Everything You Need To Know To Find The Best custom Connectors apply for Automotive

How do you go about identifying the ideal connector for your design? Going the custom route certainly has its advantages, as does opting for an off-the-shelf connector. If you&#;re working with both, you may also run into a problem where your connectors are incompatible, so how do you get your custom connectors to work with standard ones?

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We&#;ll answer that question and cover the basics of connector specifications so that you&#;re a step closer to finding the best connector for your needs.

Types of Connections

Early in the design process, the type of connector that will be used should be identified. You&#;ll determine the primary function of the connector. For example, will the connector need to be accessed frequently or is it a permanent fixture? This helps you decide what type of connector you should focus on.

Permanent

Permanent connections are the ones designed to stay connected for the life of a product. There won't be any plugging and unplugging involved. The connection scheme could be through-hole solder PCB mounted or SMT PCB mounted or soldered to wire or crimped to wire or even welded.

Semi-Permanent

Semi-permanent connections have a design that allows access for disconnecting or replacement when necessary. This happens when servicing a part or replacing a used part.

Active Connections

Connectors that get connected and reconnected often are active connections. These connectors can handle the wear of regular plugging and unplugging.

Disposable

Disposable connectors are tailored to very specific applications and markets like the medical industry. These connectors work because they have a short or one-time usage and are disposed of rather than undergoing a sterilization process.

Connection Considerations

One of the first steps in deciding the type of connector to use is the type of connector it will be. Future steps will examine a few other key considerations.

Locations

The location of the connector on the component is a factor to consider. Does it need shielding? What about the temperature and humidity or vibration considerations? You also want to consider the environment the component is in.

T

ypes

The use of the connector often determines the type of materials used for the connector. The selection of connector materials including a plastic insulator, metal connector pins, receptacles, and metal or plastic shells must be determined. Decisions on each of these characteristics each have their strengths and weaknesses for connectors.

Requirements

Connector planning must also take into consideration safety and regulatory demands. When it comes to power connectors, manufacturers must follow safety certifications like UL/CSA.

Many industries have their own guidelines that connectors must follow. For example, the automotive industry has automotive electronics standards such as the IATF standard for quality management for their connectors.

Standard Connections

Standard connectors are common connectors that many different products use. They are often mass-produced by multiple suppliers and easily accessible.

Benefits

The standard connector usually comes from different manufacturers. This protects the company from supply problems. With multiple suppliers providing the connector, companies aren't relying on just one provider. Most standard connectors are available when needed because of the volume of parts made.

Realities

Depending on the type of standard connector, not all of the common ones are always in stock. Manufacturers can have production problems due to shortages of some common connectors.

Sometimes manufacturers can make slight changes to their standard cable and connectors. This could cause serious problems for a manufacturer who has designed a product around a specific standard connection.

Even a small change to a connector could alter the ability of a part to function. If a company manufactures for a highly regulated industry, any change to a product must be studied and approved.

A change of design will present a problem for the manufacturer. They will have to stop production and wait until the new standard connector change is approved.

Custom Connection

Custom connectors are preferred when a designer chooses a custom connector for a specific application, which must meet a key purpose and function for that manufacturer.

Benefits

Since the custom connector is designed for a specific role, it won't have unnecessary parts or features. Standard connectors are produced for many different scenarios and often have multiple features.

This can bring their price per unit up. A custom connector can be designed for a specific need and can often be created at a much less expensive price per unit. When a part is a custom, the elements around it and how it will function are all taken into consideration, which could save money in their production.

When a part is custom designed, it can consider meeting regulatory requirements. The design will line up with all regulations and there shouldn&#;t be a problem with it being changed and having to be approved.

A standard connector may offer a specific number of options for pins, pin sizes and types (e.g. square, diameter, rectangular), overall mating lengths, retention feature, base metal, plating, or other important connector characteristics.

On the other hand, a custom connector pin allows you to choose the connector characteristics that meet your exact application requirements.

Realities

Custom connectors do take some planning and investing upfront. There will be time spent on the design and development of the custom part. This means manufacturers will have to plan ahead to have the parts ready.

The long-term cost savings of a custom part and other benefits can outweigh the initial investment. The manufacturer will have to work through that process to decide.

A Custom Standard Union

One of the best advantages of a custom connector is the ability to design exactly what you need. This will provide the best connection for the application and gives you creativity in the design process.

Many manufacturers are designing custom connectors so they meet the need perfectly, but can also fit a standard connection. This provides the perfect union of the custom and standard needs for a connector application.

You can benefit from the advantages of a custom connection, but also utilize the alternative for a standard connector if preferred. This could give your application an advantage in the marketplace.

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Your Custom Connector Focus

A custom connection can fit your project perfectly within your overall budget while meeting design objectives. You can design the perfect part without wasting money on things you don't need. Plus, you can even design your part to mate to standard connections.

If you&#;re working with custom connectors or standard ones on your project, and need a reliable partner to help identify the best materials and connector solutions, look no further than Bead Electronics. We are a global designer and manufacturer of electronic connector pins and have been operating in our automated site in Connecticut for over 100 years. Click here to speak to a specialist today.

Connectors are critical for applications in a wide range of industries. Devices are becoming smaller. Many manufacturers take a modular design approach to bring products to market faster.

The increasing number of printed circuit boards requires more and more connectors. Standard connectors may not meet the requirements. Custom connectors let you design a connector that fits your exact specifications.

Learn more about custom connectors and what the design process involves.

When to Consider Custom Connectors

Custom connectors are beneficial in many circumstances. They can help you launch a new product more successfully. You can scale production more efficiently.

A new custom connector can help you meet product validation dates. You can avoid long lead times.

Common reasons a custom connector instead of a standard connector may be the best option include:

• Mechanical and electrical/electronic requirements are not met with standard connectors
• Needing extra protection from extreme environmental conditions
• Failing to meet creepage and clearance standards
• Failing to meet testing standards
• Needing to align PC board contacts with your product's unique layout
• Facing long lead times or the lack of specialized parts

Custom connector pins can help you change existing products or create new ones.

Modifications vs Completely Customized Connectors

You may be cautious about using custom connectors if you're in an industry like aerospace. The process for approvals and the need to meet stringent requirements can be a deterrent.

Custom connectors can use the design of Qualified Products List parts as a baseline. This provides assurance that the customized part will meet reliability and quality specifications.

Modifications to an existing design can reduce the cost of development. A modified product may have fewer prototyping and testing requirements. The approval may be easier than for a new design.

Consider the Application for Custom Connectors

The application is a primary consideration for custom connector design. The application helps determine all elements of a new custom connector.

Some applications require a more complex configuration than others. For example, a GPS unit probably needs a multi-pin connector. A simpler application may only need a wire-to-wire crimp connector.

How Often Will the Connector Be Mated and Unmated?

Connectors fall into one of several basic categories. The primary function of the connector helps determine which type you should choose.

Permanent

Permanent connectors stay mated for the life of a product. They won't undergo repeated plugging and unplugging.

Semi-Permanent

The design of semi-permanent connectors allows access for disconnection or replacement when necessary. You can access a semi-permanent connector when servicing or replacing a part.

Active

Active connectors need to withstand repeated plugging and unplugging. They need to be wear resistant.

Disposable

Disposable connectors have specific uses in applications like medical devices. Disposable connectors have a short or one-time use. Users dispose of them instead of attempting to sterilize them.

What Is the Service Environment?

The service environment of the connector helps determine some of its design considerations. Factors to consider include:

• Operating temperature
• Placement on the component
• Exposure to substances like grease, chemicals, water, dirt, or dust

Vibration

For example, shielding can protect against unwanted electromagnetic interference radiation.

Connectors may need shielding because of their location on the component.

In applications with high mechanical stresses, the connector may need better rigidity. Bosses, threaded inserts, and pin serrations can help with retention.

Material Considerations

Many options for connector materials are available. The materials affect the weight, cost, and reliability of the component. Custom connectors give you the choice of materials.

You can select the base metal, contact plating, and the shell. Common base metals are:

• Steel
• Copper
• Brass
• Aluminum

Stainless steel is the best choice for a medical environment with frequent sterilization. Aluminum alloys are lightweight and can withstand harsh environments. Brass connectors can handle excessive wear.

Metals for contact plating include:

• Tin
• Gold
• Nickel
• Palladium nickel

Gold has excellent electrical and thermal properties. Nickel is a good choice for high-temperature applications. Palladium nickel is very durable with good electrical and thermal properties.

Electrical Requirements

The voltage and current requirements for your application determine design details like:

• Number of contacts
• Contact size
• Contact spacing
• Wire size
• Insulation material

For example, you'll need a stronger insulating material if high voltages are present. Wide pin spacing is another way to handle high voltages.

High-power signals like ground connections may require several pins connected together. You can also use dedicated pins for power, ground, and signal traces.

High-current applications can create heat from resistance in the pins. This can require extra cooling, which needs more space.

Space Requirements

Many connector applications have strict space requirements. Miniaturized connector solutions may be necessary. Space considerations include:

• A large enough connector to handle the required current
• Enough space for the necessary contacts or extra connectors
• Space for adequate cooling and ventilation elements

Nesting or ganged arrangements are possible. Combined functionalities with fewer interfaces can help reduce the space a connector needs.

Termination Style

The connector termination attaches the connector to individual conductors. The conductors can be discrete wires or jacketed cables. PCB connector terminations include:

• Through-hole
• Surface mount
• Pin-in-paste or through-hole-reflow
• Press-fit

The termination style affects how well the connector is sealed. It also determines its mechanical strength.

Choosing a Custom Connector Manufacturer

Many factors contribute to the design of custom connectors. The service environment of the connector determines many aspects of custom connector design. The right design choices help ensure the connector performs reliably.

Bead Electronics provides custom, quick, and cost-effective pin manufacturing to provide for your custom connectors.

At Bead we're dedicated to meeting the specific needs of your project. We deliver quality products on time that meet and exceed our customers' requirements.

Contact us today to request a quote for your project.

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