Car electrical wire connectors play many crucial roles inside your car. These small electrical components ensure reliable power transmission throughout your car’s complex electrical systems. So it is crucial to know how to use them.
In this article, we’ll shed light on their importance, various types, and a few other fundamentals on the subject.
(An electric car waiting set)
A Detailed Comparison Of Wire Splicing Methods
Wire splicing is critical to the cable assembly process used in various electrical and mechanical components.
Here are four of the most common wire splicing methods used today.
Heat Shrink Splice
To use a heat shrink sleeve, strip both wires of their insulating material over the required length.
Next, insert the two wires into both ends of a custom cylindrical heat shrink tubing/sleeve. This sleeve uses thermoplastic material, and it contains a ring of solder under the sleeve.
When you heat this sleeve and its solder-containing parts, it liquefies and creates a tight seal over the wires.
As the solder melts into the wires, the wires bind together, and the sleeves tighten further.
Butt Splice
Butt splices differ from heat shrink connectors due to their use of a scrimp connector and not soldering.
For a butt splice, the connector features a metal ring at both ends to enclose the wires you want to spice.
To make a butt splice, start by stripping the insulation from both wires along their required length as usual.
You can now insert both wires into both ends of the butt splice connector and crimp the connector with a professional crimping tool.
Once you crimp the connector around the wires, a connection is established inside the ring, which can transport the current between the wires.
(Butt splice connectors)
Solder Splice
Solder splices are perhaps the most common method used in industrial and regular applications today.
To make a solder splice, join both stripped ends of the wires by twisting them into each other. You can now apply the solder by heating it onto the stripped wire ends. The solder contains a fusible metal alloy that melts into the wires when heated over them.
This melting action deposits a seal around the wires that results in a strong electrical bond.
Machine Splice
The machine splice method is not very popular, but it is no less effective at creating a strong bond between joined wires.
It uses an advanced technique that splices wires automatically using specialized equipment known as the “auto-splice machinery.”
You can use the auto-splice machine to create a crimp connection with a reel of brass-coated copper.
Once you form this crimp around the wires, you can use heat shrink to wrap around the spliced portion and seal it.
The auto-splice machinery finds value in industrial-scale usage due to its efficiency and reliable operation.
Fundamentals Of Automotive Electrical Connections and Connectors
Understanding the fundamentals of automotive electrical connections and connectors is crucial to the quality and integrity of the connections you make.
Here are two major connection types discussed briefly.
Basic Connections
Basic connections are those connections you make without using any major tools or equipment.
In its simplest form, you can make a basic wire connection by twisting two wires together. Here is how.
First, strip the two wires you want to connect to their insulating cover at about ¼ inch from their respective ends.
You can now cross the wires at an angle and twist both their ends against each other in a clockwise direction.
Next, bend the twisted wires to form a U-shaped loop and press the loop against one of the wires.
Wrap the loop with the wire in a suitable insulating material to finish the connection.
(Manual twisting of wires)
Crimp Style Connections
Crimp-style connections are among the most simple and efficient wire connection types used today.
The crimp connector is a type of connector that needs a crimping tool to force two wires against each other inside a tube-like item.
To execute a crimp connection, you can use different crimping tools, crimp-style connections, and crimp connectors of different sizes.
You don’t necessarily need any technical skills to do it. However, the crimping process may vary between the different connector types used.
Step-by-Step Guide To Using a Crimp-Style Connector
Here’s a quick guide on using a crimp-style connector, starting from the non-insulated connector, which uses a ring terminal.
Crimping Non-Insulated Connectors
To begin, strip off about ¼ of the insulating material from one end of the wire. Next, twist all the wire’s strands in a clockwise direction.
This helps to force the wire’s strands to merge into one cohesive bloc that can fit freely in the connector’s ferrule.
Go on to insert the stripped portion into the ring terminal. With the wire already inserted in the connector’s ferrule, verify if you can spot at least 1/16 of the bare wire sticking out the ring connector’s other end.
For your next move, hold the crimping tool around the ring terminal such that the stake is opposite the seam.
With the scrimp in your hand, squeeze the connector together with the enclosed wires to form the crimp. This way, the connector will tightly squeeze the bare wire and finish off the scrimp.
The connector will squeeze tightly into the bare wire and complete the crimp.
(A group of crimped electrical connectors)
Crimping Non-Insulated Connector
Crimping insulated connectors is a very straightforward process, and here’s how to do it in five quick steps.
Step 1
As before, strip ¼ inch of insulation from both wires and prepare them adequately.
Step 2
Now, twist the wires into single units and insert the first wire inside the crisp connector.
Step 3
Ensure that you push the first wire end to fit inside the ferrule and that the insulation slots are seamless around the nylon.
Step 4
Next, face the crimp tool to press against the butt connector housing the enclosed wire and squeeze the connector tightly to make the crimp.
Step 5
Repeat this process for the other half of the connector. Heat the crimped area with a heat gun till the material shrinks and merges the wire.
(A wire stripper for crimping terminals)
Features Of Automotive Electrical Connectors
Versatility
You’ll find an electrical connector everywhere you look around in your car. Spot them everywhere, from the ECU to the wiring harnesses and your car’s infotainment system.
Utility
Without a connector, many components in your car would be unable to work properly. You can tailor them for any specific purpose such as in self-cleaning agents, integrated seals, cable harnesses, etc.
Variety
Electrical connectors come in different sizes and shapes. They also feature various designs that fit the functions and requirements of your automotive systems.
Conclusion
Automotive electrical connectors play a vital role in the way your car’s electrical components sets up. These small tools help to transmit current from one cable or component to another.
You’ll find them in different places around your car and they come in handy while carrying out repairs, installation works, and car rewiring.
