Wire-to-board Connectors Speed and Precision: Making Cabling Efficient

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Phoenix Contact GmbH & Co. KG

SCHURTER GmbH

MEV Elektronik Service GmbH

The networking of electrical components and the use of energy storage systems play a major role in realizing the vision of an All Electric Society. With the new wire-to-board connectors of the Connexis series, components can be networked quickly and efficiently.

Global automation, particularly in the industrial environment, continues to advance. Production lines are becoming increasingly complex – driven by climate change and the switch to electric solutions that must be operated using sustainable energy. Examples of this include automated guided vehicle systems and fully automated production lines assisted by robots (Figure 1).

There are therefore increasing numbers of components that need to be connected. At the same time, the training and availability of skilled workers is decreasing. The demographic change and the growing demand for networking are contrasting pressures.

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This development is forcing the industry to rethink. Solutions that eliminate on-site work steps are becoming increasingly important. One option is to prefabricate the cabling in large quantities and then deliver it. Connecting entire cable harnesses in one go saves a huge amount of time compared to wiring individual cables on site.

In a modern production line, many machines, robots, and systems are already planned. The cable lengths are standardized and specified. It is therefore enough to just carry out the last few device installations instead of wiring and setting up an entire machine on site.

Crimping: Fast, Reliable, and Can be automated

For applications where the specific connections and lengths of the cables are predetermined, connection technologies for fully or semi-automated processing are ideal. These technologies make it possible to machine-manufacture a reliable connection efficiently and robustly in large quantities. Crimp connection technology is one such type of connection technology.

The crimp connection is primarily used to prepare cable harnesses. When it comes to field installation, instead of wiring individual litz wires, the cable harness just needs to be plugged in. This option not only increases efficiency by significantly reducing the amount of precious time spent on site, but also offers a higher level of safety due to the lower error rate.

The cable harnesses are machine-manufactured with high precision and are extensively tested before delivery and connection in the field. This eliminates further sources of error when wiring on site. Cable harnesses speed up the complicated and time-consuming task of wiring on site while also making the logistics chain more efficient. Instead of using lots of individual components that need to be ordered, stored, and delivered, the cabling is reduced to just a few cable harnesses. This means that upstream and downstream production processes also benefit from changing the connection technology and using entire cable harnesses.

Preassembled solutions enable industrial manufacturing companies to make production processes faster and more efficient. However, there are also connections for various applications in the field, such as sensors, that have to be wired on site by a specialist.

This involves more than just the internal wiring of individual applications. Complete networking is only possible once various electronic components have been connected. Data and signals must also be securely transmitted outside of a device in order to fully protect a system.

This often requires a specialist to carry out the final production step by hand. However, various crimp contacts and the required tools are too unwieldy for such applications. Other connection technologies, such as Push-in connection technology, are suitable for this purpose.

Push-in: Simple and Direct Conductor Connection

Push-in Technology enables the tool-free connection of rigid conductors as well as flexible conductors with ferrules. The special spring of the Push-in connection enables easy insertion. This is more efficient and saves time on site (Figure 2).

In order to exploit synergies, a system is needed that combines the various connection technologies.

Systems with crimp and Push-in connection technology, for example, are particularly popular in strongly growing markets such as the energy market.

Energy storage systems are often preplanned racks that are delivered fully wired. It is just the last few work steps that need to be performed in the field.

Connexis: Technology in One System

The new Connexis series PCB connectors offer the advantages of both connection technologies in one system. Connexis was introduced at the beginning of 2023 with crimp connection technology initially. A range comprising over 300 different items has been created for the typical pitches used in data, signal, and power applications (Figure 3).

This includes versions such as vertical and horizontal headers, which can be used for conventional wire-to-board connections. The portfolio also includes items for wire-to-wire connections and other versions for panel feed-throughs for routing connections through the housing panel to the outside. The entire portfolio includes pitches ranging from 2.50 mm through 3.81 mm to 5.08 mm. Common cross-sections are supported within these pitches. For crimp connection technology, these range from AWG 28 to AWG 14 in all gradations and for Push-in connection technology there are also cross-sections from 0.2 mm² to 1.5 mm².

The Connexis system uses various crimp contacts to cover the different conductor cross-sections. These are either supplied as bulk goods for small quantities and processing with hand tools – or in taped format for large quantities. The latter version is used in large automatic crimping devices for automated cable processing and can therefore generate the advantages of efficiency and speed described above.

Record Time via Technology Shift

The Connexis PCB connectors with Push-in connection technology have now been added, which simplify and accelerate wiring in the field and in the factory.

With the expansion of this portfolio, items with Push-in and a pitch of 3.81 mm are now available. This double-row solution permits the connection of up to 1.5 mm² and currents up to 8 A.

With this pitch, the user now has the option of replacing the connector and selecting the crimp or Push-in solution depending on the application or installation location. This interchangeability in almost identical dimensions is unique to this connection system.

The new Push-in PCB connectors with spring connection technology can be used without the need for additional tools. The connection of rigid conductors is entirely tool-free. Flexible conductors can be optionally fitted with a ferrule and can then also be connected without using tools. The color-coded spring lever clearly shows how to use the Push-in Technology. With the help of a screwdriver, the clamping space can be opened by the colored spring lever and disconnection takes little effort.

In addition, all Connexis PCB connectors feature a lateral locking system as well as integrated coding systems. These enable error-free connection in the field and thus increase safety during installation. There is also the option of using the custom printing service from Phoenix Contact for the clear definition of terminal points (Figure 4). The company also focuses on customer service during the design-in phase and, in addition to drawings and 3D models, also offers a free sample service.

Summary and Outlook

Industry networking requirements continue to grow and develop. In response to this trend, Phoenix Contact is extending its portfolio with the new Connexis product series. An ever-increasing level of automation, the required connections, and the demand for greater efficiency require future-oriented and optimized approaches. The Connexis portfolio offers suitable solutions for fast and efficient networking. They can be implemented using crimp connection technology for preassembled cable harnesses as well as Push-in connection technology for wiring in the field. (kr)

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