How to avoid choosing the wrong connector? - Selection Guide for Industrial Applications
In the fields of industrial automation, communication equipment, new energy systems, etc., connectors play a vital role as key components for signal and energy transmission. However, improperly selected connectors often lead to system failures, reduced efficiency, and even safety hazards. So, how to avoid making selection mistakes? The following suggestions can provide you with reference.
1. Clarify application requirements and accurately define parameters
Different application scenarios have very different requirements for connectors. Before selecting a connector, you must clearly understand the project requirements, including but not limited to:
Electrical parameters : working voltage, current, contact resistance, insulation resistance, etc.;
Environmental conditions : temperature range, dustproof, waterproof, and corrosion-resistant grades (such as IP67 and IP68);
Mechanical properties : plug-in and pull-out times, vibration resistance, tensile strength;
Size and layout : installation space, connector volume, cable size;
Certification requirements : whether it complies with international standards such as UL, CE, RoHS, etc.
Only by quantifying the actual needs and listing the detailed indicators can we accurately select the appropriate connector model.
2. Pay attention to the connection method and locking structure
The connection method of the connector (such as thread locking, bayonet locking, push-pull connection) directly affects the installation convenience and operation reliability. For example:
For applications with frequent plugging and unplugging, quick-lock connectors should be selected;
In high vibration and high impact environments, threaded connection or slot locking products are preferred;
In situations where space is limited, a push-pull self-locking design is more suitable.
The connection stability and maintenance efficiency brought about by different locking methods are obviously different and cannot be ignored.
3. Considering both materials and protective performance
The connector material determines its weather resistance and durability:
Shell material : plastic (such as PBT, PA66), metal (such as nickel-plated copper shell);
Sealing ring material : silicone, fluororubber, etc., determines the waterproof, dustproof and anti-corrosion capabilities;
Contact material : gold-plated or tin-plated contacts affect the quality and life of electrical transmission.
When used outdoors, in humid and corrosive environments, products with **metal housing + high-level protection (IP68 or above)** are preferred.
4. Avoid Over- or Under-Specification
Many engineers tend to make two common mistakes when selecting:
Excessive specifications : lead to higher costs, larger volume, and more complicated installation;
Under-specification : Electrical overloads, seal failures, or even equipment failures can occur.
The correct approach is to leave a 20%-30% safety margin based on actual work needs to ensure reliability while controlling cost and space.
5. Choose reputable suppliers and brands
Although connectors are small, supply chain and manufacturing quality control are extremely important. Suppliers with the following standards are preferred:
Have strict quality system certification (ISO9001, IATF16949, etc.);
Provide stable batch quality;
Have complete technical support and after-sales service;
Customized solutions can be provided according to project requirements.
Well-known brands and experienced technical teams can greatly reduce the system risks caused by selection errors.
Correctly selecting the connector is the first step to ensure the stable operation of the system . Understanding application requirements, accurately defining parameters, rationally selecting materials and connection methods, and cooperating with high-quality supplier support can ensure that your equipment runs more efficiently and reliably.
Don’t let a small connector become a hidden danger of system failure. Start with professional selection to make every connection smarter and safer!
