Optimizing Wire Harness Connectors for Cost Efficiency

In electronic product design, connectors function like blood vessels, transmitting signals and power throughout the system. While seemingly insignificant, the spacing and dimensions of these connectors directly influence the manufacturing costs, reliability, and overall performance of wire harness assemblies. Have you ever encountered production inefficiencies or frequent product failures due to improper connector selection? This article examines the key considerations for connector spacing and sizing to help engineers develop efficient and durable wire harness components.

Connector spacing—the distance between the centers of adjacent terminals—is a critical factor affecting wire harness production efficiency. Multi-row connectors typically maintain uniform spacing between rows, though exceptions exist. When selecting connectors, adhere to these principles:

• Requirements-driven: If product design specifies particular pin spacing, choose connectors that match those specifications.
• Manufacturability: Where design permits, prioritize connectors with larger spacing to reduce production costs.

Smaller spacing increases manufacturing complexity

Why does a mere half-millimeter difference significantly impact production? The answer lies in operational space. As connector spacing decreases, manufacturing processes become more intricate, driving up labor costs.

In high-volume custom wire harness production, automated Cut-Strip-Terminate (CST) equipment typically draws wire from spools. Even after straightening, wires retain some curvature. If wires fail to seat properly in terminal housings, connections will fail. Smaller connector spacing means smaller terminal housings and reduced tolerance for error, substantially increasing connection failure risks.

To mitigate this issue, manufacturers must implement manual monitoring of otherwise automated processes. This necessitates slowing CST machine speeds to allow operators sufficient time to effectively monitor crimp quality, thereby improving success rates. However, such speed reductions increase costs—particularly when thousands of connections are required.

Connector spacing functions similarly to manufacturing tolerances. As tolerances tighten, production speeds decrease and costs rise. When working with suppliers that may compromise on quality, slightly larger spacing can help compensate for potential quality issues.

Whenever possible, engineers should specify standardized components and connectors. This approach strengthens supply chains and enhances manufacturability. The 2.54mm (0.100-inch) spacing is particularly common, providing wire harness assemblers adequate space for rapid, reliable connection production.

While standard components may not always meet requirements, the following table lists common connector series for various spacing options. Using these established connectors helps avoid excessive tooling costs and supply shortages.

Proper connector selection requires balancing electrical requirements, mechanical constraints, and manufacturing considerations. By understanding the implications of spacing and size decisions, engineers can optimize both production efficiency and product reliability.