Six Obstacles to High Voltage Connector Header Design

The design of high voltage cable assemblies and splice connectors is challenging and many aspects of the cable assembly must be considered. 1.Size limitations. In the design of high voltage connectors and cable assemblies, size constraints often make the design particularly difficult. In general, the high voltage cable assembly is the last issue to be considered by the user when designing the equipment. In order to meet the operation requirements, the high-pressure connection is required to obtain the required space. The whole industry is moving towards smaller, lighter, but more demanding components. High pressure with space offset is history. Nowadays, many enterprises hope that the design team can come up with effective solutions while reducing the cost of cable components. Moreover, the customized connector design of Electronic Valley Mall can achieve this goal. 2.Design around existing connectors. It is difficult to design on existing connectors. In general, the user recommends using an existing connector and cannot discard it. In general, these connectors do not meet their needs or match the rest of the older class of equipment in their design. Another reason is that the connector needs to operate at a higher performance threshold than the current configuration can achieve. Either way, the inner workings of the connector assembly require in-depth analysis. For example, the technical engineering team of Wanlian Technology, in close cooperation with users, needs to analyze every aspect of the design: What materials are used? What are the mechanical and electrical characteristics of this material? What aspects of the design can be modified to meet the required specifications without affecting the design installation, form, and function? 3. Cost. In the current economic environment, one of the main obstacles to high voltage billing is cost reduction. Designing a reliable, efficient, and robust connector is very difficult and even beyond the user's needs. In many cases, performance must ultimately drive down costs. Some techniques can be used to minimize cost without compromising performance. For example, use existing materials from inventory and on hand, use hardware from an existing design, incorporate it into a new design, use existing tools, molds, and tooling, and use new parts that are cost effective. 4. manufacturability. In design, manufacturability is critical. Designs on paper may be beautiful, but are they easy to make? The difficulty of the design will affect the direct labor time required to construct the cable assembly, thereby affecting the cost. Difficulties in design also affect the ability to maintain repeatable technology. If the technology is not repeatable, internal cable failure may occur. These possible technical issues should be addressed during the design review.

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5. Materials. It is important to select the right material to maintain design efficiency. High-voltage cable assemblies and connectors have higher requirements for the electrical and mechanical properties of materials. Careful analysis of the impact of the working environment on the material is the key. It is easy to make mistakes using different material proofs. Good adhesion between materials is especially important to eliminate high pressure. If there is no good adhesion between materials, it will not affect the voltage in the air, so it needs to be designed between the high pressure and the ground. Bonding between materials with the same material effectively eliminates high pressure and allows for smaller connections. The use of coatings and adhesion promoters can be useful when different materials are used in the design, depending on the materials you are joining. 6. Coronal prominence. It's very difficult sometimes without the Champions League. The design of the crownless assembly ensures the reliability and elasticity of the cable, which can stand the test of long time. There are many factors that need to be considered in the design of a crownless cable assembly. First, choose the right cable. Most designs use three layers of extruded cable. Thereby ensuring the smoothness and uniformity of the conductor and the ground. Second, the connector interface. The interface shall be maintained at a sufficient distance to counteract the effects of voltage and air. Tips to Prevent Design Obstacles: (1) Size: Consider cable assembly or splice construction as soon as possible. High stress may require more space than you think. (2) Use existing designs: If you need to modify an existing design, it's a good idea to work with a custom designer to make sure they meet your new needs. (3) Cost: Don't rely too much on cost. Reliability.Durability.SafetyDesign is cheaper in the long run. (4) Manufacturability: not over-designed. Your expectations are realistic. Sometimes the simpler the better. (5) Materials: To ensure the best and most reliable bonding between dielectrics, the same material shall be used. (6) Coronal/partial discharge: The geometry of the connection is important. Imilar to a crown antenna. The sharp corners should be as round and blunt as possible.

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