How to improve the efficiency of connector assembly?
Advanced technology allows companies to design and manufacture products in different locations, promoting global business development. However, these scalability capabilities often create unique challenges that can lead to inefficiencies, especially since feature-rich electronic innovations often rely on a variety of complex wire-to-wire and wire-to-board connections.
As a result, when assembly teams need to accurately match or “mate” a miscellaneous variety of cables and connectors, the risk of costly errors and production delays can rise significantly.
In addition, it is often found that spending too much time on this delicate task can also increase the likelihood of on-the-job repetitive strain injuries and musculoskeletal problems, resulting in additional costs for manufacturers.
Matching is important
Assembly quality is one of the critical aspects of connector performance that is often overlooked. Even the most robust connectors made from top-notch materials will degrade in performance if not properly mated or installed. As a result, companies are increasingly focusing on identifying and resolving connector-related assembly issues.
The difficulty encountered with traditional connectors is that they often contain multiple functions and circuits with different purposes, while the connectors themselves are small and similar in appearance. As a result, even the most skilled assembly teams can make the following serious mistakes, especially when working in a hurry:
(1) Cross-mating – The male and female connectors of two different brands are matched or bonded together.
(2) Mismating – The male and female connectors of two connectors of the same brand are incorrectly matched or bonded together.
Cross-mating: a high-risk operation
While connectors from different brands are often very similar, cross-mating them can cause serious or even dangerous problems with intended functionality, reliability, and/or safety. As industry and application demands for power continue to increase, these potential issues must be taken seriously, especially as a wide variety of design materials become available.
There is no one-size-fits-all solution that delivers superior performance in every application, so different connector manufacturers use a wide variety of materials to build their products. Each option has certain advantages in specific situations. For example, the connector body provides mechanical and environmental protection.
A wide variety of plastics or metals can be used as materials for the connector body, depending on the intended application. Therefore, cross-mating connectors may combine two incompatible materials, which may severely impair functionality.
Wrong mating: a costly mistake
Even if the connector is made by the same manufacturer if mated incorrectly it can have a huge detrimental impact on performance, production costs and end-user safety.
Improper mating can result in signal loss, mechanical failure, equipment damage or short circuits, and can require significant time troubleshooting. The risk of assembly errors may be further increased if connector labels are printed in an unfamiliar language or are lost entirely in transit.
Keying technology is the solution
Fortunately, production teams are no longer limited to traditional connector designs. An increasing number of multi-functional connector solutions are being developed to address these significant issues. These products come in two main forms:
Colour-keyed connectors – have a bright appearance or colour-coded graphics that make it easier and faster to visually match coordinated colors and identify errors.
Mechanically Keyed Connectors – Uniquely shaped to fit only the corresponding connector and can only be inserted one way.
Understand keying and polarization
In addition to preventing mismatching, mechanical keying solutions also reduce the likelihood of polarization errors that can cause problems. Since polarization and keying are two very similar connector characteristics, they are often confused.
Polarization refers to one or more features of a connector pair designed to only allow mating in the correct orientation. For example, one of two connectors may be mated correctly during assembly, but the other may be incorrectly rotated 180 degrees.
Adding mechanical keying functionality physically prevents this error from occurring. Mechanical keying is especially important if the operator cannot see the connector components during assembly (a practice known as “blind mating”).
All in All:
Keying helps assembly operators quickly and accurately match/mate connectors when working with multiple similar-looking connectors. There is no need to stop and look for subtle identification marks, greatly reducing the possibility of cross-mating or mismating.
Polarization helps ensure that correctly matched connectors mate in the correct orientation. The unique shape of mechanically keyed connectors often serves as a polarizing function because the connectors can only be assembled together in one direction.
Promote design flexibility
Given these important dynamics, forward-thinking design engineers can provide significant efficiency benefits by specifying keyed connectors early in the project.
Likewise, engineers who want specific capabilities can proactively support evolving product safety and reliability needs. Keep in mind, when considering incorporating keyed connectors, that the following characteristics often help optimize long-term performance:
① As products become smaller, compact designs save valuable printed circuit board (PCB) space
② The barriers between each mating housing can reduce the arc discharge effect caused by contaminants
③ Polarizable bonds on the shell reinforcement reduce the possibility of electrical short circuits
④ The retainer helps the crimp terminal to be fully inserted to prevent moisture from entering
⑤ Pressure lock housing provides tactile and auditory feedback to help increase assembly speed
⑥Terminal secondary lock (TPA) ensures that the terminal is firmly fixed in the connector jacket to reduce electrical contact problems caused by terminal backout
⑦ Anti-snagging design enables a more efficient process
⑧ Halogen-free materials can withstand high-temperature assembly processing
⑨ Meet European Glow-Wire standards to ensure consumer safety
Support various needs of different industries
As today’s advanced product designs integrate more and more functionality into smaller and smaller spaces, connector keying technology is becoming increasingly common in a variety of industries.
Automotive, appliances, consumer products, healthcare, industrial, telecommunications, defence and many other industries require highly reliable performance, and reliable performance depends on accurate interconnects. Factors such as rough handling and harsh working conditions require proper, secure connector mating.
Additionally, as new generations of smart devices and appliances operate without constant user supervision, correct and precise connector pairing is essential to ensure safe and reliable performance. The video in this article provides an in-depth look at the various ways keyed connectors can improve efficiency in many demanding applications.
Improve efficiency to ensure safety and performance
Today’s fast-moving business environment leaves little room for error, but safe and reliable product performance remains a top priority. Color-keyed connectors and mechanical keying controls help prevent costly mating errors, simplify the assembly process, speed up production, and even improve workplace ergonomics.
When specifying keyed connectors for a specific design, intentionally selecting specific features also often helps improve the long-term functionality of the product. These innovative connection solutions represent in many ways the “key” to increased efficiency, and that’s not empty talk.