Even if you have the perfect cable and connector for your application, using the incorrect technique to connect the connector to the cable might lead to an unreliable, troublesome connection. Soldering or crimping are the two techniques used to connect cables. When used properly, each approach may produce a reliable, high-performance cable connection, but each approach has its own pros and cons.
The sole industry-accepted standard for requirements, specifications, and accepted standards of wire and cable harness assemblies is IPC/WHMA-A-620D. For the purpose of manufacturing crimped, mechanically fastened, and soldered connectors, as well as the accompanying assembly tasks connected to cable and harness assemblies, the ipc-a-620d standard assemblies specify materials, procedures, tests, and acceptance criteria.
IPC, as well as the Wire Harness Manufacturers Association (WHMA), an IPC affiliate, created the IPC/WHMA-A-620 D standard. This standard’s goal is to depend on a process control approach to guarantee constant quality levels while products are being manufactured. Any technique that results in an assembly that satisfies the acceptance requirements outlined in this standard is acceptable.
Soldering
The most conventional and cost-effective technique for wire termination is soldering. To connect a wire conductor to a contact, soldering requires melting and cooling an alloy made of lead, brass, silver, or tin into solder cups. This approach is often advised for general-purpose, industrial, and commercial applications that demand dependable signal and power connections.
Nearly every size wire and cable via solder contact can be easily terminated with a basic soldering kit, in contrast, to crimp terminations that call for specialized tools. Potential cost savings exist because the tooling is so low, and the only materials needed are flux and solder. In summary, soldering’s main advantage is that it is inexpensive.
Soldering can have drawbacks, though. The soldering procedure causes heat to build up in the contacts, connector, and cable. Problems could arise from this inevitable heat generation, particularly if the temperature exceeds the insert’s working range. A soldered connection must also use a solder that complies with RoHS regulations. This is a problem since the metal lead, which RoHS forbids, is present during soldering.
If not done correctly, soldered connections may also be more susceptible to corrosion and vibration. This can be particularly difficult when used in applications that operate in hostile environments. A perfect solder connection, however, may be less prone to corrosion and will survive shock and vibration like a crimp connection.
In addition to taking more time than crimping, soldering can negatively affect quality and dependability if done incorrectly. For instance, if the solder does not entirely melt, “cold” solder junctions may develop. As a result, the surface becomes rough, uneven, or lumpy, which leads to an unstable connection. In fact, fissures can grow over time and result in major problems. In addition, the soldering connection’s filler metal will deteriorate with time and may result in connector failure.
Crimping
Crimping is the process of applying pressure on a contact to secure it to a wire. Using a crimping tool, the connection is established by squeezing the tool’s handles and crimping the contact and wire together to create a strong connection. For applications that need great dependability in challenging settings, crimping is advised.
Compared to soldering, crimping has various benefits. It’s an easy, quick technique that can be carried out manually or automatically using a crimping machine. Crimped connections result in durable, dependable connections shielded from environmental factors like moisture, sand, dust, and dirt because they form an air-tight barrier between the connector and the cable.
When a knowledgeable technician handles the crimping procedure, the connection may produce a strong “cold weld.” Crimping is also more reliable than soldering, which can be inconsistent depending on the technique or technician’s level of expertise.
Crimping does, however, call for costly specialized tooling depending on the contacts utilized. And for a reliable connection to be made, the crimping procedure must be done correctly.
Overall, the most crucial element is the caliber of the crimp or solder connection. Flaws in either connection frequently cause electrical failures due to vibration, stress, and corrosion.
IPC-a-620d standard assemblies might be useful for applications involving severe environment RJ45 connections for sending data for oil field uses or efficient circular connectors for factory automation. The established standards and compliances help you set up efficient cable and wire harness assemblies for all the products of all class divisions and in any environment, from specifying the right connector to selecting the most suitable contacts, establishing custom packaging or kitting, and choosing the best connection method.
