Challenges in the Selection of Connectors and Wires for Industrial and Medical Equipment

The selection of connectors and wires for industrial and medical equipment has something in common with high volume industries such as home appliance, automobile, communications and consumer electronics. For example, engineers need to consider whether the electrical properties, mechanical properties, signal indicators, safety standards and certification, environmental adaptability and other functionalities of the selected materials can meet the requirements on equipment characteristics, so as to achieve the purpose of equipment development. However, industrial and medical equipment are characterized by:

1. High value, small production quantity and long life cycle;
2. High requirements for reliability in critical application scenarios.

In addition to the above factors, there are also the following challenges in selecting connectors and wires for industrial and medical equipment:

Reliability challenges:

Reliability is defined as the ability of a product to complete specified functions under specified conditions and within a specified time. This definition reveals the difficulty of achieving product reliability:

1. Under “specified conditions”, R&D engineers are required to fully imagine and understand the application scenarios of products, and define the requirements of products by application scenarios as specific working conditions. In the selection of connectors and wires, the working environment and conditions of connectors and wires shall be further determined according to the established product working conditions, so as to determine the functional performance of connectors and wires. For example, the working condition of connectors and wires in the execution part of high-end machine tools is: dynamic connection under constant temperature and humidity indoor environment. The working condition of connectors and wires in the execution part of engineering machinery is: dynamic connection in an outdoor dusty environment. Obviously, the functional performance of corresponding connectors and wires will be greatly differently due to the significant difference in their operating environment.

Engineers in office buildings often struggle to accurately imagine and understand the harsh working conditions of wiring harnesses, connectors, and wires, making it difficult to make correct selections. In addition, the working environment of connectors and wires is further accurately simulated to verify potential reliability problems in connector and wire selection.

2. The premise “within a specified time” presents greater challenges. On the one hand, although engineering technology has been developed for so many years, we still lack a clear understanding of the relationship between time elements and connector and wire failures in many application scenarios. Currently, we only have some empirical formulas or qualitative experience accumulated through lessons. On the other hand, this premise also shows that there is a lag in the occurrence of reliability problems, which may not be exposed and improved in the “new product qualification” test.

These circumstances show that despite the existence of reliability theory and textbooks, the current pursuit of reliability depends more on the years of experience of engineers. Unfortunately, with the rise of the Internet and the development of emerging industries such as APP programming, sharing economy, e-commerce and MCN, college students have more choices and fewer talents are willing to join traditional industries. To some extent, it has caused a generational break in engineers and further increased the difficulty of pursuing reliability.

Assemblability and detectability challenges:

As a large number of manufacturing operations are outsourced in Europe and the United States, new-generation engineers have little opportunity to participate in the manufacturing process and accumulate manufacturing experience. In China, as mentioned above, young college students are attracted by emerging industries and unwilling to take up boring manufacturing jobs with low incomes. The inheritance of manufacturing experience also encounters many difficulties.

While serving customers, we have gained valuable insights. Even some well-known customers often have obvious assemblability and detectability challenges in the selection of connectors and wires. For example, matching AWG 22 terminals with 18 AWG wires, and selecting pre-insulated OT terminals that cannot be tested for crimp appearance.

Procurability and cost efficiency challenges

“The negotiating ability of purchasing personnel depends on the amount being purchased”. Industrial and medical equipment sales volumes are typically small, and the demand for parts can differ significantly from that in larger manufacturing fields, such as home appliance, automobile, communications, and consumer electronics. However, many engineers and even some experienced engineers do not realize this problem. When selecting connectors and wires, they often focus more on functional matching, ignoring the attainability and cost efficiency of materials. It is common to choose materials from first-class manufacturers or local small-brand manufacturers. The former often disdain the demand for industrial and medical equipment and cannot give sufficient support, resulting in price and supply problems. The latter often cannot supply products globally due to their own limitations, even with the risk of going concern, resulting in serious supply problems.

When faced with challenges, if we cannot make progress in one aspect, it may be more effective to take a step back and consider solutions from a broader perspective. The reluctance of young talents to enter the manufacturing industry is an irreversible trend. It is also a reality that engineers who are not involved in back-end supply cannot take into account the relationship between supply and demand. If we can’t change this trend and reality, then why don’t we try in another direction? On the one hand, we should attach importance to connector and wire normalization and material list optimization; on the other hand, we should openly cooperates with experienced high-mix low-volume wiring harness manufacturers to make a good selection of connectors and wires relying on their experience.

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