged in two rows&#;eight pins at the top row and seven pins below it.
DB 15 connectors are popularly known as Game ports because they serve to connect joysticks and game controllers. Aside from this use, they functioned very well as connectors for VGA connections, and they connected monitors, projectors, and computers.
With 25 pins arranged in two rows, printers make use of the DB-25. They connect printers to computers, and their ability to transfer signals fast makes them suitable.
DB25 connectors also function well with the RS-232 serial, and they transmit asynchronous data through the RS-232 standard.
The DB-37 connector has 37 pins arranged in two rows&#;nineteen pins at the top and 18 pins below.
Hardware that uses the RS-499 serial communication, like Cisco and other applications, uses a DB-37 connector. This connector has a broad metal shell for connecting.
A Man Connecting A DVI Cable with A D-sub Connector to A Monitor
Other areas where DB-37 connectors find their application are specific sensors, satellite antennas, and security control systems.
DB 50 connectors have 50 pins. In this style of DB connectors, the 50 pins may appear in either two or three rows. For the two rows type, the top and bottom row has 25 pins each. The three rows of needles have 17 in the top, and the last row has 16 hands in the middle.
A Bundle of D-sub Connectors in A Cable Harness
DB 50 connectors are works compatibly with sensors and control application. The vast number of pins enables the DB-50 to transmit different signals through a single wire.
5. Advantages and Disadvantages of DB Connector
There are always pro and cons to everything. Here there are some benefits from D-sub. They include
&#; DB connectors do not have a specific length like USB. They can be used to connect distance devices in the industry.
&#; DB connectors have a connection securing tool. The screws at both sides of the connector function to keep mating firm and untampered unknowing.
As there are advantages, there are also disadvantages as to why these connectors aren&#;t favorable.
&#; One of the reasons USB, firewire, etc., existed was that the DB sub cables could not transmit data over the shortest time possible.
&#; The use of its thumbscrew makes the unplugging and plugging process difficult.
6. The Difference Between Connector, Plug, and Jack
Some persons interchangeably use the words connector, plug, and jack. We will now give you a clear picture of their differences.
A plug is a piece of electrical equipment with outward extending metal terminals. These terminals are so that it inserts into a hole meant for it or a socket. The plug is the male gender of connectors.
An Electric Power Plug with Two External Terminals
An example is the power plug, which connects to the mains to carry power to a device.
A jack is a piece of electrical equipment, most time embedded on a device. It has holes into which a plug can fit properly. It is the female gender of an electrical connector.
An example is the audio jack. The audio jack has a depression in it that allows for the plug to insert into it. Most often, you can see more examples with sounds, microphones, audio mixers.
A Jack on an Amplifier Panel
A connector could either be a plug or a jack, and it does not have a different form from those mentioned above.
8. DIN Connector &#; Everything You Need to Know
Another chapter that is part of our topic is the DIN connectors. Is the DIN connector a type of D-sub connector? Is it something different? In this chapter, we will be writing about everything you need to know about DIN connectors.
DIN connector is a multi-pin electrical connector in line with Germany&#;s Deutsches Institut für Normung (DIN) standard.
It implies that DIN connectors do not refer to any particular type of connector.
A Black 5-pin DIN Male Cable
DIN connector looks more like a circular connector with a circular metal sheath within which the round pins stay. The metal sheath provides the locking technology associated with DIN connectors, and it does allow the plugs to connect in a proper orientation to prevent the damage of its pins.
There are two applications of DIN connectors. They are as follows.
Analog Audio: DIN connectors for the audio span across a range of applications. They aid connection in stereos, audio mixers, microphones, and others.
Before now, the Europeans used the 3/180&#; and 5/180&#; connectors for various audio equipment interconnection. These standardized connectors possessed features like an interference shield that enabled the smooth transmission of audio signals among connected equipment.
For example, connecting a stereo tape recorder to a stereo amplifier requires using a five-pin DIN connector. As with other connectors, the DIN connectors are gender-based &#; Male and Female connectors.
Male Connector
The male connectors bear the pins. When viewed outside the connector, these pins are in a specific arrangement, precisely 1- 4-2-5-3, from right to left.
Female Connector
Female connectors have the same numbering as male connectors but start from the left to the right.
Other users
Apart from audio equipment use, the DIN connectors found other areas of application. For example, the 5/180° connectors were of good use for;
There are two types of DIN connectors. They are;
Circular Connector
All male connectors belong to this category of DIN connectors. They (plugs) have a circular metal skirt of 13.2mm in diameter, protecting all straight pins. These pins are 1.45mm thick and spaced equally at various angles.
DIN Plug Connector
These circular connectors have seven common patterns of arrangement of pins starting from three to eight pins.
Loudspeaker Connector
Loudspeaker connectors connect speakers and audio power amplifiers, and stereos.
Speaker terminals have two wires pairing together as one terminal. These wires are polarized, and hence they are often differentiated by the color of the wire. Wires colored red are wires carrying positive signals, while black colored wires are the negative charge carriers.
The three-hole female connector is the most common, with one circular hole on either side of the spade hole. One has auxiliary contact, and one has none. It provides the option to leave the internal speaker connected by inserting a plug by twisting it 180&#;.
Older devices generally use it, such as 16mm film projectors. Becker radio in Mercedes Benz, LED lamps and halogen lamps connect the bulbs to the power supply. There are also three- and four-pin versions of this loudspeaker connector used by Bang and Olsen.
Both the DIN and Mini-DIN connectors are in line with the standards of the Deutsches Institut für Normung. However, the mini-DIN is smaller in size than the more considerable DIN. The pins in mini-DIN have an arrangement different from those of DIN, and as against the circular structure in DIN, mini-DIN pins have a horizontal format.
5. What is Mini-DIN Connector
This mini-DIN is a type of DIN connector with a smaller diameter of 9.5 mm. They come in seven patterns, having several pins from three to nine.
There is a problem which the DIN connectors could not solve that the mini-DIN can solve. Because DIN connectors have a uniform key feature, it can allow for the wrong mating, eventually damaging its pins. The mini-DIN is not so. Each mini-DIN pattern is unique to allow for the same pattern mating, and any other way cannot fit into it.
6. Application of Mini-DIN Connectors
Mini-DIN connectors find their application in several areas centered on various types of consumer electronic devices. Some of which include
7. NON-Standard Mini DIN Connectors
These connectors are non-standard because the Deutsches Institut für Normung&#;s body does not approve of them. However, they are helpful in many ways.
One way is that they provide extra conductors, and this feature helps them conserve space during installation. In the place of two standard DIN connectors, one non-standard connector will suffice.
Several of these connectors mate effectively with standard DIN connectors, and others do not. They are also mini-DIN because they have a 9.5mm body diameter with standard mini-DIN. In all, they show themselves as very useful in application.
8. Benefits of buying DIN Connectors
There are benefits associated with buying DIN connectors.
Purchasing DIN connectors allows you to use them in solenoid valves, pressure switches, and other devices.
Also, suppose you wish to convert your device connectors to use Deutsche technology. In that case, you could simply purchase the pre-wire design connector and plug it into the available compatible connector. This cable converts to Deutsche technology significantly when the device&#;s connectors are unchangeable from the source.
9. How to Custom DIN Connector Step by Step?
We need to connect our electronics from day today, and hence the need for connectors.
However, we should be extra careful when buying connectors. Some could either have a positive or negative effect.
Here are steps to follow when getting custom DIN connectors&#;
Step 1: Finding a Professional Manufacturer
The first step is finding a professional manufacturer. We say this because of the fundamental reason for getting a product, and it&#;d it is because we want it to offer value to us. In our case, a manufacturer determines the quality of the connectors. If you seek a product with good quality and continuously render value, you should find a professional manufacturer.
Step 2: Drawing Confirmation
After finding a professional manufacturer, you should then confirm their claims and promises.
Step 3: Sign the Contract
As they say, the faintest of ink is better than the best memory. Ensure that there is a written agreement for your request. It must be documented and signed by both parties involved. This contract will be something to fall to when one party deviates from the agreement.
Step 4: Sample Confirmation
Before you proceed to payment, it is not out of place to request samples of what you want. Ask for examples of their previous work. It enables you to be doubly such of their competence.
Step 5: Delivery to Customer
After taking the steps above, ensure you know the details of the product and company. Where the goods are coming from, their delivery duration, shipping details, and other necessary information.
It will be of great relief if the company has its delivery service.
DIN Connectors
In this subtopic, we will be looking at the 4 DIN connectors based on the number of pins they possess.
4 Pin DIN Connector
5 Pin DIN Connector
5-pin DIN female connector
6 Pin DIN Connector
PS/2 Connector
8 Pin DIN Connector
If you made it through to this part of the article, then you deserve some accolades. What length! We will be wrapping up the paper here as we touch various wire connectors and wire terminals.
9. Electrical Connector&#; Wire Connectors & Wire Terminals
Speaker Wire Connectors
Speaker Connector
Waterproof Wire Connectors
Push in Wire Connectors
Wire Crimp Connectors
Wire crimp female connector.
Twist on Wire Connectors
Twist-on Wire Connector
Quick Disconnect Wire Connectors
PCB Connectors Wire to Board
An Arduino Uno Board
Waterproof Solder Wire Connectors
Heat Shrink Wire Connectors
Wire Butt Connectors
Blue butt connector
Low Voltage Wire Connectors
Marine Wire Connectors
Wire Connectors
Grey-colored wire connector.
Car Stereo Wire Connectors
Car Stereo Wire Connector
Bullet Wire Connectors
Bullet wire connectors
Plastic Wire Connectors
Plastic wire connectors
Aluminum Wire Connectors
Aluminum terminal connector
Push on Wire Connectors
Push type connector
Multiple Wire Connectors
Connector housing multi terminals with a single output
B Wire Connectors
Battery Wire Connectors
Two battery wire connectors
Conclusion
Electrical connectors play a vital role in our lives today, even more in this age of innovation.
We have been able to speak extensively on the subject matter. We believe this article informed and enlightened you. You can reach out to us in the comment section below for assistance. Thank you for the time to follow through with the article.
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