Electrical Connector Industry

General Information

Electrical Connectors are parts or devices used for electrically connecting or disconnecting circuits etc. They can connect and disconnect by hand or with simple tools without requiring special tools or processes such as soldering.

Electrical Connector is an electromechanical component that connects the electrical circuit. It is composed of a fixed female contact (socket), and a free male contact (plug). According to the shape, there are circular electrical connectors and rectangular electrical connectors, and each type can be subdivided based on the connection method.

To select a suitable electrical connector, we should carefully consider their parameters, which include the electrical, safety, mechanical, and environmental parameters. In the future, electrical connectors will develop in many directions, especially in high-speed transmission.

Electrical connectors mentioned in this writing are the most common electric connector used in the industry. There are many kinds of shapes and function, the most common being the circle-shaped (circular connector) and square-shaped (rectangular connector).

Thousands of configurations of connectors are manufactured for power, data, and audiovisual applications. Electrical connectors can be divided into four basic categories, differentiated by their function:

• inline or cable connectors permanently attached to a cable, so it can be plugged into another terminal (either a stationary instrument or another cable)
• Chassis or panel connectors permanently attached to a piece of equipment so users can connect a cable to a stationary device
• PCB mount connectors soldered to a printed circuit board, providing a point for cable or wire attachment.[6]: 56  (e.g. pin headers, screw terminals, board-to-board connectors)
• Splice or butt connectors (primarily insulation displacement connectors) that permanently join two lengths of wire or cable
  In computing, electrical connectors are considered a physical interface and constitute part of the physical layer in the OSI model of networking.

In addition to the classes mentioned above, connectors are characterised by their pinout, method of connection, materials, size, contact resistance, insulation, mechanical durability, ingress protection, lifetime (number of cycles), and ease of use.

It is usually desirable for a connector to be easy to identify visually, rapid to assemble, inexpensive, and require only simple tooling. In some cases an equipment manufacturer might choose a connector specifically because it is not compatible with those from other sources, allowing control of what may be connected. No single connector has all the ideal properties for every application; the proliferation of types is a result of the diverse yet specific requirements of manufacturers

Kind of Connector

An electrical connector is an electromechanical device used to create an electrical connection between parts of an electrical circuit, or between different electrical circuits, thereby joining them into a larger circuit.

Electrical connectors are classified into three types based on their termination ends:

• Board-to-board connectors,
  • Board-to-board connectors are used to connect PCBs without a cable. The board-to-board connectors can save space on cables, making them suitable for systems with limited space.
• cable/wire-to-cable/wire connectors,
  • Wire-to-wire connectors connect two wires, as the name suggests. One end of the connector is permanently connected to the wire. The other end of the connector forms a separable interface.
• Cable/wire-to-board connectors
  • Cable-to-board connector, as the name suggests, connects a wire/cable to a PCB. The wire connections are similar to the one used for wire-to-wire connection, and the board connections are, for the most part, press-in or soldered two-piece connectors; although, some card edge versions remain in use.

Component electrical connector

• The main components of a connector include the contact springs, contact finish, and connector housing. The contact interface is defined by the physical electrical connection of the pieces of the connector that are mated, and this determines how well the connector performs.
• Plug and Socket: There are two different formats for connectors, the male, and the female.
• The Number of Pins: When choosing a connector, it is crucial to consider the number of pins that will be required you’re your application.

These connectors are often called jacks but the correct name is plugs. The term jack connector or jack plug often refers to the type of plug pictured right. These come on various sizes and configurations, and are very common in audio equipment.

Electrical Connector Parameters

Electrical connectors are electromechanical components that connect electrical circuits. Therefore, the electrical parameters of the connector itself are the first issues to be considered when we select the connector.

Rated voltage

Rated voltage is also called working voltage. It mainly depends on the insulating material used by the machine and the distance between the contact pairs. Some components or devices may not be able to perform their proper functions when the voltage is below their rated value.

Rated Current

the connector generally works normally under the rated current. In the connector design process, the thermal design is to meet the rated current requirements. When there is a current flowing through the contact pair, due to the conductor resistance and contact resistance

Contact Resistance

Contact resistance refers to the resistance generated by the two conductors at the contact part. There are two issues to be noted.

First, the contact resistance index of the connector is actually the resistance of the contact pair, which includes the contact resistance and the conductor resistance of the connect pair. Usually, the conductor resistance is small, so the contact pair resistance is called contact resistance in many technical specifications.

Shielding Property

In modern electrical and electronic equipment, the increasing density of components and related functions between them has imposed strict restrictions on electromagnetic interference. Therefore, the connector is often packed with a metal shell to avoid the internal electromagnetic radiation and the interference from the external electromagnetic field. At low frequencies, only magnetic materials can significantly shield the magnetic field.

In this section, we will present some connectors with brand Nanaboshi from Japan, Harting connector from german, TE electrical connector from the UK, and Hirose connector from Japan.

Industrial Electrical Connector

Nanaboshi Connector has a various model with contacts ranging from 1 pin up to 40 pins. And also various ampere capacity ranging from 3 amperes up to 500 Ampere with low voltage at 6.6 KV

Nanaboshi Connector manufactured by Nanaboshi Electric mfg co. Ltd from Japan. And for the connection system, it is directly welded instead of using a screw. The material used in this Connector production, for housing connector is made using aluminum alloy dan zinc alloy.

The whole set of Nanaboshi Connectors consists of two main parts, plug, and receptacle, with insert contact in the form of insert pin, and often referred to as male contact, and socket insert that often referred to as female contact.

Nanaboshi connector has two types, the S type and the G type which classifications determined based to shell shape, which inside is located pin insert or socket insert.

Nanaboshi has various model and series, these are Nanaboshi electrical connector series that are commonly used in the industry :

Hirose Connector

Heavy Duty Rectangular Connector

The connection method of the plug and the socket of the rectangular electrical connector generally has two forms: straight plug and pull and thread locking type.

Safety Plug

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