Description: What are IDC connectors? Learn its working principle, efficiency, and functions in this article.
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IDC connectors are fast and reliable, and they are commonly used in electrical and electronic applications. The connection between the wires is gas-tight, but the crimp connection must be secure to avoid oxidation. IDC connectors are generally gas-tight, but a pull test should be conducted to ensure that the crimping is solid. If the crimp is not strong enough, the resulting break may indicate poor criterions or incorrect size of the crimp.
What are IDC connectors?
IDC connectors are usually mass-terminated flat cables. The contacts on IDC connectors are positioned at 45-degree angles to the axis of the conductor. The metal-to-metal contact eliminates the need for splicing wire insulation prior to connecting. Furthermore, the IDC blade cold-welds the conductor to the block. This makes it easier to connect flat cable assemblies than to strip them.
The mechanical stability of an IDC connector depends on the spring properties of the terminals and the load placed on the wire. It is enhanced by the design and shape of the connector. A cable should have an external strain relief to prevent movement at the wire-terminal interface. IDC connectors are generally reliable. This feature helps reduce cost and time-consuming assembly. The IDC is also compatible with different electrical standards. Its compatibility makes it easy to integrate with other devices.
IDC connectors efficiency:
IDC terminations are quick and efficient. These connectors are ideal for fast and accurate wire termination. In addition, the IDCs are resistant to vibration and heat. The use of IDCs and crimps in these applications is common, but they also require special handling and are therefore not as flexible as many other types. It is recommended to follow the manufacturers’ guidelines for IDC connectors, because they meet their requirements.
In electrical and electronic applications, an IDC connector is a type of wire connector that allows multiple wires to be connected to one another. They are generally used in industrial and automotive applications. A number of IDCs can also be customized to the specifications of a customer. It is possible to make a custom IDC connector using a standard electrical cable, or it can be made to match a specific cable. If your application requires multiple connections, IDCs may be the most appropriate option.
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Why are IDC connectors used?
IDCs are commonly used for electrical and electronic applications. They are available in various sizes, colors, and positions, and are used in a variety of applications. IDCs are commonly used in automotive devices. They are commonly available in male and female versions. There are also IDCs for RS-232 interfaces and other electrical devices. If you need a bare-wire or a high-frequency IDC for a rotary switch, you can choose a DB-compatible connector.
IDCs are a popular choice for electrical engineers because they offer a wide range of benefits. They are versatile, and do not need to be soldered or individually crimped. And because they don’t require any special tools, they are a great choice for fast and efficient harness assembly. These cables are often used in consumer electronics. Whether they are wired for audio or video, IDCs provide the flexibility to connect to many applications.
Functions of IDC connectors:
An IDC allows power and signal wires to be terminated quickly, and they have a low-profile design. They are often a better choice than crimping. IDCs can be installed quickly and easily, and they are very durable. They can even be easily removed from cables. In addition to their high-tech capabilities, IDCs are a great option for industrial applications. So what are you waiting for? Get your IDC today!
IDC connectors are multi-position interconnects with low-voltage, high-contact density, and no stripping. The two-piece IDC has been used for years for multiwire interconnects, but IDC connectors that use a flat cable are more versatile and offer greater flexibility when it comes to board arrangement and cable routing. This is a great option for electronics that need a flexible, reliable and fast connection.
IDC connectors and automotive industry:
IDCs are a great choice for automotive and industrial applications. These connectors are very versatile, and can be used with different interfaces. They are most commonly used on PCBs. They are highly efficient and are used in high-volume projects. They are easy to install and can be easily removed by a single person. These cables can be soldered on as well. These are ideal for use in electronic equipment. This article will tell you about idc connector types, idc connector datasheet, idc connector rj45, idc connector tool, idc male connector, idc connector pinout, 10 way idc connector and 16 pin idc connector.
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martincho
IDC vs. Crimp vs. Spring Connectors
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on: February 10, , 07:36:20 pm »
I am working on a design that requires wire splicing. One set of wires is carrying 400 VAC at about 1 A. Another set is 100 VDC at 3 to 5 A. No vibration other than whatever the product might be exposed to during shipping. No temperature extremes.
The options are:
- Insulation displacement connectors (3M Scotchlok)
- Crimped butt connectors (TE PIDG or Plasti-Grip
- Spring Connectors (Wago)
Here are random examples of the above (these are not selected for my application):
https://www.mouser.com/ProductDetail/3M-Electronic-Specialty/560B-BULK?qs=3gW96gqhLborxsSEYKXv0A%3D%3D
https://www.mouser.com/ProductDetail/TE-Connectivity/?qs=2ECNu9wPwy5ix9YN1BeGuA%3D%3D
https://www.wago.com/us/wire-splicing-connectors/splicing-connector/p/222-413
IDC connectors are attractive because they reduce labor. You don't have to strip the wires and don't have to deal with any of the issues that can arise from stranded vs. solid wire.
Crimp-type butt connectors require stripping. The advantage I see is that you can use full-cycle tooling to ensure a solid connection. Generally speaking, crimp connections are very reliable and reasonably resistant to moisture.
The spring-type connector is interesting. I am less familiar with reliability on these. They do require wire stripping, so there's that extra step in time and labor. They seem to be rated for a wide range of wire size and currents. This could mean stocking a single part number to cover the range I mentioned above. Not sure how these do with regards to moisture and long-term reliability.
I am looking for general commentary from anyone who might have considered these wire-to-wire joining options in applications with similar requirements.
Thanks,
-Martin
jpanhalt
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #1 on: February 10, , 08:05:45 pm »
I have done no comparisons, but in a recent motor installation, I used spring connection like you show instead of wire nuts.
For anything except telecoms and very low voltage, I do not use IDC. I like IDC for some narrow pitch signal connectors as it is easier to do than crimp with my cheap tools.
To me, crimp connection are great for a permanent connection. They are the most difficult to redo without reducing the conductor lengths. Wire nuts used to be a standard in the US for such things a household and infrequently re-done connections. Spring connections are supposed to be a better alternative to wire nuts.
martincho
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #2 on: February 10, , 10:09:16 pm »
There's also these push-in connectors:
https://www.wago.com/us/wire-splicing-connectors/compact-pushwire-splicing-connector/p/-403
They are UL rated for 600 V and 20 A. Very low cost. Interesting.
thm_w
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #3 on: February 10, , 10:21:35 pm »
Surprised that 3M part is rated 7 to 15A. Its basically a vampire tap, which are not known to be terribly reliable.
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martincho
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #4 on: February 10, , 11:16:44 pm »
Here's an interesting set of videos where some of these connectors are tested to brutal limits:
I feel far more confident about standardizing on these now.
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langwadt
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #5 on: February 11, , 12:33:18 am »
Surprised that 3M part is rated 7 to 15A. Its basically a vampire tap, which are not known to be terribly reliable.
looks like something a sketchy mechanic would use to make questionable and unreliable bodges on a car with
Berni
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #6 on: February 11, , 07:38:08 am »
For a permanent connection crimping is usually the most reliable option. The forces involved create cold welding of the wire making it a reliable low resistance connection that is also mechanically strong. Does require a crimping tool but is faster than a screw terminal.
Also if moisture is a big concern it might be worth covering the crimp with heatshrink tubing to seal it in.
Crimped connections also tend to visually look 'more professional' as compared to blocky splice things hanging off cables that give it more of a look that someone DIYed that connection in there garage.
As for stripping insulation you can do it pretty fast with some decent automated stripping pliers, just put the wire in there, squeeze down, release and the wire is stripped. The speed advantage of insulation displacement connectors is not worth the worse reliability, especially at high currents.
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jpanhalt
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #7 on: February 11, , 09:56:44 am »
Yes, crimp is great for stranded wire. But what about solid/solid and solid/stranded wire connections?
In my experience, crimp on heavy gauge solid is not very reliable, at least using ordinary crimpers. Even smaller gauge (e.g., 22 awg) is prone to loosen. Also, the need to occasionally remove a connection (e.g., with electric motors) or modify it (e.g., household, offices) support something less permanent and/or more appropriate for solid. That is where wire nuts and the newer "spring" connections come into play.
As I mentioned earlier, my first use of lever-spring connections was quite recent. So far, I was impressed and have had no problems. Subjectively, they were a little harder to pack in a connection box than wire nuts, but years of experience v. first-time use makes that a biased observation.
EDIT: I also used WAGO
« Last Edit: February 11, , 10:12:51 am by jpanhalt »
JohanH
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #8 on: February 11, , 10:05:18 am »
Vote for Wago here. I wouldn't use anything else in electrical installations (1.5 mm2 / 16 AWG and larger). They are so good. Solid wire or stranded, both works.
tooki
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #9 on: February 11, , 12:48:50 pm »
Surprised that 3M part is rated 7 to 15A. Its basically a vampire tap, which are not known to be terribly reliable.
No they’re not. They work like punchdown blocks (but with the movement in reverse): a v-shaped blade that slices the insulation and clamps down on the conductor. This is a very reliable connection.
IDC is a broad term that covers many different contact geometries. Most are the punchdown type. Others just stab little teeth into the wire. Either way, though, IDC is widely used and certainly isn’t considered unreliable.
Yes, crimp is great for stranded wire. But what about solid/solid and solid/stranded wire connections?
In my experience, crimp on heavy gauge solid is not very reliable, at least using ordinary crimpers. Even smaller gauge (e.g., 22 awg) is prone to loosen.
Crimping is always a precision operation, and whether solid or stranded, the contact, wire, and tool must all be matched. Anecdotally, I’d say that the vast majority of crimp systems are designed for stranded wire exclusively, but some do work with both. It’s no problem at all with circular indent crimping (the military/aerospace type).
One issue with solid wire and crimping is stripping precision: if a strand is nicked during stripping, on stranded wire it doesn’t cause catastrophic damage: future flexing may break the one nicked strand, but the others will be fine. With solid wire, a nick leaves the only strand weakened, and the crimping process may exacerbate the damage.
Ultimately, again anecdotally, practically all of the crimped solid wire I’ve seen is to specialty wire that can’t be soldered, like nichrome wire in heating appliances.
jpanhalt
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #10 on: February 11, , 01:27:04 pm »
NASA does not seem to allow an exception for terminations. I think I know what you mean by circular indent type, but doesn't that induce work hardening and a breaking point for solid wire?
tooki
Re: IDC vs. Crimp vs. Spring Connectors
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Reply #11 on: February 11, , 04:23:14 pm »
I’m sure it does to an extent. I can certainly understand why NASA would prohibit it since they’re the ultimate high-risk high-vibration environment. For the most part, the question of crimping solid wire is irrelevant since we rarely use solid wire in electronics any more. And certainly crimping solid wire is vastly less forgiving than crimping stranded wire, not that I would call crimping a particularly forgiving technology to begin with!