Meet the Connector: Cable Termination Methods

However, in some situations another cable termination method is preferable. A designer might choose a cable termination method without a connector for applications that benefit from improved reliability and reduced signal loss. Non-connector terminations can provide stronger, more secure bonds, which are less prone to failure from movement or vibration. Non-connector cable termination methods can also be more cost-effective and save space in tightly packed applications. In situations where a connector isn’t the ideal choice, a variety of alternate cable termination methods are available. Each of the following options is suited to specific cable types (e.g., copper, fiber optic) and application requirements (e.g., electrical power transmission, data transfer).

Common Cable Termination Methods

The application’s operating environment, performance requirements, the skill level of the assembler or operator, and the ability to access the connection in the future should all be considered in the selection process. Options beyond connectors include:

• Soldering: The use of solder creates a strong, conductive bond. This cable termination method is commonly used in environments where vibration could cause other termination methods to fail. It’s ideal for precise, low-resistance connections that won’t need frequent reconfiguration or maintenance. This method requires the precision application of heat and a solder compound by a skilled assembler.
• Crimping: A cable termination method where a connector is attached by squeezing it onto the cable using a crimping tool. This is often used in coaxial cables and network cables (e.g., Ethernet). This method requires skilled assembly. A disadvantage of crimping is that it can lead to unreliable connections if not done properly, as inconsistent pressure or poor tool quality can result in weak or loose crimps. Additionally, crimped connections are more prone to failure in environments with vibration or movement compared to soldered or welded connections.

Avnet offers a full range of crimp tools

• Screw Terminals: The cable is secured by tightening a screw to hold it in place. This method is often used in electrical systems and some industrial applications. This is a simple and reliable method for connecting wires without the need for special tools, and allows for easy disconnection and reconnection, making it ideal for installations that require adjustments or maintenance. However, over time, screw terminals can loosen due to vibration or thermal expansion, leading to poor connections or failures, and may not provide as secure or consistent a connection as other termination methods.
• Fusion Splicing: This method is exclusive to fiber optic cables and involves fusing or welding two fibers together to form a continuous signal path, used mainly in fiber optic communication networks. Fusion splicing creates a highly reliable, low-loss connection by permanently welding two optical fibers together, which is ideal for high-performance fiber optic networks requiring minimal signal loss and reflection. It also provides strong protection against environmental factors and physical stress. The process is expensive and requires specialized equipment and technicians, and it is time-consuming compared to other fiber termination methods, such as mechanical splicing. Additionally, once spliced, the connection is permanent and cannot be easily altered or reconfigured.