Terms used for cable terminals

There are many different designs of cable terminals - tab, pin and timer are all examples. Here are some terms which apply to all cable terminals.

• The different types of cable terminals are described in Cable terminals, different types .

Fig 1: Cable Terminal Size

Courtesy of VOLVO CARS OF NORTH AMERICA.

Size 

Cable terminal size is calculated as the width of the tab section. The receptacle terminal size is given as the matching tab's size. For pin/socket terminals the size is the diameter of the pin.

Cable terminal specifications are written with the size first, for example 2.8 Tab.

Cable areas 

Every cable terminal type is available in sizes (approx 2 to 4) for different cable areas, so the size of the core wings and insulation wings vary.

Fig 2: Core Wing/Insulation Wing

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Seal SWS (single wire seal) on cable terminals 

On SWS  (single wire seal) cable terminals a seal must be used. The seal is crimped round the cable at the insulation wings and seals against the cavity in a housing.

Fig 3: Identifying Locking Tab On Terminal

Courtesy of VOLVO CARS OF NORTH AMERICA.

Locking tab 

Most cable terminals have one or two locking tabs which retain the cable terminal in the cavity. There are also cable terminals without any locking tab.

It is important that the locking tab is sticking up from the cable terminal so that it catches properly in the housing when it is connected.

Fig 4: Dimple In Terminal Housing

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Dimples 

Some tab/receptacle terminals in single pin (and multi pin) variants have dimples in the housing.

The dimple is a mechanical locking device between the tab and receptacle terminals.

Fig 5: Identifying Core Crimp And Insulation Wings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Core crimp and insulation wings 

The cable terminals crimping section consists of two parts, which are both formed at the same time in the crimp tool.

Core crimp  (1) for the electrical connection with the stripped section of the cable (the core).

Insulation wings  (2), which are pressed on to the cable's insulating sheath and support the core crimp, reducing the effects of mechanical stress.

Primary locking and secondary locking 

The cable terminals are retained in position in a housing by different types of locking devices which prevent the cable terminal being pushed out of the rear of the housing when they are connected together.

The locking catches must be opened when inserting a cable terminal in a housing.

Fig 6: Identifying Locking Tab On Terminal

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Fig 7: Identifying Locking Tabs On Terminal

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Primary locking 

Primary locking is normally on the cable terminal, consisting usually of one or two locking tabs. See examples shown.

• Single primary locking uses one locking tab
• Double primary locking has two locking tabs

If there is no primary locking on the cable terminal there may be a type of locking catch located in the housing cavity instead. There is always one separate primary locking for each cable terminal.

Fig 8: Identifying Opened Locking Lid/Catch

Courtesy of VOLVO CARS OF NORTH AMERICA.

Secondary locking 

Secondary locking is always located in the housing itself. Secondary locking can be a socket section or locking lid with catches, which must be opened in order to remove a cable terminal. Secondary locking protects, supports and holds the cable terminals in place.