Electrical connectors are essential components in electrical circuits, serving the crucial purpose of establishing a secure and reliable connection between different components. They enable the flow of electricity to pass through them, ensuring that power is transmitted effectively and safely. Without electrical connectors, modern electronic devices and systems would not function properly.
Electrical connectors are used in a huge array of applications. Some of them are –
- Connectors are ubiquitous in the electronics world.
- Automotive Industry
- Industrial automation
- Infrastructure
- Telecommunications
- Power Distribution
- Railways
- Defence
- Aerospace
However, making an ideal connector that meets all your requirements can be a baffling task.
Firstly, there are various types of connectors to choose from. For example – circular connectors, rectangular connectors, D-Sub connectors, M – Series and N – Series Connectors to name a few. Besides this, there are various other considerations that one has to take into account while building a connector –
Shell Style – There are various shell styles like wall mounting receptacle, cable connecting receptacle, box mounting, Straight Plug, Right Angled Plug, to choose from. Each differs in its placement, usage, and purpose.
Connector Class – This is to ensure the environmental sealing and protection one needs for the proper functioning of the connector
Shell Size – One has to select Shell Size based on the appropriate no. of contacts, contact size as well and service rating. This depends on the usage and space availability of the connector. The shell size starts from size 8 and goes upto 40 shell as well. These are pre-defined sizes as per American military standard (MIL – Grade).
Insert Arrangement – These connectors come with various insert arrangements denoted by the number of contacts, contact size, and their layout to suit different electrical and signal needs. One has to understand contact size along with current rating requirements to conclude the same.
Contact Type – One must also understand whether one needs the male (or pin) side of the connector or the female (or socket) side of the connector. Together they make one single set.
Backshells – Backshells are protective accessories that provide strain relief and environmental sealing, ensuring the integrity of the connection. By securing and shielding the cable entry point backshells, in many cases become a necessity. Understanding the extent of environmental protection one needs, one may use backshells from a range of options available in the market
Plating Modifications – These connectors can have various plating modifications, such as cadmium, nickel, or zinc plating, to enhance corrosion resistance and conductivity. These modifications are typically applied to the connector’s shells and pins to suit specific environmental or electrical requirements. The plating on pins is generally that of gold or silver as per requirement.
Contact Modifications – Contact modifications typically involve changes in pin layout or material to suit specific application needs, such as improved conductivity or reduced electromagnetic interference. These modifications aim to enhance the connector’s performance and functionality while maintaining compatibility with the standard 5015 connector shell.
Selecting the right electrical connector requires a careful consideration of the specific application requirements, environmental conditions, electrical and signal transmission needs, and compatibility with existing equipment. By carefully evaluating these factors, engineers can ensure the selection of a relaine and high-performance connector that will meet the demands of the application.