Wire Harness Connectors And Terminals – Making The Right Choice


A wire harness is a component that houses multiple similar electrical wires that transmit signals or power; the wires being bound together by electrical tapes, conduits, string, or the like. But, these wire harnesses aren’t of any use if they don’t connect with the right connectors and terminals. The connectors help to form a continuous electrical signal by connecting the wire harnesses to a power source or circuit; and the terminals help terminate the conducting wires to establish an electrical connection. So, how do you choose the right connector and terminal for your particular wire harness? This can be done if you understand the various types of connectors and terminals available, so that you can decide as to which one will suit your precise requirement.

Types of connectors

To decide upon the kind of connector you should use, there are multiple performance factors that you need to consider, such as the power contacts, signal contacts, insulation requirements, and mating type. There are also various configurations available, such as wire-to-wire, board-to-board, and board-to-wire. You also need to know the wire size, current rating, operating voltage, circuit density, circuit size, and engagement force while deciding upon a connector.

Types of terminals

Ring terminals – These are round ended terminals that allow screws and studs to be attached.

Hook terminals – These are simple open-ended terminals, which help easy attachment and removal in harness applications.

Spade/Fork terminals – These are fork shaped terminals, open-ended for easy attachment and removal in harness applications, with tight space requirements.

Bullet terminals – These provide secure connections between male and female connectors, intending to prevent corrosion and damage from dangerous materials.

Flagged terminals – These have a 90° bend like a flag on a pole, which is why the name. They are ideal to be used in tight spaces, providing easy connections.

Butt terminals – These are used to easily extend wires by installing them on open ends of connectors. They are expert in guarding the wires against moisture, corrosion, and abrasion.

Quick-disconnect terminals – These are designed for rapid disconnect in automotive, industrial, and consumer applications.

Considering all of the above, you can decide upon the types of wires, connectors, and terminals that you want implemented in your wire harness. If it seems like a difficult job, you can partner with professional wire harness manufacturers to help you make the right decision. After all, it is important that your wire harness is correctly designed with the right connectors and terminals, so that you have a well-performing wire harness, which won’t require any repairs of replacements for a long time to come; thus extending the life of the wires.

Miracle Electronics is one of the most reliable wire harness manufacturers from India, where you can work with the professionals to have a customized wire harness designed for you, specific to your particular application and requirements. Besides, Miracle Electronics will assure you the best quality products because every production process executed here is certified for quality to ISO 9001, AS9100C; and the quality of every wire harness manufactured here is approved and certified by DGAQA and MSQAA. Moreover, the products are perfectly tested for dimension, weight, continuity, Megger/Hi-Pot, and pull tests, guaranteed you assured products.

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