This guide will provide all the information you need to become a pro on DVI cable. Then you can use your knowledge to buy the right DVI cable. You will get to know about the following:
Different DVI formats
Their use and differences from other cables
Places to purchase DVI cables
Chapter 1: About DVI Cable
DVI is among the many video cables you find in the market. DVI stands for digital video interface. You can use a DVI cable for LCD monitors and modern GPUs. Before we go into the depths of DVI, let’s check out the main types of cables.
DVI is among the many video cables you find in the market. DVI stands for digital video interface. You can use a DVI cable for LCD monitors and modern GPUs.
DVI Vs. HDMI
HDMI supports both audio and video. DVI only supports video signals. You need a separate cable for audio.
DVI is not compatible with HDCP encryption. You may not be able to play HD content or Blu-Ray videos.
DVI is more common for LCD monitors and computers. HDMI is the default cable for smart TVs, HDTVs, and home theaters.
Dual-link DVI can support resolutions up to 2560×1600 pixels. HDMI can support up to 1920×1200 pixels.
DVI cable has three formats. On the other hand, HDMI has five different connector types.
HDMI may be more user-friendly than DVI cables.
Chapter 2: The Different DVI Formats
You can find different formats of DVI cables in the market. Here’s a breakdown of the formats to help you choose the right one.
DVI-D
You can use DVI-D cables for connecting video sources to a video output device directly. For example, you can use DVI-D to connect GPU with LCD monitors.
DVI-D cables support higher qualities and offer more speed. This is due to the digital format of the signal.
DVI-D cables eliminate the need for format conversion, and most video cards produce digital signals. But they convert them to analog signals for transmission.
But DVI-D cables can transfer the digital signal to the monitor directly. The monitor then again converts the analog signal to digital.
DVI-A
You can use a DVI-A cable to connect to a VGA monitor. DVI-A cables transmit analog signals to analog display devices. You can use them for cheap LCD monitors or other analog devices.
DVI-A and VGA cables carry the same analog signal. Like VGA, you may experience some quality loss.
DVI-I
DVI-I cables come in integrated forms. They can transmit digital-to-digital or analog-to-analog signals. For this reason, you can use them in versatile applications. DVI-I is suitable for both analog and digital transmission.
Remember that DVI digital and analog formats are not interchangeable. You can’t use DVI-A for digital devices or DVI-D for analog devices.
You may connect analog to digital, but you need a converter (VGA to DVI-D converter). For connecting digital to analog, you will need a DVI-D to VGA converter.
Chapter 3: Single and Dual DVI Links
DVI cables that carry digital signals may come in a single link or dual link. That means you get single and dual links for DVI-D and DVI-I cables. Dual-link cables can support higher resolutions. A single-link DVI cable has 12 pins missing. Dual-link DVI, on the other hand, uses all 24 pins.
So, what is the difference between the two?
Single Link DVI Cable
DVI cables transmit signals using a format called TMDS (transition minimized differential signaling). Single link DVI takes the help of one TDMS 165MHz transmitter. It can support resolutions of 2.75 megapixels at a 60Hz refresh rate.
On-screen, this translates to a resolution of 2,098 × 1,311 pixels for a 16:10 ratio. For 4:3 ratio, it supports resolutions of 1,915 × 1,436 pixels.
Dual Link DVI Cable
Dual-link DVI supports higher resolutions than single-link DVI. You can enjoy resolutions of 2560×1600 pixels at a 60Hz refresh rate. This is ideal for high-end gaming and high-definition videos. At 120Hz, you can get a resolution of 1920×1200 pixels.
Dual-link DVI cable uses two TDMS 165MHz transmitters instead of one. Each link comes with 3 data channels to carry RGB information. The dual links enable the cable to double the power transmission. You can also take advantage of high speed and strong signal quality.
Chapter 4: How to Identify a DVI Cable?
With so many cables out there, you may find it confusing to identify a DVI cable. That’s why we thought of giving you a few tips. Here’s how you can recognize a cable quickly.
1. Look for a flat pin on the side of the DVI cable. It will tell you whether it’s a digital or analog cable.
If you find a flat pin with four pins around it, then it’s either DVI-A or DVI-I cable.
If you see a single flat pin, then it’s a DVI-D cable.
2. The pin sets of the cable will tell you whether it’s analog, single-link, or dual-link.
A single link cable will have two separate 9-pin sets in six rows.
A dual-link cable will have 24-pin sets in rows of eight.
A DVI-A cable will have separate 8-pin and 4-pin sets.
Chapter 5: Where to Buy DVI Cables?
You will get DVI cables in various stores and shops. But you may need to shop around a bit for custom cables. You can try the following places.
Local Electrical, Audio/Video, and Computer Shops
Many electrical stores sell DVI cables. You can also find them in your local computer and audio/video shops. Before buying, check whether they sell custom DVI cables. You may also be able to place an order for custom cables.
Online Stores
You can browse various online stores that sell custom DVI cables. A simple Google will help you find many online stores.
You should check the reputation of the seller before you place your order. Also, check reviews to ensure the cables are of good quality.
It’s best to go for online stores in your area to enjoy free or low shipping rates.
Custom DVI Cable Manufacturers
If you cannot find your custom cable, you can approach DVI cable manufacturers. They will be able to produce DVI cables matching your design and specifications.
Placing an order with a manufacturer is also suitable if you are ordering large batches. You can also get your cables at much lower prices than in retail stores.
Chapter 6: Top Things to Look for in Custom DVI Cable
Before you put your cable to use, there are a few things to check. You need to make sure your custom DVI cable matches your specifications. Only then can you use it effectively.
DVI Connector
The DVI connector is the first thing you should check. Make a count of the pins to ensure they match your design. The number of pins and their arrangement should also be on your inspection list.
You can count the pins to determine whether it’s DVI-D, DVI-I, or DVI-A.
The arrangement will also tell you whether it’s a single link or a double link.
Cable Length
The next thing to check is the length of the DVI cable. Your custom cable should be long enough to establish the connection. It would help if you didn’t have to pull or stretch the wire. This will only damage the cable.
For best results, decide the cable length you will need. Then place the order for your custom DVI cable.
Quality
You must also want your DVI cable to be durable and of high quality. Nobody wants to compromise on quality! So check if the quality matches your expectations. Carefully inspect the insulation, connector, pins, and other components of the cable. If you find any quality issues, ask for a refund or place a new order.
You can also do a few things to ensure quality-
Go for a reputed cable shop or manufacturer.
Check the products of the company before you order
Read reviews and testimonials of existing customers
Ask for a sample
FAQ
1. What DVI cable do I need for a 144Hz monitor?
You can use a DVI-D dual link cable for a 144Hz monitor. Dual-link DVI-D supports 144Hz at 1080p.
2. What cable do I need for my CRT monitor?
Your CRT monitor is compatible with only analog signals. So it would help if you had a DVI-A cable.
3. Which cable is suitable for high-resolution gaming?
You can take the help of a dual-link DVI-D cable for intense gaming. It supports a resolution of up to 2560×1600 pixels. DVI-I is also suitable for moderate gaming needs.
4. Which DVI cable do I use for audio signals?
DVI only supports video formats. To transmit audio signals, you have to use a DVI-to-HDMI converter or cable.
5. My graphics card has two connectors. Which DVI cable do I need?
The two connectors on your graphics card may be for analog and digital signals. For the analog connector, use a DVI-A cable. You can use a DVI-D or DVI-I for the digital connector.
6. I have an old HDTV. Which DVI should I use?
First, check whether your HDTV has a DVI or HDMI connector. If it has a DVI connector, you can use a DVI-D cable.
Conclusion
By now, you must have learned a lot about DVI cable. You can now pick the right cable for whatever you need to have. We have also told you about other cables to make you fully aware. If you still haven’t found the right DVI cable, we recommend you contact us. We manufacture the highest quality, custom DVI cables based on your design and requirements.
USB cables have become the market leader, but they’re not always the right wiring option for your data transfer needs. You can find FireWire cables in everything from general automobiles to military aircraft.
FireWire cable may seem daunting to a layperson, but don’t fret. They are much more intuitive and easy to understand than you think! This article is your one-stop guide on their applications and importance.
Chapter 1: Why It’s Important To Use Firewire Cables
FireWire cables are a premier option for unparalleled data transfer speeds. They are instrumental when connecting multimedia devices such as video-editing equipment and camcorders. They may carry a higher overall cost ratio than USB 2.0 and USB 3.0, but they make up for it with performance.
FireWire cables also transmit and transfer power while transferring data. This cuts down on the need for multiple wires and the dangers which arise from a wealth of power points. The cable provides a solution if you’re worried about a complicated wiring pattern for your networking setup.
Using FireWire cables to match peak transfer speed with power supply capability is crucial. There are also plenty of audiovisual devices, television set-top boxes, and other consumer electronics which require FireWire connectivity.
They are important. The versatility and performance of the cable make it a true data transfer wiring superstar.
Chapter 2: What To Use Firewire Cables For
You can use FireWire cables for a host of different data transfer and power needs in various consumer automobiles.
They’re also a massive data transfer and power source for a wealth of cable television boxes. If you have a digital cable, you likely have one attached to your signal box.
These are also the cables used by military personnel for data transfer needs in aircraft and other vehicles. In such a high-stress environment, the high-speed capabilities of cable are an absolute must.
Are you looking to set up an ad-hoc computer network at your job site? FireWire cable provides versatility, data transfer speeds, and power supply to make such a setup possible.
Do you need to connect two computers? The cable is perfect for that too!
There’s also no better data transfer option for pressing audiovisual needs than the FireWire cable. If you need to transfer tons of video from a camcorder to your computer, the FireWire cable can’t be beaten.
There are plenty of other uses for FireWire cable, including charging and syncing older Apple devices. If you want to use the old iPod you just found, you’ll need a custom FireWire cable to get things going.
Chapter 3: How A FireWire Cable Works
FireWire cable uses a specialized copper cable up to 15 feet long in most common implementations. It moves data at 400 Mbps in its basic form. The newest IEEE-1394b advancement, FireWire 800, moves data at twice that speed.
FireWire cables are incredibly versatile when it comes to supporting multiple connector types. It features a six-pin cable to plug into a computer while also sporting a four-pin cable to connect to a peripheral.
This versatility comes in handy when connecting multiple device types on a single network.
One huge advantage of using FireWire cable is its ability to stream real-time data. It can also provide power while doing this.
FireWire cable offers reliable, fast data transfer through high-quality cable and versatile implementations.
Chapter 4: Signs You May Need A FireWire Cable
Is your networking setup overloaded with cables and wires, which present logistical issues? Do you suffer from lagging data transfer speeds, especially when providing power to a peripheral from an external source?
FireWire cable is a fantastic solution for complex wiring problems because it is versatile. While newer devices may need a FireWire cable adapter, it’s worth it if you’re looking for consistent, high data transfer speeds.
Are you transferring a bunch of different videos from a professional camcorder? Are you always sharing multimedia across your networking setup, professional or otherwise?
There is no match for FireWire cable to efficiently and effectively transfer multimedia files at high speeds.
Chapter 5: Where To Buy A Custom FireWire Cable
You can’t go to a retail store to buy a custom FireWire cable. You’ll need to enlist the help of a wiring company that provides data transfer solutions.
While you’ll be able to find stock FireWire cables online, they may not connect all the devices you need connecting.
A wiring company can build a custom firewire cable that eliminates the need for stock wires. During your consultation, they will listen to your needs and custom-craft the right FireWire cables.
There are a host of custom wiring services out there with varied reputations. Don’t settle for a second-rate wiring company that promises cheap rates instead of an excellent product!
With the help of a top-rated wiring company like Cloom Tech, you can get the right custom cable the first time!
Wiringo is your one-stop shop for intuitive wire harness and cable assembly solutions. Wiringo’s experienced technical team has made thousands upon thousands of custom cables for customers around the globe.
There isn’t a custom cable company out there that boasts the track record and customer satisfaction ratings of Cloom Tech.
Chapter 6: How Custom FireWire Cables Can Benefit You
Custom FireWire cables are the perfect solution for networking problems where there is no stock solution. They can help provide peak networking capabilities for a cache of devices and computers, both new and old.
Custom FireWire cables will cut your cord usage significantly while providing a simple data transfer option that’s blazing fast.
If you’re struggling with lag or unnecessarily long download times, get a custom FireWire cable designed for unparalleled speed and efficiency.
Chapter 6: What To Look For In A Cable Company
A FireWire cable company needs to be well-versed in your particular areas of need. They must have an innate understanding of wiring problems and solutions.
They should have years of experience setting up FireWire cables and the interfaces which utilize them. If you have questions on the whats and whys of cable, your cable company must have the answers.
The best cable companies have a game plan. If you’re struggling with lagging data transfer speeds, the right cable provider will demonstrate how they can help.
It’s all about simplicity. A top FireWire cable company combines technological knowledge to explain it in terms of relevance to a consumer.
Don’t settle for a FireWire cable company that pushes you to pay for a job without transparency. You deserve expert advice, installers, and technicians who anticipate problems instead of reacting.
Chapter 8: The General Cost
Customization of FireWire cables will save you money in the long run. While you’ll pay for materials and labor, the right custom FireWire cable is well worth it.
Imagine the money you’d spend on multiple wires that a single cable can replace. Besides, a custom FireWire cable is made for your current and future needs for whatever you need to use it for.
So it will replace unneeded wires now, and paying for a custom cable will limit future costs.
There are a lot of custom wiring services out there that can build a FireWire cable for you. However, there’s a varied cost breakdown for each.
With the glut of options out there, it can be very confusing which custom FireWire company to choose.
Well, there is one custom wiring service that can promise you the perfect balance of quality craftsmanship and no hidden fees.
Conclusion
Look no further if you require custom FireWire cables or multiple FireWire cables for your data transfer needs. Wiringo has made many custom FireWire cables for customers like you. Let the experienced staff work with you to meet and exceed your data transfer needs.
Since day one, we have been using computers for a long time, and VGA cables and VGA connectors have been part of our electronics and computers. VGA stands for Video Graphic Array, and there are many ways to connect the video sources to monitor and display devices like LCD.
If you are looking for commercial VGA cable manufacturing or want to buy bulk products for your business, you must know the basics of VGA cables.
We will discuss every aspect of VGA cables for commercial and industrial use. After reading this guide, you can decide the best manufacturing option for your business.
Chapter 1: What is a VGA Cable?
The standard VGA cable connects the video source to other displaying devices. You might have seen a blue-colored cable that connects the CPU to the LED.
This cable is the VGA connector that has three rows of 15 pins. VGA cables are the oldest connection method; even in 2019, we can see these connectors in many devices and industries.
Mostly the computing sector uses VGA cables in display devices.
Although the style and numbers of the pins have changed, the main working and model of VGA cables are still the same.
If you decide to buy a new bulk order of VGA cables for your industry or business, please get in touch with CLOOM Tech. At CLOOM Tech, we can design custom-made VGA cables for your business and devices.
CLOOM Tech is the industry leader in manufacturing customized cable harnesses and VGA cables.
Due to the increasing demand for VGA cable manufacturing in the computing sector, we provide all kinds of cable assembly, cable harnesses, and other electrical services for small and multinational businesses.
We have decided to write a detailed post about the VGA cables and everything you need to know about these cables.
History of VGA Cables
VGA cables are not always the same in terms of size. The traditional 15-pin VGA cables are used for general desktop computers, which is inappropriate for laptops and other mini devices.
Mini-VGA cables are used for small devices like the latest desktop PCs and laptops.
Still, in 2019, you cannot deny the importance of VGA cables in electronics. The latest technologies and cables like HDMI and DVI replace traditional VGA cables.
Most devices have replaced these traditional VGA cables. But you will need these cables if your system has some display devices as components.
Which Devices use VGA Cables?
Suppose you think that only computers use VGA cables. Several other devices use VGA cables to connect display sources and display devices.
Here are some devices we see daily in our surroundings that use VGA cables. In these devices, you can see the use of mini VGA cables and traditional normal-sized VGA cables.
Laptops
TV Screens
LED Displays
Video Cards
Video Devices
Chapter 2: How to Choose the Suitable VGA Cable?
There are many VGA cables, but there are no universal for. The choice of VGA cable depends upon your requirements and the design of your device.
If you have a normal-sized computer, you need a different VGA cable. And if you are into laptop manufacturing, you will need a mini VGA cable.
If you feel that this VGA cable choice is not an easy task for you, let us help you make the right choice for you. You can contact CLOOM Tech to manufacture VGA cables for your device and electronics.
Choosing a suitable VGA cable is not rocket science if you know the basics of VGA cables. First, you must decide the type of device you want cables for.
If that device is already available in the market, you can easily buy VGA cables from the market or contact CLOOM Tech for bulk orders.
But if you are designing a new device for your business or client, you may not find a suitable VGA cable.
You can consult with experts at CLOOM Tech for custom-made VGA cables. We have already worked with many top brands and developed customized wiring harnesses and assembly cables for several industries.
Things to look for in a VGA Cable
If you are making the first purchase of VGA cables for your electronics, you must have a checklist to check before making the payment. Here are some essential things that you need to consider:
· Quality of the VGA Cable
The quality and material used in manufacturing the VGA cables are paramount. The quality of the connectors and the VGA cables are also essential for the device’s safety.
You should never compromise on the cable quality if something goes wrong with the VGA cables; the whole device and the system can fail.
Although most of the VGA cables are not part of the device’s internal circuits yet, if something goes wrong with VGA cables, you will lose the display.
There are no universal or international standards to define the exact quality of the VGA cables.
But in general, high-quality VGA cables use coaxial cables of high material, and the external coating is there for extra protection.
The protective coating of inexpensive cables makes the cables thicker and protects the wires from damage and cuts.
· Design of the VGA Cable
The design means what kind of VGA cables you are looking for. If you are looking for traditional VGA cables for your electronics, you can quickly get the cables from any quality manufacturer like CLOOM Tech.
But if you are looking for unique wires with exceptional pins, you need to consult your design with the experts. So they can design custom VGA cables for your electronics.
While buying VGA connectors, you must see that the design follows the safety standards and that the wires fulfill the quality standards.
The internal design of VGA cables can vary depending on the size. The quality cables are generally thicker in size due to the protective layer of insulation.
At CLOOM Tech, our R&D team always works on making the design according to the latest electronic demands and standards.
We pay attention to the design of the VGA cables, and the quality is also important to our team.
Price of average VGA Cable
The cables’ cost depends upon the cord’s length and quality. If you look for top VGA cables on Amazon, you will see that regular VGA cables range from $7 to $15.
The price can vary if you want to buy lengthy wire for a specific purpose.
If you want a customized VGA cable for your business or electronics, you can consult our CLOOM Tech team to get a quote.
We provide the best quality wiring harnesses and cable assembly at a reasonable price for industries and businesses.
The price of the VGA cable can vary from brand to brand. We have analyzed this price from top online stores.
Chapter 3: VGA Cable for business-Levell Use
Many businesses and services require bulk VGA cables for professional use. Just imagine that you are setting up a new office in a new location.
You will probably need hundreds of VGA cables for your monitors, LED screens, and other devices. Buying these cables from any typical store will cost you a fortune.
VGA Cable Business
Due to the increasing demand for these connectors and cables, you can choose the business of VGA cable selling. You can set up an online or physical store in your local town.
If you want to place a bulk order for VGA cables, you can contact us at CLOOM Tech. We will deliver the most advanced cable assembly in the market.
How to get customized VGA Cables?
CLOOM Tech is one of the top brands for cable assembly, wiring harnesses, and automobile wiring. Generally, usual stores and sites don’t offer customized VGA cable manufacturing.
You have to contact a manufacturer that can design custom wires and cables for your devices. But before making the final deal, don’t forget to do a quality check on the company you choose for your transaction.
You can see testimonials of our top clients on several review sites, and you will find us the top pick of all businesses.
Many types of computer cables connect the different components of the computer with each other. Here are some of the most important types of computer cables that you must know.
You will see that many devices use these cables in different styles and designs. Some cables transfer data from one component to another, and some transfer energy from the source to the components.
VGA cables
DVI cables
HDMI cables
Ethernet cables
USB cables
Power cords
Display ports
Chapter 4: Where to buy VGA Cables?
Buying a quality VGA cable is not a hard task, as these are readily available in the market. Can buy VGA cables from any physical hardware store, and you can also purchase these cables from any online store.
You can find VGA cables for different purposes on Amazon, eBay, and any other online store.
You can contact any wholesale dealer or us at CLOOM Tech if you want bulk cables. We will provide the best quality VGA cables at the most reasonable price in the market.
If you are not sure about your requirements, you can consult us for your needs. Our expert professionals will guide you on each step, and we always put your business as our priority at CLOOM Tech.
Chapter 5: Where to get Customized VGA Cables?
At CLOOM Tech.Ltd, We deal in all VGA cables and wiring harnesses, including power cables, signal cables, automobile harnessing cables, and heavy-duty industries.
Our team and R&D department are always adopting new trends and technologies, so our customers always get the best solutions for their VGA cable needs.
If you are looking for an experienced team to develop VGA cables for your project, get in touch with our team. We will analyze the project to offer the best solution for your projects.
Conclusion
VGA cables by CLOOM Tech not only deliver the best results, but our technology is always focused on providing futuristic results for your electronic needs. In this article, we have covered almost everything that you should know about VGA cables.
If you have any queries, please get in touch with our CLOOM Tech team, and we will be more than happy to assist you.
CLOOM Tech offers wiring harness and cable assembly services for all sectors of industries. Our team of experts is always focused on delivering customized solutions for wiring harnesses, cable assembly, and custom electronic designs.
Do you have a custom design for your electronic system and want customized wiring solutions for your project? CLOOM Tech provides fully customized integrated design solutions from scratch.
Does your trailer have the right wiring system? With time, the wiring system in your trailer may need a relook. Are you worried? Don’t be. It’s time to design your trailer wiring harness that will fit your trailer and your vehicle.
With the right guide and a little help, you can ensure that it’s simple to wire your trailer the right way.
In this guide, you will learn about the common wiring systems, the different ways to wire your vehicle for towing, and the methods to convert different wiring systems. You will also learn how to rewire your trailer using a wiring harness.
Chapter 1: Types of Trailer Wiring Systems
People attach all kinds of trailers to their vehicles. You can attach a boat trailer or tow a trailer to your car to tow on the road.
To use the trailers on the road, you have to make sure they abide by laws and regulations. One such law is having working lights and turn signals that sync with your vehicle.
You have working tail lights, brake lights, and turn signals. You also need them to make way for safe towing and alert other drivers on the road.
Before you wire your trailer, you need to know your vehicle’s wiring system. We will discuss some common vehicle wiring systems used by cars and automobiles.
Two-Wire System
Two-wire systems are the most basic type of wiring in vehicles and trailers. The system uses one wire to transmit the stop or brake signals.
The taillight signal flows through another wire. You can find two-wire systems only in some vehicles right now.
Three-Wire System
As the name suggests, three-wire systems come with three wires. It uses three cables to transmit the stop, turn, and tail signals.
You will mostly need a converter to connect three-wire systems to your trailer. It’s also the most common system used in the automobile industry.
Pulse Width Modulation (PWM) System
Pulse Width Modulation (PWM) System is also a multiplex system. The system uses a single wire to send stop, turn, and taillight signals.
It does so by using signals of varying intensity. Most of the current vehicles use this wiring technology.
You can use LED with PWM systems which fall into two categories-
ST systems: ST system refers to the stop and tail system. It takes the help of a single wire to transmit taillight and stop signals. You have separate wires to send the turn signals.
You may need an ST converter to connect the vehicle wiring to the trailer wiring. STT systems:
STT system refers to stop, turn, and taillight signals. The system uses a single wire to control all three- stop, turn, and tail signals.
You will generally need an STT converter to hook your vehicle wiring to trailer wiring.
Now, we will show you how to prepare your vehicle for towing.
Chapter 2: Trailer Wiring Harness—How to Wire Your Vehicle for Towing
You will need something to connect your vehicle wiring to the trailer wiring. Some vehicles come with a built-in connector to facilitate connection. Custom wiring is the ideal answer if your car doesn’t have a connector.
You can customize custom harnesses to match the wiring of your vehicle. A custom trailer wiring harness is also known as T-connector. It provides a socket to connect to the trailer, commonly using a 4-way flat.
You can use two types of custom wiring for connecting your vehicle wiring to the trailer-
Custom wiring harness
Custom wiring connectors
Both may seem identical look-wise, but they differ entirely in function.
Trailer Wiring Harness–Custom Wiring Harness
A custom wiring harness comes with several plugs. The plugs can connect directly to the taillight assembly of the vehicle.
The harness sources its power from a battery or the taillights. Using a custom wiring harness, you will need two connection points to set up a connection. You don’t generally need any splicing or soldering.
Custom Wiring Connectors
Not all vehicles have a connector to hook up trailer wiring. They may come with a special socket provided by the manufacturer.
The socket helps you to connect your vehicle wiring to trailer wiring. The system uses a single plug to connect to the factory-made socket of the vehicle. It helps you set up the connection using standard trailer wiring connectors.
Check out whether your vehicle has a socket for connecting trailer wiring. Then decide if you need a custom wiring harness or a custom wiring connector.
In the next section, we will explore the ways to convert two different wiring systems.
Chapter 3: How to Convert Two Different Wiring Systems
You may not always get a custom wiring harness for your trailer. In that case, you will need an electrical converter.
An electric converter helps you connect your vehicle’s wiring to the trailer. It provides a way to hook up complex vehicle wiring with simple trailer wiring.
For instance, most cars use the three-wire or PWM system. On the other hand, trailers generally use two-wire setups.
Now, the two configurations do not match. Here, an electric converter comes in handy. It allows you to connect the vehicle and trailer through a regular plug and socket.
You can try searching your local automobile spare parts shop for electric converters. Else, you can also search online.
Now comes the turn to find out the differences between plugs and sockets.
Chapter 4: Trailer Wiring Harness—Differences Between Plugs & Sockets
Plugs and sockets help you connect your vehicle’s wiring to the trailer. Socket refers to the connection that resides with the car.
Plug refers to the connection of the trailer side. You may find plugs and sockets with two to seven wires. The electrical requirements of the trailer determine the number of wires you need.
Most plugs and sockets have color-coded wires to facilitate easy connection.
Trailer Wiring Harness–Common Plug Ends by Trailer Type
Trailers come with different types of plugs. The electrical components of the trailer determine the type of plug. Here is a list of different trailers and the plugs they use-
Boat trailer without surge breaks: 4-way flat plugs are the most common. You may also find 7-way RV blade plugs in some cases.
Boat trailer with surge breaks: Commonly uses 5-way flat plugs. They may also use 6-way round or 7-way RV blade plugs on rare occasions.
Utility trailers:
4-way flat plugs are the most common. Sometimes they also use 6-way round or 7-way RV blade plugs.
Camper trailers:
Camper trailers generally have 7-way RV blade plugs. At times they may also use 6-way round or 7-way round plugs.
5th wheel trailers:
Uses 7-way RV blade plugs. Few of them may have 6-way round plugs.
Gooseneck trailers:
6-way round plugs are the most common. Rarely do they use 7-way RV blade plugs.
In the next part, we will learn how to adapt to two different connector types.
Chapter 5: How to Adapt Two Different Connector Types
You will find countless types of connectors in vehicles. For instance, your vehicle may have 6-way round connectors while the trailer uses a 4-way flat.
That means your trailer connector may differ from that of your car. How do you establish a connection in such cases?
The answer lies in using a simple adapter.
An adapter is a simple electrical device. You can connect your vehicle wiring to trailer wiring in case of different plugs and sockets.
Adapters don’t need any extra work to establish the connection. They act as a bridge between two different connector types.
In rare cases, you may need extra wires to ground the system. You may also need wires to splice into your current vehicle wiring. Some common types of adapters include-
4-way flat to 6-way round adapter
4-way round to 4-way flat adapter
7-way RV blade to 6-way round adapter
7-way RV blade to 6-way round adapter
6-way round to 4-way flat adapter
Now we will tell you how to rewire your trailer to make it road-ready.
Chapter 6: How to Rewire Your Trailer
Rewiring your trailer is not a difficult task. You will only need a few tools and some of your time to do the job. The main thing to arrange is your trailer wiring harness. Tools You Will Need
Trailer wiring harness
2. Pliers
3. Wire brush
4. Clips
Follow the steps mentioned below to rewire your trailer. If you are not confident enough, you can also go to a professional for the task.
Set Up Your Trailer
Step 1: Trailer Wiring Harness—Take Out Old Wiring
Remove the old wiring of the trailer using a set of pliers. Also, remove the trailer wire connector if present. Keep the wiring layout in mind to assist you in rewiring the trailer.
Step 2: Clean the Area
Use a wire brush to clean any corroded material from the space of the old harness. You can also spray the area with anti-rust paint to check corrosion.
Step 3: Trailer Wiring Harness—Re-Route the New Wiring
Now place the new harness through the frame to reach the back of the trailer. Try to route the wire along the frame rail of the trailer. You can use rubber grommets to secure the harness.
Step 4: Connect the Ground Wire
Check if your trailer wiring harness comes with an attached plug. It would help if you connected the white ground wire to the trailer connector. Then you don’t need to do any wiring at the coupler.
Leave enough wire at the connector to reach the trailer plug. Also, allow enough slack in the wire to accommodate the turning radius of the trailer.
Installing the Lights
Step 1: Trailer Wiring Harness—Mount the Marker Lights
Use the bolts to install the marker lights. Then use snap locks to splice the wires of the marker lights.
Step 2: Trailer Wiring Harness—Secure Wires to the Frame
Use the clips from the wiring kit to secure the wiring to the frame. Protect the harness by the trailer frame to keep it safe from contaminants and movable parts.
Step 3: Trailer Wiring Harness—Mount the Taillights
Now attach the taillights to the frame of the trailer. Then connect the wires to respective connection points.
Test Your Connection
It’s always better to test your trailer lights before you hit the road. Also, ensure that the lights sync with your vehicle’s lights.
Pro tip: Most electrical issues arise from problematic ground connections. It may result in lighting issues even when your voltmeter displays the available charge. For best results, use the manufacturer-provided factory ground connection. Else, connect the ground wire to the chassis using a bolt.
The next section will tell you where you can get a custom trailer wiring harness.
Chapter 7: Where to Buy Custom Trailer Wiring Harness?
Custom wiring trailer harnesses may be available from multiple sources. Here are some of the avenues you can try to buy your custom harness.
You can check out your local automobile spare shop for a custom harness. They may have a harness in stock that suits your vehicle’s needs.
Be sure to note the specifications of your vehicle and trailer wiring. That will help you select the right harness for your car and trailer.
Online Stores
Many online electrical stores deal in automobile harnesses. You can search the internet and browse various online stores to locate your harness.
Make sure to determine the reliability of the seller before placing your order. Also, look for fair return policies. You may need to return the harness if it doesn’t match your requirements.
Cloom Tech Supply Custom Trailer Wiring Harness
You can also contact us to create your custom trailer wiring harness. We make custom harnesses that match the specifications of your vehicle and trailer.
We adopt strict quality control procedures and meet all professional standards. Have you covered if you are looking for harnesses tailored to your needs!
Trailer Wiring Harness–Conclusion
Trailer wiring harnesses are crucial if you want to tow a trailer. It helps you connect your vehicle wiring to trailer wiring. Without a harness, your trailer lights and turn signals won’t work.
You can respect the law and avoid getting tickets using a harness. You can contact us for high-quality custom trailer wiring harnesses.
We manufacture custom harnesses with high standards matching your exact specifications.
Are you tired of making the wrong choice of ribbon cables? Do you know the difference between a ribbon cable and a flexible flat cable?
It comes in various sizes and is necessary for different applications. Often, these cables appear quite confusing to individuals who find it difficult to spot their differences.
Not to worry, it is not as difficult as it seems. The information you crave is available at your disposal. Read on!
Chapter 1: Understanding a Ribbon Cable
There is much discrete cable that you could use for a project and still get the desired out. However, one basic need for flat ribbon cable assembly is space. The use of flat ribbon cable assembly in the internal wiring of electronics devices conserves space. This cable assembly can transmit both power and data from point to point in the computer. It is necessary to stress that flat ribbon cable assembly is not limited to computing devices only.
What is a ribbon cable?
Another name for ribbon cable is multi-wire planar cable or hippie cable. It is a cable type with many conducting wires running parallel on the same flat plane.
The ribbon cable is flat and rectangular. The flexibility of the ribbon cable makes it easy to hold many connectors simultaneously and transmit a large amount of data through signals. Furthermore, ribbon cables help to manage conductors effectively, even where space is limited.
A typical instance that proves the usefulness of ribbon cable is its function in computer hardware. The ribbon cable connects the disk drive to the disk drive controller.
These cable types are specialized cables that connect IDE surfaces to IDE connectors.
Ribbon cable color coding
The essence of ribbon cable color coding is to prevent the occurrence of reverse connections. One rule for ribbon cable color coding is that the edge of the cable, which bears a red stripe, connects to pin 1 of the connector. The cable color-coding makes it easy to identify the different sets of connectors.
More importantly, it helps make the installation easier because it can easily identify the different conductors important to the connection.
Ribbon cable size
A pertinent question that engulfs individuals’ minds is the exact size of the ribbon cable that suits their needs. There are two ways of identifying ribbon cable sizes. The two factors considered are:
• The pitch or spacing of conductors
• The number of conductors or ways.
For the conductors’ pitch or spacing, a spacing of 0.05 inch (1.27 mm) is the most common form of ribbon cable spacing. This spacing type allows for a two-row connector with a pin spacing of 0.1 inches (2.54mm). Most personal computers favor this exact spacing ribbon cable size. It is a common type of ribbon cable size in floppy disk drive cables and custom parallel ATA cables.
Other types of ribbon cable connectors’ sizes are 4, 6, 8, 9, 10, 14, 15, 16, 18, 20, 24, 25, 26, 34, 37, 40, 50, 60, 64, and 80.
Ribbon cables are unarguably handy and play significant functions in printers and computers.
Benefits of the Ribbon Cables
Ribbon cables are flat and flexible, and these features afford them the ability to fit comfortably well in any compartment.
Also, the fact that ribbon cables are lightweight contributes very little to the device’s overall weight, and it explains why you see so many connectors in a computer but weigh less.
Another benefit is the reduction in overheating of devices. They can fold in a compartment and make more space, and these rooms are channels through which air can flow. Therefore, the device is less prone to failure due to overheating.
With a flat ribbon cable assembly, you can easily adjust the cables to suit the device’s connections. Also, it comes with its hand press for insulation piercings during adjustment. Rbbon cable assembly also comes color-coding to prevent reverse connection. In the absence of this, a reverse connection can damage the device.
Furthermore, the ribbon cable assembly is a good conductor. They possess good electrical qualities, and these qualities make them able to carry a larger current capacity.
Lastly, using ribbon cables eliminates the stress associated with troubleshooting bulk wires. They are organized already in a single piece.
IDC Ribbon Cable
Insulation-displacement contact (IDC) has another name to be Insulation-piercing contact (IPC). This process involves the forcefully inserting of a selectively sharpened blade or blades through the insulation. In this case, there is no need to strip the conductor bare before connection.
Application of Ribbon Cable
Ribbon cables are almost indispensable in manufacturing industries. They play a significant role in the consumer electronics manufacturing industry.
Additionally, ribbon cables are essential in building many electrical products. A good number of electrical products make use of ribbon cables. It is because of the miniature nature of ribbon cables, which makes them easy to use for designing electrical products.
Quite a several manufacturers rely on Flat flexible cable(FFC) to build laptops and mobile phones.
More so, ribbon cables are important for military-based equipment construction. They are also important in industrial environments.
These cables are necessary for the automotive industry. In constructing automobiles, manufacturers make use of ribbon cables.
Industries like aviation industries and space exploration find the ribbon cables essential in carrying out their activities.
Chapter 2: Ribbon Cable Types
Ribbon cables, like other cables, have different types. Hence, we shall consider the five types of ribbon cables, which include:
Rainbow Ribbon Cable
Rainbow ribbon cables are similar to the standard ribbon cables available. But this time, the wires have, by default, rainbow coloring. The rainbow coloring helps with easy identification and organization. Also, similar to the resistor color doing, where Brown can depict pin 1. It works as with the red stripe on one edge of a standard ribbon cable
Twisted Flat Ribbon Cable
The twisted flat ribbon cable is different from the standard ribbon cable. In contrast, they have two pairs of their conductor twisted and bonded. One benefit of twisted flat ribbon cables is that it reduces cross talk.
Standard Ribbon Cable
The standard ribbon cable comes with the ease of mass termination. A typical way to know one is by its color – They are grey.
Round to Flat Ribbon Cable
This unique type of ribbons cable combines mass termination ability with the ease of discrete wire cable. The conductors are folded into a circular frame and are split apart at the other end, and it allows them to ease access to use. Generally, this type of ribbon cable is suitable for areas with tight space.
Bonded Ribbon Cable
Bonded ribbon cables are organized and do not seem scattered about the place. However, it is also less flexible than other types, making its application difficult in tight spaces. One exciting advantage of this cable is that it provides straightforward mass termination with a range of cabling products. In addition, Bonded ribbon cables are of 3 types: Single Hook-Up wire, Coaxial cable, and Multi-Conductor cable.
Folded ribbon cable
Folded flat ribbon cable assemblies are the best when it comes to limited areas. Depending on the nature of a project, folded cable assemblies afford the needed flexibility for installation. You can fold them in the desired directions; however, you would require some arrangement tools for permanent folding.
Chapter 3: Ribbon Cable Connectors
There are quite a handful of ribbon cable connectors that are available with IDC termination. They are:
BT 224 connector
Another name for BT 224 connector is the IDC connector. Many standards define this connector type, such as BS 9525- F0023, DIN 41651, and MIL-C- 83505.
• BT 224 connectors mate with a purpose-made plug or two-row gird of header pins with 0.1 inches 2.44mm spacing.
• They are compatible with ATA cables.
D- Subminiature connector
These connectors are not as common as the crimp and solder bucket types.
• D- Subminiature connectors are suitable for serial ports and printer ports. It means that these connectors work perfectly for both printers and serial ports.
DIN 41612 connector
It is a connector type that is very common among different suppliers that operate together. Although the standard is now in an internationally standard form of IEC 60603-2 and EN 60603-2
• The DIN 41612 connector suits the Euro card bus, NU bus, Futurebus, VMEbus, Multibus 11, and Tram motherboards.
• All of the applications of DIN 41612 use a male Eurocard bus in a female DIN 41612 on a backplane.
PCB transition headers
PCB represents the Printed circuit board. It is a connector type with two rolls of pins with the same spacing as BT 224 connectors. For efficiency, these pins connect directly to the PCB.
This connector possesses high low contact resistance and long life. It also offers a cost-effective means of connecting PCB to other applications.
• It connects the wire to the board.
• It is also effective for separable header/sockets
• Suitable for dual-in-line application
Micro Ribbon connector
There are a host of names for the ribbon connectors. These names are a telco, 25 pair, miniature delta ribbon, mini D ribbon, MDR, Amphenol, or even miniature ribbon connector.
Microribbon connector possesses a shape similar to D- Subminiature connector with two parallel rows of contact. Its contacts are not pins. Rather, they are small bands of metal in the form of ribbons.
The female connectors of the micro ribbon connector possess a bail lock that connects them to the male counterpart for a secure connection.
• The micro ribbon connectors are a suitable fit for telecommunication equipment.
• It is also important for computers with a lot of contacts.
DIL Headers
The DIL headers possess pins with the same spacing as standard DIL ICs. They connect two Printed circuit Boards. Also, they work well with appropriate DIL sockets to form a plug and even socket pair.
• These connectors work well within replacing an IC in connection to an external device.
• It is also suitable as a PCB transition header on stripboards.
https://www.youtube.com/watch?v=EFyFhcmeS2I
Chapter 4: Ribbon Cable vs FFC (Flexible Flat Cable)
Are there indeed differences between Ribbon Cable and FFC? Yes!
What are flexible flat cables?
Flexible flat cables are a type of ribbon cable that is flat and flexible. These are direct connections without any additional components. It is a thin flat cable commonly found in high-density electronics applications. Its material is very flexible.
These cables possess a special sort of makeup. Its makeup is a flat and flexible plastic film base and multiple conductors on a surface.
FFC (Flexible Flat Cable) vs FPC(Flexible Printed Circuit)
Flat flexible cables (FFC), as we have discussed, are ribbon cables used mostly in high-density devices like computers. Their flat and flexible nature allows them to connect two components freely in a limited space.
However, FPC stands for Flexible Printed Circuit. Like FFC, it is flexible, having a conductive circuit sandwiched in between elastic polymers. Technically, FPC is more than just a cable; and it is more of a flexible printed circuit board. However, it is thinner, lighter, and less rigid compared to the traditional PCBs.
FFCApplication
Flexible flat cables are important for easy cable management in high-flex environments.
It is a suitable cable for printers, scanners, copiers, fax machines, DVD stereos, LCD appliances, and other electrical products.
It is common in modern equipment to assist the printer connection between the head and the motherboard.
The FFC plays a considerable role in signal transmission and plate board connections.
FFC Specification
Pitch: Examples of pitches are 1.00 mm, 1.25 mm, 1.27 mm, and more.
Types: FFCs are Type 1/Type A and Type 2, or Type D. The difference here is that type A cables have contacts on one side and at both ends, and in contrast, Type D has connections on both sides and at both ends of the line.
Conductors Size: You can determine the size by measuring its width and thickness
Exposure Length: FFC cables gave their exposure length, and you can check for it at the end of the cable.
Stiffener: An extra layer of material at the opposite side of the cable’s exposed length helps ZIF or LIF connections.
Benefits of Flexible Flat Cable
The wires of a flexible flat cable are not wound like a round cable. They are lighter and more flexible. It makes it easy to protect the individual wires.
They do not occupy too many spaces like round cables
It offers a more sophisticated EMI/ RFI suspension. As such, it eliminates wire coupling issues.
The ends of flexible flat cables are thick.
Ribbon cable VS FFC: Difference
Both cable types are important in diverse ways. While one assist in a particular field, the other remains relevant in a field that suits it. However, flat cables existed long before the ribbon cables came into existence.
Ribbon cables are efficient in various areas like computing, aerospace, military, and robotics. These cables possess good superior quality, flexibility, and packaging efficiency and reduce the presence of electronic noise.
Despite these numerous advantages, the ribbon cables handle termination techniques rather poorly.
More so, there are also problematic cases of frictional heat in the cable during its repetitive motion cycles — also, conductors inside the cable move relative to one another.
The flexible flat cables don’t move within the jacket to retain their electrical properties and qualities. Another interesting feature of the flexible flat cable is that the cable’s conductors have similar physical and electrical lengths.
In flexible flat cables, the conductors are isolated to keep them stable. These cables are more flexible than ribbon cables.
Therefore, it is necessary to understand the capabilities of both the ribbon cable and flexible flat cables to ensure proper usage. In all, flexible flat cables possess better features than ribbon cables.
An image of a technician holding the flexible flat cable in a workshop
Chapter 5: How to Choose Ribbon Cable
Asides from recognizing ribbon cables, the confusion lies in choosing them. In choosing ribbon cables, there are quite a several factors to put into consideration. These cables are:
Pitch
Pitch is spacing. It refers to the spacing of conductors within the ribbon cable. The pitch depends on the cable requirements and specifications. Some examples of pitches include 0.5mm, 1mm, 1.25mm, and 2mm.
Ribbon cable pitch VS connector pitch
The ribbon cable pitch of the connector and that of a ribbon cable is never the same. The ribbon cable is always half of the connector pitch.
By this implication, the ribbon cable pitch is usually half of the connector’s pitch when there is a two-row connector pitch.
Another way of determining the pitch of the ribbon cable is by measuring the outside edge of the cable and then dividing the figure by the total number of connectors.
Extreme temperatures
Ribbon cables tolerate all sorts of temperatures, be they harsh or friendly. But, if ribbon cables operate perfectly in unfavorable temperatures, a silicon jacket is the best bet.
Flexibility
In choosing ribbon cables, flexibility is a necessary factor. Since ribbon cables are flexible, there is still a need to purchase a more flexible type. If the design is limited or requires a more flexible type, purchase a custom ribbon cable with greater flexibility that suits the job.
Long life
Consider the life span of the ribbon cable you intend to purchase. Like every other electrical component, choosing a ribbon cable that can survive the test of time is necessary.
Choose a ribbon cable that is adequately proven by professionals and assured of a long life cycle.
Fire resistant
Fire resistance is another factor to consider when choosing a ribbon cable. The importance is not only for the benefits of the electrical equipment but also for safety.
Make it a duty to settle for a ribbon cable type in line with the EU’s Restriction of Hazardous Substances Directives and fit according to fire safety standards.
Chapter 6: Custom Ribbon Cable Serviceat Wiringo
Wiringo is not just a body of professional teams specialized in different areas of expertise. With us, you are guaranteed a superb custom ribbon cable service, as it is a part of what we are known to do well; we are a team of seasoned professionals who take a keen interest in delivering effective results.
Shielded Ribbon Cable Assemblies:
As we stated earlier, shielded ribbon cables are the best fit for tight spaces. More so, they have numerous applications in computers and computer peripherals. Floppy drivers, hard drives, and CD drives use shield ribbon cables. Also, printers and some computer devices are not left out here.
However, there are limitations to shielded ribbon cables. Because they have fire and stab resistance, the cooling rate is also meager.
There have been adjustments to shielded ribbon cables in recent times, and these advancements now make them safer to use and much more feasible.
Shielded ribbon cables consist of an outer shield made out of copper braids. Also, some ribbon cables are double-shield. Aside from the external protection, they have an inner foil that bridges contact between the wires and the outer shield.
PCIe Ribbon Cable Assemblies
A PCIe ribbon cable is a cable type with many flat wires put parallel and side-by-side. Hence, they look more like a ribbon cable. PCIe ribbon cables help transfer data at a fast rate. We can see more of its use in computer systems and mobile devices.
A PCIe ribbon cable
Color coding is essential in PCIe ribbon cables. So, users can avoid any unpleasant cases. Color coding helps in pin identification and prevents reverse connection. In line with this, one edge of the ribbon cable has a red color to tell pin 1.
Determining the size of a PCIe ribbon cable is similar to that of ribbon cables, and we can classify them into two, namely Pitch and Number of conductors.
The pitch is simply the spacing between two conductors in the ribbon cable. Some of the commonly used spacing is 0.05inches and 0.1 inches. The wires of t
Conclusion
Ribbon cables are indeed important for various connections of sorts. They play important roles in connecting various applications like mobile phones, laptops, and electronic devices.
These colored-looking cables are very efficient in producing second-to-none output results. They appear in various sizes and pitches. It is important to derive all its information to fully use the ribbon cable.
Fortunately, the information you require is available in this write–up. If you want to know more about how ribbon cables work, reach out to us at Wiringo.
The introduction of flexible PCB technology resulted in innovation in electronic gadgets. You may be surprised that even laptops and smartphones also use this technology. In this blog post, let’s read about myths about flexible PCB assembly.
What are flexible PCB assemblies?
Flexible PCB assemblies refer to mounting components on the surface of the flexible printed circuit board or flex boards. They require thin laminates in their manufacturing. Manufacturers cannot assemble them directly on SMT lines as rigid circuit boards. First, these flex boards need to be fixed on some rigid career to be treated like rigid PCBs.
Caption: PCB
Flexible PCB assembly properties
Compared with rigid board assemblies, flex board assemblies have the following properties.
Flexible nature
The assembly of flexible printed circuit boards and their soldering is unlike the assembly of rigid PCB boards due to the flexible nature of flex PCBs. It is essential to use a special carrier board for flexible PCB assembly for fixing, transmission, and completing the surface mounting of the components.
Low density
Manufacturers use flexible PCBs for some module connections. As a result, the circuit density on the flexible PCB is relatively low. The number of electrical components remains under 50, and some flex boards only have as few as two connectors.
A large number of panels:
Miniature electronic devices like smartphones and digital cameras make maximum use of flexible PCBs; thus, the board size is small. As said above, the number of components in the flex circuits board is also low. Therefore, to improve the efficiency of the PCB, manufacturers use panels for assembly, which are later separated through punching.
Wide application of auxiliary fixtures
The flexible PCB assembly process uses many institutions as it damages and deforms easily. These fixtures include a board carrying tray, PCB baking fixture, function test fixture, cutting fixture, and electrical test fixture.
High-quality product requirement
Components must meet application requirements because flexible PCBs are mainly sued in applications requiring repetitive bending and accuracy. Thus, it is essential to maintain cleanliness, have soldering reliability and take antistatic precautions.
High assembly cost
As the Flex PCB assembly process needs different fixtures, a low rate of equipment utilization, high accessories demand and longer manufacturing time, and higher standards for product quality, the assembly cost goes high compared to rigid PCBs.
Caption: high tech electronic PCB
Design consideration of Flexible PCB assembly
The three crucial flexible PCB specifications include:
Material of Flexible PCB:
The materials you need to manufacture the flexible PCB include a metal conductor layer, adhesive, substrate material, and cover layer. The primary material is the flexible insulating film, which acts as a carrier with superb electrical and mechanical performance. Other ordinary materials include polyimide film and polyester, from which polyimide film is most common. Other substrate materials, such as thin FR4 and PEN, are also included.
Structure of flexible PCB:
You can classify flexible PCB into these different categories:
Single-sided flexible PCBs have a simple structure and are very easy to fabricate.
Double-sided flex PCB has a more complicated structure than single-sided PCB, and thus you may face more control difficulties.
Multi-layer Flex PCB has the most complicated structure as it has more than two layers. It becomes more difficult to control its fabrication quality.
Single-sided rigid-flex boards.
Double-sided rigid-flex boards.
Multi-layer rigid-flex boards.
Bend radius:
The bend radius of flex PCB varies typically between 5mm to 11mm.
Flexible PCB assembly process
The flexible PCB assembly process’s success depends on the board’s consistency, position accuracy, and flatness. Here is the process of the flex circuit assembly.
FPC pre-treatment
The FPC board tends to absorb moisture during transportation and storage. If manufacturers do not extract this moisture, it will vaporize during reflow soldering and protrude from the FPC board in the form of water vapor. To avoid this situation, FPC boards go under baking at a high temperature of around 80-100°C for about 4-8 hours. Sometimes, the baking temperature goes up to 125 degrees Celsius, but manufacturers must shorten the baking time. Generally, experts advise not to stack the FPC too much, and 10-20 PNL is more than enough.
Sometimes, manufacturers also put a piece of paper between each PNL to ensure isolation between different layers. Makers ensure that FPC does not undergo discoloration, warping, deformation, or other defects. They put it into line only after IPQC qualifies it.
Production of FPC assembly fixture
After baking, manufacturers study the drilling hole layers of FPC to develop an FPC positioning template and carrier fixture. Makers ensure that the positioning template pin diameter is the same as that of the positioning hole on the carrier board and the hole diameter of FPC. FPCs may differ in thickness to protect certain parts of the section or for design reasons.
Thus, the carrier board and the FPC must follow a similar order process. The main aim is to keep the FPC flat during placement and printing. Further, it is also essential that carrier boards comprise light and thin material with low heat absorption, fast heat dissipation, high strength, and little warpage deformation. Common carrier material includes synthetic stone, silica gel plate, aluminum plate, etc.
Positioning of FPC:
Once manufacturers fix the FPC on the carrier board, the printing, soldering, and mounting time should be as little as possible. Thus, they ensure that FPC fixes on the carrier board accurately. There are two carrier boards, one with positioning pins and the other without.
The carrier board without positioning pins works with the one with positioning pins on the positioning template. To fix the carrier board on the template, first put the carrier board on the template so that positioning pins come out from the holes of the carrier boards. Now, put the FPC piece-wise. Now, fix the pins with the tape and remove the FPC board from the template to proceed with printing, soldering, and patching. Manufacturers fix the carrier board with the help of several positioning pins of 1.5mm in length, and they can put the FPC on spring positioning pins and fix them with tape.
While fixing the FPC board on the carrier board, manufacturers use single-sided tape so that FPC does not shift or warp. Here, the tape viscosity is moderate, so makers can easily peel off after the reflow soldering process. Sometimes, Assembly makers also use automatic tape machines to cut tapes of similar lengths to improve efficiency and to make them cost-effective.
Besides the above method, manufacturers sometimes use double-sided tape to fix the carrier board to the FPC.
FPC solder paste printing:
The solder paste composition does not matter much for FPC, and the metal or size only depends on the presence of the fine-pitch ICs. However, FPC does have special requirements for solder paste printing. The solder paste must be convenient to print, have excellent thixotropy, and be firmly attached to the FPC. The soldering flux printer has an OP system or optical positioning to improve printing quality. Despite a proper fixation of the FPC and carrier board, some gaps remain. Thus, set equipment parameters appropriately to get the best printing effect.
FPC assembly:
Manufacturers use high-speed placement machines based on the components’ number, product characteristics, and the efficiency of placement needed. Due to the optical marks on FPCs for positioning, the surface mount technology on FPC and rigid circuit boards remains more or less the same.
As mentioned above, there are always some gaps between the carrier circuit board and FPC. Hence, manufacturers ensure the accurate setting of blowing pressure; the suction nozzle drops its height and other equipment. You must also know that as FPCs are connected boards, their yield is always low. Thus, the complete PNL has some damaged PCS. Thus, the placement system should have a function for bad mark identification to enhance production efficiency.
FPC reflow soldering
Manufacturers use hot air convection reflow (infrared) so that temperature in FPC changes more uniformly, avoiding poor soldering.
Flex PCB Assembly Production Equipment
With the help of the equipment, production can be efficient.
Solder paste printer
The paste printers have plate loading imprinting, the addition of solder paste, and transferring circuits. To use it, fix the flexible board on the top of the printing table. Print the solder paste/red glue on the pad via stencil and left scrapers. Next, put a transfer station into the machine to place the components.
Pick and place machine.
In the production line, you may also know it as a mounting machine or surface mounting system. It is a form of a device that you place on a flex PCB pad. Manufacturers configure it once the solder paste printer is and use the placement head for mounting the surface components accurately.
Reflow soldering
A heated circuit heats the nitrogen and air in reflow soldering to generate high temperatures. The soldering on the components’ sides melts, creating a tight solder joint with the motherboard. Reflow soldering can easily control the temperature and avoid oxidation.
AOI detector
AOI, or automatic optical inspection, is equipment to detect common defects during welding production. Based on the optical principle, it is a newer technology that manufacturers are rapidly adopting. Now, you can also find AOI test equipment in the market.
During the AOI inspection, the equipment scans the flexible circuit assembly with the help of a camera, collects the images, and compares the junctions with the approved database parameters. Once the image processing is complete, it will mark the defects with the automatic signs or display. The maintenance personnel takes out the defective pieces for repair.
Component trimming machine
You can cut and arrange the components with the help of this machine.
Wave soldering
It can ensure that the board’s soldering surface is in touch with the high-temperature soldering liquid tin so that soldering occurs perfectly. The liquid tin creates a slope, forming a wave-like process with the help of a particular device. Here the primary material is solder bars.
Tin furnace
In electronic welding, the tin furnace is the welding tool. The tin furnace gives good welding consistency in discrete flex boards. The process is fast and easy and delivers high efficiency.
Cleaning machine
You can clean the flex circuit board and remove the residue after soldering with the help of this machine.
ICT test fixture
ICT test fixtures help test short circuits, open circuits, and welding conditions of different parts. Technicians use test probes to check the PCB layout’s test points.
FCT test fixture
This Functional test checks the flex boards in simulated working conditions and whether the tested PCB boards will work in different design states. With this, the manufacturers get the values of different states to confirm the unit under test.
Aging test frame
In this test rack, PCB assemblies are tested in batches by pretending the user’s operation for extended periods.
Conclusion
We would like to know how the flex PCB fabrication and assembling process is completed. If your application requires any help regarding the flex PCB and assembling service, contact Cloom. We design, manufacture, and customize all types of Printed circuit boards and wire harnesses to meet our customers’ every need.
About DVI cable assembly， Cathode Ray Tube monitors require analog signals to get image data from the computer graphics card. Here, you will need DVI cables to convert the original digital signal into analog to support these CRT monitors. Similarly, digital display devices like LCDs needed to be compatible and adapt with analog source devices like old computers. As a result, the analog output signals were converted into digital. Also, when LCDs were introduced as digital display devices, they needed to convert analog output signals into digital ones. As both computers and LCDs accept digital signals, there was an unnecessary conversion of signals from D/A to digital. Further, the process also made the signal weak and low in quality. The DIV digital connection eliminated this conversion process and minimized the information loss and accuracy.
The versatile nature of the DVI interface gave manufacturers the flexibility to support digital devices and be compatible with analog devices. How does the DVI cable assembly make things happen?
What is DVI?
DVI is an abbreviated form of Digital Video Interface. It maximizes the flat panel of the LCD and Video graphic cards. The DVI format has replaced the Plug & Display (P&D) standard or an advanced version of the DFP format. Video cards have one or more than one DVI output port.
Apart from being a typical computer interface, it was a digital transmission method for High Definition TVs and other displays. Even the topmost DVD players had DVI outputs, the component video output (analog). However, today, the DVI is used explicitly for computers only, and the High Definition Multimedia interface has become more popular for TVs and DVDs.
Caption: Dvi digital pc video connectors
What are DVI connector types?
DVI-I, DVI-D, and DVI-A have different pins for digital and analog signals. Equipment manufacturers use DVI ports with open pinholes to support both digital and analog signals. DVI connectors with open pin holes do not mean they will support both digital and analog signals. It pins defensive measures to avoid pins breakage if you accidentally insert the wrong cable. You can verify the DVI connector either through its label or manual.
Let’s understand these three DVI formats in detail.
DVI-D: Truly Digital Video
DVI-Digital cables set a direct digital connection between the source and LCD or liquid crystal display monitors. As a result of direct connection and digital format, you get high-quality video displays too fast. The video cars first create a digital signal of videos.
A VGA output converts this digital signal into analog, which travels through the cable to the LCD display. At the receiving end, the signal again converts into digital. However, DVI-D has no such conversion process as it sets direct connections digitally.
DVI-Analog: High-Resolution analog
When connecting a VGA monitor to a DVI computer, you will need a DVI-A cable, as both these ports carry the same signal. The DVI-Analog cable has DVI signals to analog displays like LCD and CRT monitors. However, you will experience some signal quality loss due to the conversion from D/A.
DVI-I: The best of both
DVI-I (digital and analog) cables can transfer D/D or A/A. The versatile nature of these integrated cables makes them suitable for both digital and analog situations.
You must understand that you cannot interchange DVI analog and DVI digital formats, meaning a DVI-Digital cable assembly will never work for a DVI-Analog system. You will need a VGA to DVI-Digital converter for connecting an analog device to a digital system. Similarly, you will need a DVI-D to VGA converter to connect the digital source to an analog display.
Caption: computer connectors for connecting monitors
What are single links and dual links?
There are different forms of DVI digital formats, namely, DVI-Digital single link / dual link and DVI-Integrated single link cable/ DVI-I dual link type connectors. The DVI cables transmit information through TMDS. The cable’s bandwidth capacity makes the single and dual-link different. A single link cable uses only one 165Mhz TMDS transmitter, and the dual link uses two. As a result, the latter becomes more powerful and transmits information at incredible signal quality and speed. For example, a single-link DVI can give a low resolution (1920*1200) compared to a high resolution (2560*1600) of a dual-link DVI.
Are single-link/ dual Link Digital Visual Interfaces compatible?
You can use a dual-link in place of a single link, but that is not possible vice versa. Similarly, you can use DVI-I cable assemblies for DVI-D cable assemblies. If you use dual-link connectors for single-link purposes, the PIN on the female connector will be the limiting factor.
What is an M1/P&D/30-Pin DVI connector?
When a connector’s width is more than a standard DVI connector, it is a VESA P&D connector. You can also call these 30-pin DVI M1 connectors, and you can find them in projector breakout cables carrying digital and analog video signals.
How do you connect DVI and VGA?
Depending on the connectors present on your display and the source, you can convert:
When the source is DVI and the monitor is VGA: You will require a DVI-to-VGA adapter for a DVI-I source. On the contrary, you will require a DVI-D to VGA adapter for a DVI-D source.
When the source is VGA and the monitor is DVI: In this case, you can use a DualHead2Go VGA to Dual HDMI/DVI Converter or VGA to HDMI/DVI converter.
How do you connect DVI and HDMI?
You can convert DVI into HDMI through an adapter or a cable.
How do you connect DVI and DisplayPort?
Use an adapter that connects DisplayPort to DVI to connect the DisplayPort source to the DVI display.
Conclusion
DVI cables can improve the visual and photo quality of your electronic devices. Choosing the wrong cable will not disappoint you in picture quality, but it can cause damage to your ports. Get the help of professionals to select the right cables for your job.
Cat6 cable assembly are the perfect choice for home applications as they allow for future growth and versatility compared to Cat5. However, with that in mind, Cat6 cables are harder to terminate. Keep yourself in the game, and read on to learn more about Cat6 cable assembly.
What are Cat6 Cables?
Manufacturers build the Cat6 cables with a UTP design that serves as an advancement of the Cat5e cables. However, the Cat6 design requires enhanced precision during manufacturing to enable reduced crosstalk and noise, allowing better performance.
Cat6 cables feature twisted pair wires applied in the ethernet and various network layers capable of backward compatibility with Cat3 and Cat5/5ae cables. However, Cat6 cables must meet tougher system noise and crosstalk specifications compared to Cat5/5e cables.
The Cat6 cable offers performance at rates of about 250 MHz and a decreased maximum length of 180ft when applied in 10GBASE-T. Later, manufacturers introduced an enhanced Cat6 cable, the Cat6a cable, which offers a better performance of about 500 MHz. Also, Cat6a cables offer better alien crosstalk capabilities, allowing for a maximum length of 330ft for 10GBASE-T.
Caption: Cat6 Twisted Pair Cable
Cat6 vs. Cat6a
Cat6a cables are ANSI/TIA-568.2-D-compliant, a standard brought forth by the TIA for enhanced performance standards for twisted pair cable systems. The standard was instituted in 2018. The Cat6a cables have performance rates of up to 500 MHz; that’s twice as much as Cat6 cables, not forgetting its Cat6a ability to pick up high levels of alien noise at high frequencies.
The ISO/IEC 11801 international cabling standard was extended by adding a second amendment. The new amendment defines the specifications for Cat6a components. The specifications require modern connecting hardware that offers better performance based on the TIA standard.
The performance difference between the TIA and ISO component specifications for the next transmission parameter is crucial. ISO Cat6a connectors at a frequency of 500 MHz perform 3 dB better than TIA Cat6a connectors. The difference means a 50% reduction of crosstalk noise signal power.
Often, there’s confusion in the naming conventions and performance benchmarks created by the ISO and TIA, which differ from the European EN 50173-1 standard. However, of the two (ISO and TIA, the ISO standard is more stringent than the European standard.
(Caption: RJ45 Connector)
Cat6 Patch Cords and Cables Wiring Standard
Generally, Category-6 patch cords and cables get terminated in 8P8C modular connectors by either T568B or T568A pin assignments. Their performance is comparable as long as you terminate both ends of the cable identically. It’s important to ensure that for Cat6 wiring, you use Cat6-rated patch cables, connectors, and jacks to ensure effective performance and compliance with various performance specifications and standards.
TIA/EIA-568-B.1-2001 T568-A Wiring Scheme
Pin
Pair
Wire
Color
1
3
1
White/Green
2
3
2
Green
3
2
1
White/Orange
4
1
2
Blue
5
1
1
White/Blue
6
2
2
Orange
7
4
1
White/Brown
8
4
2
Brown
TIA/EIA-568-B.1-2001 T568-B Wiring Scheme
Pin
Pair
Wire
Color
1
3
1
White/Orange
2
3
2
Orange
3
2
1
White/Green
4
1
2
Blue
5
1
1
White/Blue
6
2
2
Green
7
4
1
White/Brown
8
4
2
Brown
Caption: Crimp Tool
How to Crimp RJ45 Cat6?
If you’re looking to learn how to crimp an RJ45 connector, you’ve come to the right place. Follow the steps below to help guide you.
Step 1: Prepare the Cable and Remove the Insulation
Most professionals first mount the cable connectors before running the cable. Often, you can succeed because you don’t want to have to pull a connector through the conduit, wall, or behind furniture. First, remove the entire cable from the spool and lay it where you intend to use it. Use a sharp cutting tool or wire striper to strip off the outer insulation. If the cable has a non-metallic shield and core, cut them back. You’re left with four pairs of exposed ethernet wires. These pairs include blue, green, brown, orange, and their white counterparts.
Step 2: Cat6 Crimping Color Code
An important point in crimping an RJ45 connector is knowing the color code. There’s a diagram you can follow to help you properly position the wires into the RJ45 jack. Use the table below to help you make your way through this step.
Cat5e Wiring Diagram for T568B (Straight Through Cable)
RJ45 Pin Number
Wiring Color
1
White/Orange
2
Orange
3
White/Green
4
Blue
5
White/Blue
6
Green
7
White/Brown
8
Brown
Step 3 – Prepare The Wires for The RJ45 Connector
The wires observed in the last step aren’t as easy to maneuver as you’d think. It’s essential to take time to carefully sort out the wires to allow you to set them in the RJ45 connector properly. Otherwise, failure to do so will result in you having difficulty inserting the wires into the plug, increasing the chances of creating a poor crimp. If you’re unsure of the orientation, placing wires in the wrong position is easy. To succeed in this step, it’s best to use needle nose pliers that will help you save assembly time. Also, remember to use a sharp cutting tool to cut about half an inch of the wire to ensure the connector is biting the cable’s insulation. Failure to do so would increase stress on the signal conductors.
Step 4 – Prepare The RJ45 Connector & Crimping Tool
During this step, you’ll prepare the necessary tools for crimping. Insert the RJ45 connector into the crimp tool. Often there’s a slot to help keep the connector in place. Ensure you press the tool at the right time to avoid inserting the pins improperly, which will mean you’ll have to throw them away. This is important because RJ45 connectors aren’t reusable even when slightly misplaced.
Step 5 – Insert the Wires Into the Connector & Crimp
Some people opt to insert the wires while the connector is inside, and others prefer otherwise. Insert the wires accordingly and squeeze.
Step 6 – Verifying Your Work
The last step is validating your work. With RJ45 crimping, there’s often room for errors, hence the importance of inspecting your cable. You’ll need a cable checker complete with two modules. Place a module on either side to determine if you’ve established a reliable connection or need to re-crimp the cable. Never assume everything is okay, especially if you have multiple connections.
Caption: Cable Tester
Conclusion:
Wiring a Cat6 Ethernet cable isn’t as difficult as you might think, and it gives you endless customization options for your home network. At Wiringo, we provide all CAT6 and CAT6a cable assembly services. Feel free to contact us for the best services.
The high-tech world uses electrical and electronic devices in almost all areas of our life, and every application uses cable assemblies. People working with these cables must be careful while terminating cables, especially in harsh and dangerous environmental conditions. One such very reliable component for sealing cable ends is the cable gland. This blog post discusses cable gland assembly techniques.
What are cable glands?
You can use cable glands as mechanical cable entry devices in combination with cables and wiring for:
The cable glands mainly work as terminating and sealing tools; you can call them to cord grips, cable fitting, or cable connectors.
The function of cable glands
In addition to the protection of electrical equipment and enclosures, cable glands have multiple other functions, including:
Holding force
Cable glands also ensure mechanical cable pull-out resistance on the cable.
Earth Continuity
In armored cables, cable glands are present as a metallic structure. In such systems, you can test the cable glands to identify if there is sufficient peak short circuit fault current.
Environmental protection
Cable glands seal the cable sheath’s outer side, protecting from moisture and dust to the enclosure or the instrument.
Additional environmental sealing
At the entry point of the cable, cable glands ensure the correct rating of ingress protection with the help of different accessories.
Additional sealing
It also offers high ingress protection (if required) at the cable area near the enclosure.
Weatherproof
Cable glands come with an IP68 waterproof function which means you can use them to make watertight exit points in severe or adverse environmental enclosures or through bulkheads. The cable glands help compress a seal into a round cable so that there is no ingression of water or other particles which may damage electronic devices.
For example,
You must drill a hole to pass a cable through a watertight enclosure. As a result, it will no longer be watertight. To make it watertight again, you can use a cable gland to create a waterproof seal around the cable passing through the enclosure.
For cable from 3.5mm to 8 mm in diameter, an IP68 waterproof function works well.
Caption: electrical cable with connectors
Components of cable glands
You can determine the different parts of cable glands based on the type of cable glands. There are two types of cable glands:
Single compression cable gland
The single compression cable gland does not have a cone and cone ring. Instead, it only has a neoprene rubber seal to provide mechanical support to the gland when attached to the cable. The other parts of the single compression cable gland are:
Gland body
Gland body nut
Flat washer
Check nut
Rubber washer
Rubber seal
Neoprene
You can use these cable glands for lightly armored cables, and the cable has some scope of getting damaged through corrosion or moisture with these cable glands.
Double compression cable gland
This cable gland differs from the above as it has a double sealing feature. Its cone ring and cone offer mechanical resistance to the cable, and you can use them where large armored cables and wires are coming out and getting into the board.
These cable glands work as weatherproof or flameproof cable glands. The different components of the double compression cable glands are:
Check nut
Cone ring
Cone
Neoprene rubber seal
Gland body
Gland body nut
Caption: cable connectors
Specifications of cable glands
You need to consider several specifications before you pick one for you. Here are some.
Stainless steel cable glands have high-pressure ratings and provide corrosion and chemical resistance.
There are cable glands made of steel.
You can also opt for PVC or polyvinyl chloride cable glands featuring smooth surfaces, non-toxic features, and good flexibility. As PVC is passive, manufacturers use some food and chemical processing grades.
Apart from this, there are PTFE (Polytetrafluoroethylene) cable glands. These glands are highly resistant to chemicals and have a low friction constant.
There are nylon glands that are tough and exhibit a high-pressure rating.
Some others are made from brass, offering low magnetic permeability, good conductivity, corrosion resistance, cold flexibility, high-temperature ductility, and good bearing properties.
Some cable glands comprise aluminum which is a bluish-white metal. It is an easily malleable and ductile element and shows excellent thermal conductivity.
The metal also provides high reflectivity and resistance to oxidation.
Performance
The performance of the cable gland type is also essential which depends on the:
Complete ambient operating temperature
The pressure that a cable gland can bear without leakage
Size selection that cable glands can accommodate
Number of elements accommodated by assembly
Size of thread or mounting feature
Installation of cable gland
When installing cable glands, you must follow local regulations and codes of practice. Carry out cable gland installation only if you are an experienced person. You must have the skill and knowledge needed for gland installation and take training. Here is a guide to ensure cable glands’ safe and reliable installation.
Installation tools
While you carry out cable gland installation, you need to choose some cable gland tools that ensure the safe installation of cable glands without damaging any material or equipment.
PPE: Wear this to avoid personal injury while terminating or handling cables.
Digital Measuring Device: Check and record the cable size to verify it for each cable termination.
Spanners: You can use them to install the product correctly.
Armor forming tool: It helps prepare armor wires for the termination in the body of the cable gland.
Hacksaw: It helps to cut armor wires.
Outer seal tightening guide: You can correct the cable gland size.
Safety knife: It helps cut only the armor wires without damaging the bedding and insulation layer beneath them.
Electrical scissors: It helps remove excess cable braid. Ensure that you pick a sharp one so there is a clean cut without any snagging.
Installation standards
The installation codes and standards for cable glands and accessories are:
1.IEC & EN 62444: for cable glands used in electrical installations
During installation, you can ensure safety in many ways, such as:
Ensure that you do not damage entry threads while installing cable glands.
Do not start installing cable glands in live circuits. Similarly, wait to open the glands until you de-energize the circuit.
Different components of cable glands are compatible with each other only if they are from the same manufacturer. Further, installing components from the same manufacturer ensures the safety of the installation.
Cable glands fall under certification protocols, and a manufacturer cannot sell the installed products’ spare parts.
The sealing rings of the cable gland come with cable glands right from the factory. Under no circumstances are sealing rings removed from the cable glands.
Do not expose sealing rings to dirt, chemicals, and other foreign bodies.
Installation instruction:
Follow these instructions to install cable glands:
Detach the two components of the cable gland, i.e., the entry point and nut
Now, fix a shroud over an outer cable
The Remove the cable outer sheath and braid to properly manage the cable to fit into the equipment geometry.
Remove the outer sheath 18mm away to reveal the armor
Remove any wrapping or tapes to reveal the inner sheath if required
Now, secure the cable entry component into the equipment
Allow the cable to pass through the entry item and space the braid around the cone in an even fashion.
Prevent contact between the cone and the armor and screw the nut tightly to engage the armor.
With this, you complete the installation.
Check the performance
After the installation, you must ensure the safety of the cable gland.
Sealing performance: Check the sealing ring’s suitability, functional performance, and reliability. The things that can affect the cable glands’ performance include material choice, sealing design, and valid and effective testing program. Different tests include pull-out resistance tests, thermal endurance, ingress protection, and cable anchorage.
Armor clamping: Loose armor clamping can also result in improper cable gland installation. Using the right armor cone and clamping ring ensures that you create the proper termination that secures the armor wires during the crimping process.
Earth Continuity: If you do not clamp the armor cables correctly, it will affect the potential equalization adversely. With the right armor clamping method, you can create a low-impedance termination that does not undergo self-loosening. Instead, it enables reliable earth passage.
Conclusion
The cable gland is a crucial component for cable assemblies and wiring harnesses. If you need help buying or installing cable glands, contact Wiringo. We manufacture a wide range of cable assemblies and deal with all the related components, and our team has extensive knowledge about the cables used in different applications.
When designing a custom wire harness and custom JST cable assembly, you’ll often need to use JST connectors. However, there’s much to know about JST connectors to effectively use them for your project.
What are JST connectors?
The JST connector got its name from Japan Solderless Terminals, a Japanese company. The company has several connector series. The company designed the electric connector as a terminal that would not need soldering. Its sleek design and remarkable features have made it a common choice for various electronic projects, batteries, 3D printers, motors, PCBs, and servo motors.
Professionals use JST connectors to convey signals or electric currents in electronic projects. However, manufacturers recommend you avoid using them in mechanical applications that subject the connector to tension and other types of force. That’s because the connector will fail to resist the force.
JST Connector Standards
It’s essential to mention some aspects of the JST connector standards that often confuse users. Firstly, there are ten families of various JST connectors, each with subcategories and models. Therefore, the term JST applies to the general solderless connection that all the connectors have in common, not a specifically categorized connector.
To differentiate between the connectors, professionals normally use the JST-SS-D nomenclature to verify the names.
JST: refers to the connector
SS refers to the family or series and sometimes is preceded by a different letter. An example is X, thus XSS. The preceding letter describes the connector’s shape and specifications (size, voltage, and current).
D: refers to the dimensions within the series.
To ensure proper operation of the custom connector and prolong the connector’s lifespan, there are a couple of manufacturer suggestions to keep in mind:
Ensure the JST cable is slightly longer than required to avoid cable stress.
While disconnecting the JST cable connector, never pull on the wires, as you could loosen them up.
Ensure you limit room for movement to about 15 degrees in every custom cable.
JST Connector Series
Below is a table to help you navigate types of wire-to-board connectors.
However, for wire-to-wire connectors, you’ll require different guidance. Below is the table to help you.
JST connectors can be found in a wide variety of products across many industries. Select a category below to explore how they are used.
JST SH
This wire connector has a spacing of about 1.5mm between the connecting pins. It features a 4-pin variant, a common JST connector often used in laptops and most flight controllers.
JST GH
Though similar to the SH connectors, the JST GH features a 1.25mm pin spacing. And if you take a closer look, you’ll notice the pins are bigger and spread wider apart. Also, the plastic housing is taller and thicker. Manufacturers designed the JST GH connectors for use in small video cameras. Despite the connectors having a different number of pins, the spacing is always a standard 1.25mm.
JST ZH
The JST ZH connector features a 1.5 mm pin spacing. These connectors are pretty rare compared to other connector types. Professionals use JST ZH connectors mainly in satellite receivers and, in some cases, 3D printers.
JST PH and PA
The JST PH and PA connectors feature a 2mm pin spacing. However, they differ in current capacity. The PH connector’s current capacity is 2 amps, while the PA connector has a current capacity of 3 amps. Professionals use these connectors in fabricated hobbyist PCBs and low-quality electronics primarily because of their low price and compact nature.
JST XH / XA /EH
The JST XH/ XA/ EH connectors have a pin spacing of about 2.5mm. The connector on the circuit determines the type of connector you’ll need, as each has a different number of input wires. In terms of current capacity, each connector offers the same capacity of 3 amps. Professionals often use these connectors for low-consumer products.
Although the connectors have similar characteristics, they come in different shapes. Therefore, you can use an EH instead of an XH. People consider the XH connectors a larger version of the previously mentioned PH connectors. The resemblance is in the head design and the tall plastic housing.
People rarely use the JST XA connectors since most projects require the XH connectors. Professionals mostly use JST XA connectors in Japanese-made LED TVs and other products.
JST Connector Crimping
Manually crimping JST connectors is challenging. Therefore, people often buy crimped wires that slip easily into the connector housing, creating any sequence. However, some people prefer to make their crimps. Read on to learn more about creating a crimp.
For a Good Crimp
Before diving straight into creating a crimp, let’s first discuss what a good crimp entails. When purchasing crimp connectors, you’ll notice some metal strips attached. These strips should go through a machine that automatically creates a crimp. However, we are looking to accomplish this manually.
Every crimp connector has two sets of wings you’ll need to bend as the process continues. The first set holds the insulation, while the second holds the wire. After the wires are crimped, they snap directly into the plastic housing, ganging them together. Upon pushing the wire inside the housing, you’ll hear a click. Just be careful not to cause too much damage to the crimp connector.
Crimping Tools
You’ll need to get a variety of tools to do the job. Ensure you get the best tools. Otherwise, you’ll need to crimp twice (first for the insulation and again for the wire). Also, ensure the tools are not hard to use to minimize room for errors. The key difference between the PA-20 and PA-09 is the scope of crimp sizes.
If you find the PA-09 ineffective, you could opt for the JST crimpers. The JST can crimp both wings at the same time while automatically positioning the crimp connector to its rightful position. However, it only works for one type of connector, the JST-PH.
Crimping Procedure
With crimping, you have to be careful to avoid mistakes. Although there’s no definite procedure for creating the crimp, below is a general flow to guide you.
First, strip the ends of the wire and twist them a little bit. You’ll need a stripping tool to create a perfect strip of about 2 to 3 mm.
The next step is to break the crimp connector away from the strand. Then, hold it in one of your hands and push the wire wings inside the appropriately sized tool. Make sure the crimp is pointing to the crimper as they bend backward. Also, ensure the outer insulation wings aren’t inside the crimper because you only want to crimp the inside wings of the first crimp. After this, don’t jump straight to crimping. Instead, push down slightly to ensure the crimp connection is held in the same position while using your other arm to lift the wire.
Next, push the wire inside the crimp connection, ensuring the plastic insulation ends at the crimper’s edge without sticking out of the connection. Sometimes the connection might be too large to fit inside the connection or sides of the crimp to prevent it from slipping in.
Now, the next step is to crimp. Ensure the wire strands stay beneath the folded wings while the outer wings remain open.
Follow up by using the end of the crimp to slightly bend the outer wings so they can fit inside the crimping tool. Ensure that they’re parallel.
Finally, put in the crimp connection from the opposite end and crimp.
Often, while crimping JST connectors, people encounter the following challenges:
Over-crimping or bending the connection.
Stripping too much or too little wire.
Not pushing the wire far enough, and as a result, failing to crimp the insulation.
Caption: Crimp Tool
Conclusion:
There you have it all you need to know about JST connectors. Feel free to reach out to Wiringo for all your custom cable assemblies. Our team of professionals has extensive experience in designing cable assemblies to the exact customer design, guaranteeing you get what you want.
