Selection Guide for Electrical Connectors
Electrical parameters of electrical connectors
Electrical connectors are electromechanical components used to connect electrical circuits. Therefore, electrical parameters are the first consideration when selecting electrical connectors.
Rated Voltage
Also known as operating voltage, which mainly depends on the insulation material used by the electrical connector and the distance between the contact pairs. Some components or devices may not be able to perform their functions when operating at voltages lower than their rated voltage. The rated voltage of the electrical connector should be understood as the highest working voltage the manufacturer recommended. In principle, the electrical connector should work normally at voltages lower than its rated voltage.
Rated Current
Also known as operating current. In general, the electrical connector can work normally at currents lower than its rated current.
Contact Resistance
Contact resistance refers to the resistance generated by the contact part of two contact conductors.
Shielding
In modern electrical and electronic equipment, the increasing density of components and their increasing functionality have imposed strict restrictions on electromagnetic interference. Therefore, connectors are often enclosed in a metal shell to prevent internal electromagnetic radiation or interference from external electromagnetic fields.
Safety Parameters of Electrical Connectors
Insulation Resistance
Insulation resistance refers to the resistance value that occurs when a voltage is applied to the insulating part of the connector to cause leakage current in or on the surface of the insulating part.
Withstand Voltage
Withstand voltage refers to the critical voltage that the insulated part between contact pairs or that between the insulated part and the ground can withstand without breakdown within a specified time period.
Combustibility
Since any connector is inseparable from the current when working, there is a risk of fire. it is required that the connector not only prevents ignition but also can self-extinguish quickly in case of ignition and fire.
Mechanical Parameters of Electrical Connectors
Single-foot Separation Force and Total Separation Force
Contact pressure is an important index that directly affects the contact resistance and wear of the contact pairs. In most structures, direct measurement of contact pressure is quite difficult. Therefore, the contact pressure is often indirectly calculated by measuring the single-foot separation force.
Mechanical Life
The mechanical life of the connector refers to the insertion and withdrawal life, which is usually specified as 500~1000 times. When the specified mechanical life is reached, the contact resistance, insulation resistance, and withstand voltage of the connector should not exceed the specified values.
Number of Contact Pairs and Pinhole Properties
The number of contact pairs should be selected according to the needs of the circuit, taking into account the size of the electrical connector and the size of the total separation force. If higher reliability is required and the volume allows it, a method of parallel connecting two contact pairs can be used to improve the reliability of the connection.
Vibration, Impact, and Collision
Mainly consider the electrical continuity of the contact pairs of the connector when it is subjected to vibration, impact, and collision under specified frequency and acceleration conditions.
Connection Method of Electrical Connectors
Connectors generally consist of plugs and sockets, of which the plug is also called a free-end connector, and the socket is also called a fixed connector. The connection and disconnection of the circuit are achieved by the plugging and separation of the plug and socket, resulting in various connection methods for the plug and socket.
Installation Method and Appearance of Electrical Connectors
Connectors can be installed in advance or later, and the installation and fixing methods include rivets, bolts, retaining rings, or quick locking pins of the connector itself, etc. There is also a type of connector with free-end connectors for both the plug and socket, which is called a relay connector.
The appearance of connectors varies greatly, and users mainly choose them from straight or curved shapes, the outer diameter of wires or cables, the fixing requirements to the shell, volume, weight, and the necessity to connect metal hoses. For connectors used on panels, they should also be selected based on their aesthetics, shape, color, etc.
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