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What's a test lead or connector that may pierce insulation?

Author: Site Editor     Publish Time: 2022-10-10      Origin: Site

Wire Piercing Connectors are often designed and built as individual components. Test leads & cable assembly can be made by soldering or crimping one of these connections onto a wire or cable. 


The insulating jacket of the wire is pierced by two or more distinct needles on a Wire Piercing Connector, allowing the tester to access the wire's inner conductors.Manual screw fastening mechanisms or a simple springy activation are common in couplings to trigger the piercing needle. Using insulation-piercing components, users may easily and quickly attach them to wires. A wide range of sizes & needle bed combinations are available from E-Z-Hook, which produces both handheld & deployable connections.


Wire Piercing Connectors can cut through the insulation and how they work. 


There is a strong correlation between the connection method and the connector's reliability and performance. Electrical testing requires a secure connection. Thus the contact interface must be held in place with enough force. Thumbs screw locking or spring-loaded mechanisms pressed by hand force are two basic connection mechanisms that are readily available and typically suited to varied purposes. 


Some people will use a combination of two or more techniques to increase the strength of their connection and/or their safety. When making connections, it's crucial to use an insulation-piercing connector calibrated for the diameter of the wire. Needle(s) must be positioned to pierce the cable's center to provide a secure connection. Hence wires must be positioned in the exact center of the tip of the needle. It can be difficult to pierce a small-bore wire with a large needle or point cluster, damaging the wire or leading to poor contact. The connector may not make a solid connection in a wire of a greater diameter if its tip is too tiny. 


The Variables Are: 


· Different types of needle contacts are available. 

· Use a screwdriver or a spring-loaded/manual force connection. 

· Needle touch as the material of construction 

· Compatible wire gauge sizes for piercings might vary. 

· Banana jack, pin jack, threaded post, and wire stub 


Form of Contacting Node: 


The contacting tip of a connector is shaped in a certain way to facilitate the insertion & pierce of the wire. For a single syringe or a small group of needles, this often comes in the form of a "V" or "U" at a radius large enough to hold wires of a certain size so that they can be centered under the needle (s). Needle insertion devices typically have a flat surface or jaw-like construction to reliably force needles into the cable at a consistent depth when activated. Tips inside the shape of a 'V' are the most versatile since they can be used with a wider variety of wire sizes and the wire can be more readily centered before piercing. 


Connecting with a Thumb Screw: 


Once tightened by hand, this clamp provides a more secure & stable connection. Though thumb screw parts are more time-consuming to install than spring-loaded or hand force piercing connections, they are the best option for prolonged electrical testing. In addition to making a secure connection using the Wire Piercing Connector, it is necessary to have adequate wire access when using this form of connection. 


Flexible Link: 


When the needle is sunk into the insulation of the wire using the tension of the springs, the needle makes electrical contact with wire conductors. Elastic materials, like those found in springs, spring back to their original shape & size when no longer subjected to the same force or pressure that originally deformed them into their functional configuration. The spring tension is determined by the spring's dimensions, substance, & amount of coils.




The non-destructive testing method is ideal for out-of-reach cables since it does not need stripping or cutting the wire to enter the conductor. Needles leave only tiny holes or cuts after removal, protecting the wire's strength.