Connector Selection Guide: Wrong Connector Can Burn the Device
Connector Selection Guide: Wrong Connector Can Burn the Device
Most failures in the field come from the connector. Loss of contact, heating, disconnection in vibration. All are caused by wrong selection.Choosing the right connector directly determines the life of the device.
What are Connector Types?
1. Board to Board: Connects two PCBs to each other. High density, low profile. Used in modular designs.
2. Wire to Wire: Connects cable to cable. Locked system is mandatory for field assembly. Ideal for automotive and industrial applications.
3. FFC / FPC: Flexible circuit. Like laptop screen cable. Very low profile, compact design. No.1 in LCD connection.
4. Terminal Block: Screw strong connection. Offers removable structure for power inputs.
5. USB / Type-C: Data + Power together. Type-C is now standard: 100W power, reversible, 10Gbps data.
6. Pin Header: Classic male / female. Used everywhere from prototype to mass production.
7. RF Connectors: For high-frequency applications SMA, N-Type, BNC, TNC are used. Wrong selection on RF side means signal loss.Choose the Right Connector in 5 Steps
STEP 1 - Determine the Application: Power? Signal? High-speed data? Or RF? For power current, for signal impedance, for data frequency is important.
STEP 2 - Current & Voltage: If you give 5A power to a 0.5A signal connector, it melts. Leave margin: If you will draw 3A, choose 5A one.
STEP 3 - Environmental Condition: Outdoor? IP68 required. Is there vibration? Locked connector is mandatory. -40 / +125°C industrial class?
STEP 4 - Mechanical & Size: What is pitch? 0.4mm or 5.08mm? Is there space on the board? SMT or TH?
STEP 5 - Life & Standard: How many times will it be plugged and unplugged? 500 cycles or 10,000? Is there UL, RoHS, REACH certificate?Conclusion: Connector looks like a small part, but it can burn the whole device. When choosing, don't just look at price, choose the right type for your application.
For connector selection support: https://www.karinaelektronik.com/
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