An overview of how connectors can reduce cabling costs!

Connectors and hardwiring are commonly used wiring methods for industrial machines to provide power and signal connections. While hardwiring can significantly save installation costs, the assumption that hardwiring will minimize wire installation costs is wrong, while connectors do require a larger upfront investment, but are more cost-effective in the long run. In this article, Huichengyuan connector manufacturers mainly share with you how connectors reduce wiring costs!

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When all the wiring costs of connectors and hardwiring are taken into account, the cost savings are actually only minimal. These installation costs obviously include the cost of time and materials, wires, accessories and labor, and there are hidden installation costs considering labor and time to market. For example, many machines must be disassembled when they are shipped and reassembled when they are started, so you must hardwire the parts of the machine at least twice. But field wiring errors are common, especially when a local electrician unfamiliar with the machine is handling the wiring, and these errors can cause delays in machine commissioning, and at worst they can damage the machine, requiring increased testing costs, which can be complex and expensive in hardwired systems. These hidden costs will grow exponentially with the number of connection points on the machine, and connectors can avoid all of these costs by connectivising, which is one reason connectors have advantages over hard wiring, and the use of connectors is more cost-effective than hard wiring. Connectors make machines less costly: Connectors give engineers the flexibility to create modular machines that can be built faster and less costly, with this machine design approach that allows commonly used subsystems and components to be pre-built, tested, and stored for installation. Many machines can be designed from reusable modules, including control panels, junction boxes, filler cable tracks and motor assemblies, and sensors and actuators with pre-wired connectors are increasingly available. Connectors offer plug-and-play components, making modular machines very attractive from a cost perspective. Not only are connector modules easier to assemble, but they also ensure wiring integrity. For example, when multiple connectors can be installed side by side, they can be keyed so that each cable connector only mates with the correct receptacle. Today, electrical connectors serve almost every power, control, signal and data application you can imagine. Some of these connectors are dedicated to specific electrical specifications and have a fixed number of contacts. Also, custom modular connectors can meet specific machine requirements that can't be met with off-the-shelf specialized connectors. These modular connectors can package power and control contacts, fiber optic contacts, pneumatic ports and data bus connectors into an environmentally friendly enclosure. Connectors make machine shipping faster: When new large machines are ready to ship, they have to undergo at least some disassembly. At a minimum, cables to and from the control panel need to be disconnected from transport. With hardwired machines, this extra step can be time-consuming, expensive, and error-prone. For machines with connectors, you simply unplug any cables from the bulkhead connectors of the panel. The wiring and connections inside the panel remain the same. The same applies to junction boxes, motor assemblies, sensors and data cables. Connectors make the commissioning of the machine faster: Once the machine arrives at its destination, all wires disconnected due to shipment need to be reconnected, and a local electrician uses a set of wiring diagrams to perform this critical rewiring process, which causes costly errors and start-up delays due to the rewiring process. In contrast, connector-connected machines have a true plug-and-play startup process, eliminating the need to rewire the machine in the field, eliminating the possibility of wiring errors, meaning no expensive troubleshooting or replacement of damaged components, and quicker commissioning.

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