Application of Rectangular & circular Electrical Connector

What is an electrical connector? Electrical connectors are electronic connectors for electronic engineering equipment.
In addition to meeting the general performance requirements of the electrical connector, the particularly important requirement is that the electrical connector must achieve good contact, reliable operation, and easy maintenance. Whether its work is reliable or not directly affects the normal operation of electrical circuits and involves the safety of the entire host.
For this reason, the host circuit has very strict requirements on the quality and reliability of the electrical connector. It is also because of the high quality and high reliability of electrical connectors that they are widely used in military systems such as aviation, aerospace, and national defense. Commonly used classification methods for electrical connectors include shape, structure, and use.

circular electrical connector

Introduction to electrical connectors
In various military aircraft and weaponry, electrical connectors are widely used, especially on aircraft. Generally speaking, an aircraft electrical connector can use hundreds to thousands of pieces, involving tens of thousands of circuits.

Classification of electrical connectors
Classification of electrical connectors by shape
Circular electrical connectors, rectangular electrical connectors.
Due to the characteristics of its own structure, circular electrical connectors are the most used in military equipment (aviation, aerospace). Rectangular electrical connectors are more commonly used on printed circuit boards of electronic equipment due to their simple structure.

Spring hole – pin of power connector

Classification of electrical connectors by structure
According to the connection method: threaded connection, bayonet (quick) connection, card lock connection, push-pull connection, in-line connection, etc.;
According to the terminal connection form of the contact body: crimping, welding, winding; screw (cap) fixing;
According to environmental protection: environment-resistant electrical connectors and ordinary electrical connectors.

Classification of electrical connectors by use
RF electrical connector
Hermetic electrical connectors (glass sealing)
High temperature electrical connector
Automatic fall-off separation electrical connector
Filter electrical connector
Composite electrical connector
Airport power connector
Electrical connectors for printed circuit boards, etc.

Anderson Plug Single Pole Rectangular Connector

The structure of the electrical connector
The electrical connector consists of a fixed-end electrical connector, that is, a female contact (referred to as a socket), and a free-end electrical connector, that is, a male contact (referred to as a plug). The socket is fixed on the electrical parts through its square (round) plate (some of them also adopt welding method). The plug is generally connected to the cable, and the plug and socket are connected through the connecting nut.
The electrical connector is composed of three basic units: the shell, the insulator, and the contact body.

HID male and female 2pin car connector

electrical connector housing
The electrical connector housing refers to the shell of the plug socket, the connecting nut, and the tail attachment. The function of the shell is to protect the internal parts of the electrical connector such as the insulator and the contact body (the general name of the pin socket) from being damaged. The positioning keyway above ensures the positioning of the plug and socket. Connecting nuts are used for plug socket connection and separation. Tail attachments are used to protect the conductor from damage at the contact termination and to secure the cable. The casing also has a certain electromagnetic shielding effect.
The shell is generally made of aluminum alloy processing (machining, cold extrusion, die-casting). Steel shells are mostly used for glass sealing and high temperature resistant electrical connectors.

Insulators for electrical connectors
It consists of a pin insulator and a jack insulator. Interface sealing body, sealing body and other components. It is used to keep the pin socket at the set position, and to electrically insulate each contact body and each contact body from the housing. The sealing measures are obtained by adding the insulator to the interface sealing body and the sealing body, so as to improve the environmental resistance performance of the electrical connector.
In order to adapt to the product’s high temperature resistance, low temperature resistance and flame retardancy, it ensures that the geometric dimensions of the parts are stable and reliable. Insulators are mostly molded from thermoset plastics. The interface sealing body and line sealing body are formed by molding silicon rubber.

Contact points of electrical connectors
The contact pin of the electrical connector includes a male contact and a female contact, sometimes also called a pin socket. The connection methods are divided into welding type, crimping type, press-in type and winding type, etc., to realize circuit connection.
Pins/jacks are key components of electrical connectors, which directly affect the reliability of electrical connectors. Pin jacks are mostly machined from elastic copper alloy materials with good electrical conductivity, and the surface is silver-plated and gold-plated to achieve low contact resistance and anti-corrosion purposes. Jacks generally include split slot jacks, wire spring jacks, crown spring jacks and punching jacks.
The structural features are: environment resistance, bayonet type (quick) connection, multi-key position (wrong insertion prevention), contact body and wire crimping connection, (single pick-up and delivery are convenient for troubleshooting). The shell plus shielding ring ensures 360° electromagnetic interference shielding capability.

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