Electrical Connectors and Terminals

Wiring is used to connect different components to the power and ground source in the vehicle. In between the wiring terminal connectors are used to effectively connect and disconnect the wiring when there is a need of disconnection. Modern vehicles use more than 500 connectors for different components and circuit connection.

The terminal connections should make such connections with very low resistance and ensure minimum voltage drop on such connections. Terminal connectors are made of brass, copper or steel. They are tined, leaded or sometimes silver plated. Such plating prevents corrosion. Corrosion can cause loose connection and loose connection results in voltage drop. Voltage drop is an unwanted thing. Voltage should only be dropped on engineered circuit load. Voltage drop on cable connections and other places reduce the circuit efficiency and reliability. If had been observed if a connector used in the lighting circuit in a vehicle reduces 1.3V could reduce 33% light efficiency. To avoid this reduction in functionality all connectors and switched in the system should be of premium quality and good conductivity.

Terminals are normally crimped using a crimping tool or soldered using soldering iron to the wire conductors. As terminal connectors are making connection in wiring, they should be capable of bearing vibration as in vehicle they could be subjected to vibration during vehicle running.

Terminal connectors have different types. Their name employee their shape and function. Following are a few types of terminal connectors.

Molded connector

Such connectors normally have 1 to 4 wires which are molded in one piece component. Such connectors halves could be separated but connector cannot be separated itself.

Multiple wire hard shell connector

As the name shows such connectors have hard plastic shell which holds the connecting terminal. Wires terminals can be separated from the shell for repair.

Bulkhead connectors

Such connectors are used when many wires or cables are passed though bulkhead.

Weather pack connectors

Such connectors have rubber sealing on them to prevent terminals from moisture and water entrance. These connectors are weather safe as they don’t corrode in wet moist weather. They are normally used on computer circuits on the vehicles.

Metri pack connectors

Such connectors are like weather pack connectors but they don’t have rubber seal on them.

Heat shrink covered butt connector

Such connectors are specially used on air bag circuit applications. They have special use and sensitive use.

Splice are used to reduce connections. Splice can be used on power and ground. They are most commonly used on ground circuit. They are very useful if there are several components and devices located close to each other and they commonly use power and ground connections. In such a case those all powers and grounds are combined to a single splice and that splice is connected to the power or ground through a connector. This effectively reduces wiring and connectors.