#Disconnecting Terminal Stud Type

[elmex309]

Revolutionizing Connectivity: Stud Type Terminal Blocks by Elmex Controls Pvt Ltd

Introduction: In the realm of electrical engineering and industrial automation, the importance of efficient wire connectivity cannot be overstated. It forms the backbone of numerous systems, ensuring seamless transmission of power and signals. In this dynamic landscape, Elmex Controls Pvt Ltd has emerged as a frontrunner, pioneering groundbreaking solutions in wire connectivity.

[chetna-engineering]

Lugs Copper Solutions for Indian Industries by Chetna Engineering Co.

In India’s rapidly evolving industrial landscape, reliable electrical connectivity is critical for seamless operations, safety, and efficiency. Whether in manufacturing, construction, power distribution, or automation, copper lugs are the backbone of reliable electrical infrastructure. Chetna Engineering Co, one of the leading Copper Lugs Manufacturers in India, is meeting this demand with precision-engineered, durable, and cost-effective lugs copper solutions.

From tubular lugs to fork type lugs, Chetna Engineering Co is at the forefront of innovation and quality, providing industries across India with customized and standard solutions for all electrical termination needs.

Why Copper Lugs Matter in Industrial Applications

Before exploring what makes Chetna Engineering Co stand out among copper lugs manufacturers, it’s essential to understand the value of copper cable lugs and their role in industrial systems.

Key Functions of Copper Lugs:

Secure electrical connections in heavy-duty equipment

Minimize power loss and resistance in current flow

Withstand harsh industrial environments

Enable easy termination and detachment during maintenance or equipment upgrades

As industries continue to adopt automation, renewable energy, and smart systems, the demand for reliable copper lugs has soared. That’s where Chetna Engineering brings unmatched value to the table.

About Chetna Engineering Co: Reliable Copper Lugs Manufacturers in India

For over a decade, Chetna Engineering Co has specialized in manufacturing high-performance lugs copper solutions. Headquartered in India, the company serves a vast B2B clientele spanning power utilities, OEMs, infrastructure developers, panel builders, and more.

What Sets Chetna Engineering Apart:

ISO-Certified Manufacturing Standards

In-House Tooling and Design Capabilities

Customizable Sizes & Finishes

Stringent Quality Assurance Protocols

Fast Turnaround and Reliable Delivery

With over 100+ variants in copper lugs, including copper cable lugs, tubular lugs, and fork type lugs, the company is positioned as a top-tier copper lugs manufacturer trusted across sectors.

Product Range Offered by Chetna Engineering Co

Chetna Engineering Co’s strength lies in its diverse and specialized portfolio of lugs copper products. Let’s explore the core offerings that cater to Indian industries.

1. Copper Cable Lugs

These are designed for heavy-duty industrial and electrical applications requiring high conductivity and corrosion resistance.

Applications:

Transformer installations

Electrical panels and switchgears

Power distribution networks

Why Choose Chetna Engineering Co’s Copper Cable Lugs:

Seamless finish for easy crimping

Electro-tinned for extra durability

Available in multiple stud sizes

2. Tubular Lugs:

These tubular lugs are ideal for applications that demand compact and neat wiring. Their tube-like structure ensures optimal conductivity.

Best For:

Control panels

Power cabinets

Industrial machines

Features:

Manufactured using high-conductivity electrolytic copper

Tin plating to avoid oxidation

Uniform wall thickness

Chetna Engineering Co ensures that each tubular lug meets international specifications to suit Indian and export market requirements.

3. Fork Type Lugs:

Fork type lugs are preferred for quick installation and removal without disconnecting the screw completely, ideal for tight spaces.

Key Use Cases:

Communication equipment

Automotive wiring

Light industrial applications

Advantages:

Easy assembly

Strong grip over terminal screws

Custom coating and insulation options

Being a trusted copper lugs manufacturer, Chetna Engineering Co produces high-precision fork type lugs that meet all the safety and functional standards required for modern industries.

5 Reasons Why Indian Industries Choose Chetna Engineering Co:

When Indian businesses look for copper lugs manufacturers, Chetna Engineering Co is a name they rely on due to these key factors:

1. Custom Solutions for Complex Projects:

Need a specific type of copper cable lug for a niche application? Chetna Engineering Co works closely with project managers and electrical engineers to deliver customized lugs copper solutions.

2. Bulk Manufacturing Capacity:

With a scalable infrastructure and skilled workforce, Chetna Engineering Co fulfills large-volume orders of tubular lugs, copper lugs, and more — on time, every time.

3. Competitive Pricing:

High quality doesn’t mean high cost. As one of the most efficient copper lugs manufacturers in India, the company offers premium copper lugs at value-driven prices.

4. Nationwide Reach:

From Delhi to Chennai, Mumbai to Kolkata, Chetna Engineering Co delivers its range of copper cable lugs and fork type lugs to clients across all major industrial cities.

5. Commitment to Compliance:

All lugs copper products meet IS and IEC standards, and are RoHS-compliant — assuring clients of safe and regulation-ready solutions.

Industries Served by Chetna Engineering Co:

Chetna Engineering’s copper lugs, including tubular lugs and fork type lugs, are powering a broad spectrum of Indian industries.

Top Industries Served:

Electrical and Power Distribution

Construction and Infrastructure

Automotive and Railways

OEMs and Panel Builders

Telecom and Data Centers

Renewable Energy Projects

By offering reliable copper lugs, the company helps industries meet high-voltage challenges, ensure uptime, and reduce downtime-related losses.

Choosing the Right Copper Lugs: A Quick Buyer’s Guide

Selecting the right type of lugs copper can significantly affect system efficiency and safety. Here’s what to consider:

Key Parameters:

Conductor Size Compatibility

Current Carrying Capacity

Lug Type (Tubular, Fork, Ring, etc.)

Installation Environment

Compliance Requirements

Chetna Engineering Co provides full technical consultation to help buyers choose between copper cable lugs, tubular lugs, and fork type lugs for specific needs.

Sustainability and Innovation: The Future of Copper Lugs

With the global shift towards greener practices, Chetna Engineering Co is actively innovating in the domain of copper lugs to support energy-efficient applications.

Future-Ready Initiatives:

Using recycled copper where possible

Minimizing manufacturing waste

Investing in R&D for lighter, more efficient copper lugs

As a forward-looking copper lugs manufacturer, the company aims to be not just a supplier, but a sustainability partner for Indian industries.

Conclusion: Partner with Chetna Engineering Co for Reliable Lugs Copper Solutions

From power grids to control panels, Chetna Engineering Co is empowering Indian industries with a wide range of high-quality copper cable lugs, tubular lugs, and fork type lugs. Their proven track record as top copper lugs manufacturers makes them a go-to name for reliability, performance, and customer-centric solutions.

Whether you’re upgrading your plant infrastructure or launching a new project, trust Chetna Engineering Co for all your lugs copper requirements.

[ecswire]

Types of Electrical Wire Connectors: Choosing the Right Connection for the Job

When working with electrical systems, one of the most crucial components for safety and functionality is the electrical wire connector. These small but vital devices are used to join electrical conductors securely, ensuring a stable flow of current while preventing loose connections, shorts, or electrical fires. At ECS Electrical Cable Supply Ltd, we offer a comprehensive selection of electrical wire connectors types, each designed to meet specific application requirements in residential, commercial, and industrial settings.

There are several types of electrical wire connectors, each suited to different wiring tasks and environments. One of the most commonly used is the twist-on wire connector, often referred to as a wire nut. These are conical plastic caps with internal metal threads that twist over the ends of stripped wires. As they’re twisted, the metal threads draw the wires tightly together, creating a secure mechanical and electrical connection. They’re ideal for general-purpose wiring in lighting, outlets, and switches.

Another widely used connector is the butt splice connector. This cylindrical connector joins two wires end-to-end. The stripped ends of the wires are inserted into each end of the connector, then crimped using a special tool to create a firm connection. Butt splices are commonly used in automotive, marine, and appliance wiring, especially where a direct, inline connection is needed.

For terminal-based applications, ring and spade connectors are essential. Ring connectors have a closed circular end that fits securely over a stud or screw, providing a solid and reliable contact. Spade connectors have a forked end, making them easier to install or remove without completely removing the terminal screw. These connectors are popular in panel wiring, circuit protection systems, and control cabinets.

In environments requiring quick and tool-free connections, push-in connectors (also known as lever connectors or spring connectors) are gaining popularity. These allow electricians to insert stripped wires into the connector where a metal clamp automatically secures them. These connectors are ideal for tight spaces, renovation work, or installations that may require future disconnection or adjustment.

For environments with moisture, chemicals, or extreme temperatures, waterproof and heat-shrink connectors are essential. These connectors have insulation that seals tightly around the wire once heated, protecting the joint from the elements. They’re ideal for outdoor wiring, marine applications, or any environment where durability and weather resistance are critical.

Insulation displacement connectors (IDCs) are another specialty type, allowing a wire to be connected without stripping the insulation. Common in telecommunications and low-voltage systems, IDCs are quick to install and often used in pre-assembled wire harnesses.

At ECS Electrical Cable Supply Ltd, we understand that selecting the right connector depends on wire type, voltage, current, environment, and connection permanence. Our team can help guide you to the best option, ensuring your wiring job is safe, code-compliant, and long-lasting.

In summary, there are many electrical wire connectors types, each tailored to specific tasks and conditions. From everyday installations to complex industrial systems, ECS Electrical Cable Supply Ltd is your reliable source for high-quality connectors and expert support—ensuring every connection is a safe one.

[chetnaengg]

From Ferrules to Fork Lugs: Your Guide to Copper Connectors - Chetna Engineering

In India's rapidly advancing industrial landscape, the demand for reliable and efficient electrical connections is paramount. Copper connectors—such as Copper Ferrules, Copper Inline Connectors, Copper Ring Lugs, Ring Type Lugs, Fork Type Lugs, and Insulated Cable Lugs—play a crucial role in ensuring the safety and performance of electrical systems.

Chetna Engineering, based in Nashik, Maharashtra, stands out as a leading manufacturer and supplier of these essential components, catering to diverse industries across the nation.

Understanding Copper Ferrules:

Copper Ferrules are cylindrical connectors used to terminate stranded wires, preventing fraying and ensuring a secure connection.

Key Features:

Made from high-conductivity copper for optimal electrical performance.

Available in both insulated and non-insulated variants.

Designed to accommodate various wire sizes.

Applications:

Control panels and switchgear assemblies.

Industrial machinery wiring.

Automotive electrical systems.

Chetna Engineering offers a comprehensive range of Copper Ferrules, ensuring durability and compliance with international standards.

The Role of Copper Inline Connectors:

Copper Inline Connectors are essential for joining two conductors end-to-end, maintaining electrical continuity without the need for soldering.

Advantages:

Facilitate quick and secure connections.

Reduce installation time and labor costs.

Ensure consistent electrical conductivity.

Common Uses:

Power distribution networks.

Renewable energy installations.

Telecommunication systems.

With a focus on quality, Chetna Engineering manufactures Copper Inline Connectors that meet the rigorous demands of various industrial applications.

Exploring Copper Ring Lugs and Ring Type Lugs:

Copper Ring Lugs and Ring Type Lugs are designed to connect wires to a stud or screw, providing a secure and vibration-resistant connection.

Benefits:

Offer a permanent and robust connection.

Suitable for high-vibration environments.

Available in various sizes to match different bolt diameters.

Typical Applications:

Electrical panels and distribution boards.

Automotive battery connections.

Heavy machinery wiring.(Chetna Engg)

Chetna Engineering's Copper Ring Lugs and Ring Type Lugs are crafted with precision, ensuring reliability in critical applications.

Advantages of Fork Type Lugs:

Fork Type Lugs, also known as spade lugs, feature an open-ended design that allows for easy installation and removal without completely removing the screw or bolt.

Key Features:

Simplify maintenance and inspections.

Ideal for applications requiring frequent disconnections.

Available in insulated and non-insulated forms.

Applications:

Control wiring in automation systems.

Terminal blocks in electrical panels.

Consumer electronics.

Chetna Engineering provides a diverse selection of Fork Type Lugs, catering to various industry needs with a commitment to quality and performance.

Importance of Insulated Cable Lugs:

Insulated Cable Lugs are designed with a protective covering to prevent accidental contact with live wires, enhancing safety during installation and operation.

Advantages:

Reduce the risk of electrical shocks.

Prevent short circuits caused by accidental contact.

Color-coded insulation for easy identification.

Common Applications:

Residential and commercial electrical installations.

Control panels and switchgear.

Renewable energy systems.

Chetna Engineering's range of Insulated Cable Lugs ensures compliance with safety standards, providing peace of mind in various electrical setups.

Choosing the Right Copper Connector for Your Needs:

Selecting the appropriate copper connector is crucial for the efficiency and safety of electrical systems. Consider the following factors:

Application Requirements: Determine the specific needs of your project, such as current load, environmental conditions, and mechanical stress.

Connector Type:

Copper Ferrules: Ideal for terminating stranded wires.

Copper Inline Connectors: Suitable for joining conductors end-to-end.

Copper Ring Lugs/Ring Type Lugs: Best for secure, permanent connections.

Fork Type Lugs: Perfect for applications requiring frequent disconnections.

Insulated Cable Lugs: Essential for enhanced safety in exposed environments.

Size and Compatibility:

Ensure the connector matches the wire size and terminal specifications.

Quality and Standards:

Opt for connectors that comply with industry standards and are manufactured by reputable companies like Chetna Engineering.

Partnering with Chetna Engineering for Reliable Copper Connectors

With over three decades of experience, Chetna Engineering has established itself as a trusted name in the manufacturing of high-quality copper connectors. Their extensive product range includes Copper Ferrules, Copper Inline Connectors, Copper Ring Lugs, Ring Type Lugs, Fork Type Lugs, and Insulated Cable Lugs, all designed to meet the diverse needs of India's industrial sector.

Why Choose Chetna Engineering?

Commitment to quality and adherence to international standards.

Customized solutions tailored to specific client requirements.

Prompt and reliable customer service.

For more information or to request a product brochure, visit Chetna Engineering's official website

[firstchoiceelectricalllc]

How to Install Electrical Wiring for New Home Construction

Electrical wiring installation is one of the most crucial steps in new home construction. Properly installed wiring ensures that your home’s electrical system is safe, efficient, and up to code. Electrical wiring provides the foundation for all electrical components like lighting, outlets, and appliances, making it essential for the functionality and safety of your home. In this article, we’ll guide you through the process of installing electrical wiring for new home construction, from planning and preparation to completion.

1. Planning and Preparation

Before diving into the installation process, thorough planning is essential. Electrical wiring in a new home needs to be well thought out to ensure it meets both your needs and local building codes.

1.1 Understanding the Electrical Layout

The first step in the planning phase is to determine the overall electrical layout. This includes deciding where outlets, switches, lighting fixtures, and major appliances will be located. Creating a blueprint of your home’s electrical system helps ensure that the wiring is routed efficiently and that the placement of outlets and switches is functional.

1.2 Know Local Building Codes

Every area has specific electrical codes that must be followed during installation. These codes are designed to ensure safety and reliability. Before starting the installation, familiarize yourself with local building codes or consult a professional electrician to ensure compliance. This will help avoid mistakes that could lead to costly rework or even safety hazards.

1.3 Choosing the Right Materials

For wiring, you will need to select the appropriate wire gauge, type of wire insulation, and other components like junction boxes, switches, and outlets. The wire gauge depends on the specific electrical load the circuit will carry. For example, a standard lighting circuit might use 14-gauge wire, while higher-power circuits, such as those for electric stoves, require thicker 10 or 12-gauge wire.

2. Installing Electrical Wiring

Once the planning and preparation stages are complete, it's time to begin the actual wiring installation. This phase involves running wires through the walls, connecting them to outlets and switches, and ensuring everything is safely grounded.

2.1 Turning Off the Power and Ensuring Safety

Before starting any electrical work, ensure that all power sources are turned off to prevent electrical shock. If you’re working in an area that is already partially built, confirm that the power is disconnected at the breaker panel. If you're unsure, it’s safest to hire a licensed electrician to do the wiring installation.

2.2 Running the Wires

Once safety is ensured, begin running the electrical wiring through the walls, floors, and ceilings according to your layout plan. Wires should be routed through stud bays and secured with wire staples to prevent movement. Be careful not to damage the wire insulation, and ensure that the wires are not bent too sharply, as this can damage them and compromise their safety.

2.3 Installing Outlets, Switches, and Junction Boxes

As you route the wiring, you will need to install junction boxes where wires will be connected. These boxes should be mounted flush with the wall surface and be of the appropriate size to accommodate the connections. After installing junction boxes, connect the wires to outlets, switches, and light fixtures, ensuring that the wiring is properly secured and stripped of insulation before connections are made.

Use the correct screws and connectors for each device to ensure a secure connection. When installing outlets and switches, make sure they are properly grounded by connecting the ground wire to the ground terminal. This step is crucial to prevent electrical shock and ensure safe operation.

3. Testing and Inspection

Once the wiring is installed and all outlets, switches, and fixtures are connected, the system must be thoroughly tested and inspected to ensure it is functioning correctly and meets all safety standards.

3.1 Testing for Proper Connections

Test each circuit to verify that it is functioning correctly. Start by checking that all switches and outlets are working as expected. Use a voltage tester to check for proper voltage at each outlet, and ensure that there are no short circuits or improper connections.

3.2 Ensuring Code Compliance

After completing the installation and testing the system, an inspection may be required to ensure that the electrical wiring complies with local building codes. Typically, a licensed electrical inspector will check the installation to verify that it follows code requirements, including proper wire gauge, grounding, and safety protocols.

3.3 Troubleshooting and Making Adjustments

If the inspector finds any issues, they may require modifications or adjustments. For example, you might need to reroute a wire, add extra grounding, or install additional junction boxes. Once any issues are resolved, recheck the system to ensure everything is working as expected.

4. Final Steps

Once the electrical system is installed, tested, and inspected, it’s time for the final steps of the installation process.

4.1 Installing the Electrical Panel

The electrical panel (also known as the breaker box) is the heart of your electrical system. It distributes electricity to various circuits throughout your home. When installing the panel, make sure it is securely mounted in a dry, accessible location and connected to the incoming electrical service. Each breaker in the panel should correspond to a specific circuit in your home, and they should be properly labeled for easy identification.

4.2 Connecting the System to the Power Grid

The final step involves connecting the electrical panel to the local power grid. This task is often performed by a utility company, as it requires coordination with their infrastructure. Once connected, the system can be energized, and power can be distributed throughout the home.

4.3 Final Inspection and Testing

After the system is connected, perform a final round of testing to ensure that everything is working correctly. Check that all breakers are functioning, and confirm that all outlets, switches, and light fixtures are powered and functioning as intended.

Conclusion

Installing electrical wiring for a new home construction is a complex and essential process that requires planning, expertise, and attention to safety. By understanding the layout, following local codes, and using the correct materials, you can ensure that your home's electrical system is both safe and efficient. While it’s possible to do this work yourself if you're experienced, it’s highly recommended to hire a licensed electrician for complex installations to ensure safety and compliance with building codes. Proper electrical wiring will not only power your home but also protect your family from potential electrical hazards.

[king-lobo]

Not normally the kind of thing I do on my blog, but since a very large portion of the States (and some of Canada) are going to be headed straight for another ice age soon, I’m going to impart some knowledge upon you about keeping your vehicle alive and in one piece. Cars are expensive to buy and maintain, so keeping it safe during the coming cold is extremely important. Sources: one, two, three, four 1. 4 wheel drive doesn’t mean 4 wheel stop. Don’t drive like a dumbass. Your ‘Super Duty Hemi V8 Monster 4X4 Rancho King Semi’ Truck is equally at risk of sliding or rolling. Just because you have a big beefy 4WD vehicle doesn’t mean that you’re invincible. Driving like you are is not only putting yourself at risk, but it’s putting everyone else on the road around you at risk.

2. GOOD. WINTER. TIRES. If you can afford the expense, invest in a set of winter tires, and they will be marketed as such (and get them studded if you can!). Winter tires have a different rubber compound and different tread patterns to make them handle a little better on snow and ice. Your all-seasons aren’t gonna cut it in negative degree ice and snow. Also, instead of having your current set of tires on your car removed from the wheels, just find a second set of wheels that fit your vehicle (junkyards or someone parting out their car) and have the new tires mounted on that set. It’s MUCH easier to swap wheels than it is to swap tires. When winter is through, you can swap out the wheels again and store your winter set for next year. (ALSO: Do NOT forget to check your spare tire. The time you forget is going to be the time that you need it most.) 3. Make sure everything is functioning properly. If your windshield is chipped or cracked, get it repaired or replaced. The cold will more than likely make it worse. Have someone help you make sure all of your lights are working properly and if not, replace them. (ALWAYS replace headlights in pairs, regardless of if one still works) Check your regular headlights, high beams, turn signals front and back, brake lights, fog lights if you have them, etc. If it’s been a year or more since you last replaced your windshield wipers, replace them. Have your battery tested - cold temperatures are harder on the cells and cause it to decrease in capacity. If it’s not at peak performance, replace it with a brand new one. 4. Preventative Maintenance. If you’re due for an oil change, go get ALL of the fluids checked and changed if necessary - oil, transmission fluid, antifreeze, brake fluid, power steering fluid (if you have it), etc. Have your brakes checked and replaced if necessary, get your car aligned, have your suspension components checked out, make sure your tires are inflated to the correct psi, keep your gas tank at least half full at all times to prevent your fuel lines from freezing and in case you become stranded. If something is making a weird noise, have your mechanic take a look. Preventative maintenance is something you need to do all year round to keep your car in tip top shape - but it’s especially important in extreme weather. 5. Don’t Let Your Car Idle. It’s fine if you start your car a couple minutes before you leave, but it doesn’t help to let it sit for 10-15 minutes or longer - it can actually cause premature wear to your engine. Letting it idle for at least 1-2 minutes is ideal, but your car will warm up faster when you start out driving at slow speeds. If you can avoid it, don’t accelerate hard right away - let your car get up to operating temp first. 6. PACK AN EMERGENCY KIT. Even if you think you won’t need one, do it anyways. A good emergency kit should consist of the following:

A set of jumper cables (extra long cables if you can find them - or invest in one of these) If you already have cables, inspect them thoroughly before adding them to your kit. Are the wires exposed? The clamps corroded? If they’re damaged in any way, replace them with a new set.

Flares and/or triangle reflectors

At least 1 quart or more of motor oil, at least 1 gallon of coolant, and extra serpentine belts. (these are all vehicle specific, make sure you get the correct type for your vehicle)

First-aid kit (look here for a comprehensive guide to first aid)

Normal blankets AND Mylar blankets (mylar blankets are the best at reducing heat loss in emergencies. you most often see them used with people who may be suffering hypothermia, as they reduce heat loss by up to 90%)

Flashlights with extra batteries, or a hand-crank flashlight

Small toolkit with screwdrivers, pliers, adjustable wrench, and pocket knife

Paper towels

Spray bottle with 2/3 rubbing alcohol and 1/3 water (rubbing alcohol has a freezing temperature of -128.2 °F/ -89°C) Rubbing alcohol can damage your paint, so don’t spray it directly onto your cars finish - only on the glass

Reusable heat packs (yes there are reusable ones out there)

TWO ice scrapers

Pencils and paper

High protein snacks

Bottled water

Extra clothes - socks, hats, coats, pants, shirts, etc.

Sand bags or cat litter (when you get stuck, sprinkle it around all four wheels to help you get better traction)

7. How to Properly Jumpstart a Car. Icemageddon or not, this is something you need to know how to do properly or you could actually cause your battery to explode. NOTE: If your car has an electronic ignition system (push to start) or is an alternatively fueled vehicle, jump starting it is not recommended, as it could damage it.

Red = Positive Black = Negative Dead Car = The car that has a dead battery Live Car = The car you are using to jump the dead car

Locate the batteries on the dead vehicle and the vehicle that is going to be giving you a jump - park them close enough that the cables will be able to reach the battery on both vehicles.

Make sure both vehicles are turned to the OFF position, remove the keys from the ignitions. DO NOT turn them on.

Every set of jumper cables will have four clamps - two for each car. Positive will always be red, negative will always be black. If that is not the case, there should be a symbol somewhere identifying which is which.

From this point on, keep the clamps separated AT ALL TIMES, and keep them up away from the vehicle until you are ready to connect them.

Connect one of the Positive(red) clamps directly to the dead cars POSITIVE (red) terminal. If they’re not color coded, look on the battery for the symbols indicating which terminal is positive and which is negative.

Connect the other positive(red) clamp to the live cars positive(red) terminal.

Connect the Negative(black) clamp to the LIVE cars negative(black) terminal.

Before connecting the second negative clamp, look for a piece of bare (unpainted) metal on the dead car that is away from the battery, and not connected to any important mechanical or electrical components. Some cars will have dedicated locations where you can place the negative clamp - there will either be a sticker under the hood or it will be listed in your owners manual. Do not connect the second negative clamp directly to the battery as it could create sparks. Car batteries contain hydrogen gas which could ignite and cause the battery to explode.

Get in and attempt to start the dead car. If it doesn’t work, check the negative(black) clamp on the dead car and make sure it has a good connection. If it doesn’t start a second time, start the live car and let it run for at least 2 minutes before trying to start the dead car again.

If the dead car starts, disconnect the cables in exactly the opposite way as how you connected them: Remove the negative(black) clamp from the dead car first, then the negative(black) clamp from the live car, then the positive(red) clamp from the live car, and finally remove the positive(red) clamp from the dead car.

Alternatively, if the dead car doesn’t start after two or three attempts, remove the cables and do not try again. Cranking the engine repeatedly can cause damage, such as prematurely wearing out the starter.

[visionfuse]

What's In Your Car Fuse Box?

A fuse box is a place in your car where fuses are housed and protected from the elements. Most cars have two fuse boxes; one is in the engine compartment and holds fuses for cooling fans, anti-lock brake pump and engine control unit, while the other is located in or under the dashboard, on the driver's side to protect electrical items like the radio, power seat and power window.

There are many different types of fuses in your car fuse box. They come in a variety of shapes, sizes, and colors. The most common are rectangular and cylinder. The rectangles have two push-in connectors, while the cylinders have a glass housing with a thin wire protecting them inside.

Most modern fuses are known as blade fuses because they feature a strip of metal that breaks or melts when current passes through it. These fuses can be hard to tell if they have actually blown because the sacrificial wire is sometimes covered by plastic and appears intact when they're not working.

But you can determine if the fuse is blown by using a multimeter in continuity mode to test for voltage across both ends of the fuse. If you get a large resistance, then the fuse is blown or has been disconnected.

If you don't have a multimeter, you can use a simple circuit tester to test for voltage. Simply connect the ground clip to the negative terminal of your battery and the tip of the probe to the positive terminal. If the probe lights up, then you have a good ground connection.

Most car fuses serve as a "test point" for circuits that are constantly on or switched https://fuse-box-diagrams.com/. It can be difficult to determine which circuits are constant and which ones are switched, especially without a dealership-level technical manual that lists the circuit names and their current ratings.

For example, a constant circuit is the power feed to the radio and horn. This circuit usually lives in the left side of the fuse panel. It's fed from the Red power wires in the picture. The wires on the right side feed the same circuit but also provide grounds that are attached to a common ground point (the single stud in the picture).

Then, you need to select the right fuse for your application. For example, if you need a fuse that has no power when the key is in position one and provides power when the key is in position two, then look for a slot marked in that color in your fuse panel.

Choosing the correct fuse for your application is important, as the wrong one can cause serious problems with electrical components on your vehicle. To ensure you're getting the right fuse, check your owner's manual for the proper type and size of fuse, or ask a mechanic for help if you aren't sure what to buy. Generally, car fuses are designed to last a long time before you need to replace them, so if you notice they're blown or in need of replacement, it's best to have them replaced sooner rather than later.

[solderseal]

Solder Seal - Wire Terminal Spade Connectors

Join or terminate a single wire to a screw or stud-type electrical connection with the help of wire terminal spade connectors. We at Solder Seal have insulated and uninsulated crimp quick-disconnect terminals to provide fast and easy disconnection of electrical components and devices.

[elmex309]

Efficient Connectivity Solutions: Elmex Stud Type Terminal Blocks - Explore Disconnecting Terminal Options

Enhance your electrical connections with Elmex stud type terminal blocks. Uncover the reliability of our disconnecting terminal stud type solutions, offering efficient and secure connectivity. Elmex brings you versatile stud type terminal blocks designed to meet diverse industrial needs. Elevate your electrical systems with the precision and quality assurance of Elmex. Discover the superior performance of stud type terminal blocks – your key to seamless connections. Stud type terminal blocks, Disconnecting Terminal Stud Type, Stud Type Terminal block.

Elmex Electric Pvt. Ltd. Add : 12, GIDC Estate, Makarpura, Vadodara -390010, Gujarat, India Ph : 02652642021 / 23 Mo : (+91)8905403005 Fax : 02652638646 mail : marketing@elmex.net Visit us at : https://elmex.net/ (+91)8905403006, (+91)8905902016

Facebook : https://www.facebook.com/ElmexControls/

Twitter : https://twitter.com/elmexcontrols

LinkedIn : https://www.linkedin.com/company/elmex-controls-pvt.-ltd.

Youtube : https://youtu.be/LOooD_SvEMo

[theglitchedworld]

Glitched - Prologue

In the year 2032, the medium of virtual reality took a massive step forward with the introduction of the Spinal Link System or SLS. Though the name of the device was an initial detractor, the actual unit was not as frightening as it implied. An articulated series of plates that were worn along the user's spinal column protected the delicate sensors that used a low tack, reusable, medical adhesive to adhere to the user's skin while a clam-shell set of audio/visual devices cupped the user's head from the back and covered the eyes and ears. The device used the myriad sensors in the spinal plates to pick up the signals being sent from the brain and the series of high-grade onboard CPUs interpreted them into virtual motion.

Originally designed as an interface unit to help paralysis victims be able to walk again with the use of a cybernetic exoskeleton among other healing purposes, it wasn't long at all before non-injured users began to see the potential for other uses as well. The military, especially, pushed for the development of virtual worlds for the purpose of training their soldiers without the expense and hazard of real world live fire training. The medical world soon jumped on the same bandwagon, sending would be surgeons through hundreds of hours of virtual surgeries with all manner of outlandish complications to prepare before ever touching a laser knife to a real world patient.

But it was the gaming community that made this new interface truly blossom once it came into contact with the general public two years after initial development. The ever improving CPUs allowed for more and more detail to be layered into the virtual worlds shared by so many as MMOs. Eventually even scenes such as scent and taste joined the original trinity of sight, sound, and touch. People from around the world were brought together in an instant and able to interact with each other in landscapes that previously only existed in the fevered dreams of artists and writers of the past. Social media fell to the wayside once people realized they could connect virtually in person with people they'd only dreamed of meeting before. No one had time for typing status updates or posting selfies when whole worlds waited to be explored.

However, it took almost eight years in the public sector before the next step into what became known as True Virtual Reality or TVR managed to occur with the development of the TVR Suit. Before the Suit, the SLS could only be used in specially prepared empty rooms or with the user sedated into a dream-like state in order to avoid accidental injury. There was also an alarming number of cases of death relating to more hardcore users forgetting to tend to the needs of their real world body due to being too engrossed in their virtual activity. But the TVR Suit changed that.

The Suit was to all outward appearances a skin tight bodysuit, similar to a wetsuit in the way it hugged the body, with a interface slit for connecting to a user's SLS along the back. However on the inside, countless tiny sensors studded every inch of the material and fed real time data to the SLS the entire time it was worn. It could detect everything from an abnormal heart rhythm to a need to eat or drink or even something as relatively minor as a full bladder and send a signal to the SLS to remove the user from the virtual world. But more than that, the sensors could also detect nerve pulses to trigger a movement in the body - such as the user attempting to raise their arm - while the SLS was logged in and send a counter-acting pulse to cancel the movement before it could occur, eliminating the need for special rooms or sedation drugs to log into virtual worlds. The introduction of the Suit revolutionized the SLS and it quickly became standard to purchase a custom-fitted Suit as a package with a SLS. Logging in without one was soon considered just as dangerous as getting into a race car without a proper helmet and harness. And foregoing the evident advantages of not needing a specialized place to login or the fogginess of sedation made even the most stubbornly resistant to console accessories line up to be fitted for their own Suit. As adoption of the Suit increased, the tragedies of death relating to logging in too long decreased. And the development of Safety Protocols that would derezz a user once they hit the last 1% of their HP - or higher if the user put higher focus on safety - to prevent the rare case of mental conviction that they'd died actually killing the user in real life made even that possibility far rarer than it was at the beginning of TVR.

In 2047, one last major change was released - the introduction of the Dive Tank. Previously a medical use only device, the Dive Tank completely immersed the user in a oxygen rich nutrient solution that could remove waste and feed the user for as long as it remained powered. Suddenly, the need to log out in order to survive was effectively removed and those who wanted to truly disappear into a virtual world now had the ability to do so. Provided they had the real world funds to afford it. Dive Tanks were exorbitantly expensive when they were initially made available with only the wealthy able to afford the cost of a unit and its inevitable upkeep. The price slowly decreased as demand increased, but it still remained out of reach of many but the most determined gamers.

But around the time of the Dive Tank's introduction, a rumor began circulating through the virtual worlds. It spoke of people disappearing while logging in of being routed to some other place where no one could find them. No one sharing the story ever knew the people who were said to disappear. They were always a loner, someone who spent more time taking risks like soloing party dungeons or trying to raid above their level, and most of the time the story was from a different world altogether. And all that seemed to happen was they stopped logging into that world. No one ever really knew them in the game and it was hardly the first time that someone lost interest in a game and moved on without telling anyone.

But the rumors persisted despite the lack of evidence that anything truly nefarious was happening. Eventually whenever someone wasn't logged in, the first thing anyone looking for them would hear was "maybe they glitched" followed by a laugh. No one took it seriously, just a meme carried on for fun and games.

In 2055, that all changed.

"Glitches" began to happen to more well known players and more frequently. It became harder and harder to laugh off the old throw away comment about them glitching as the number of possible glitched players steadily grew higher. The media didn't get involved until someone went looking for a possibly glitched player they knew in the real world and found them in the unresponsive state of a logged in user. Nothing would log the user out and trying to trace the signal of their log to the world it connected to inevitably became lost in a bewildering series of jumps between virtual worlds. It was like something had grabbed their signal and dribbled it throughout the whole of the virtual multiverse like some sort of digital basketball before throwing it at some unknown basket without ever disconnecting their consciousness from it.

The discovery of one glitched player quickly snowballed as more people investigating possible glitches and more and more glitched players began to be found around the world. For some, discovery came far too late even with the use of a Suit - death by malnutrition and lack of care once the Suit and the user's SLS couldn't pull them from the login. Some could only have been the sources of the first rumors, they had been gone so long once they were found. Others were taken into the care of their local government, long term facilities set up with Dive Tanks to hold the players in each country while their mental disappearance was investigated. The numbers steadily grew until they seemed to level off somewhere in the thousands of victims.

Fear began to take hold in the virtual multiverse as players started wondering what made a person glitch. Some stopped logging in altogether, giving up the pleasures of the virtual world in favor of the real world's placid sameness. Others developed a sort of paranoia, constantly scanning and updating their SLS's software for viruses and flaws or only connecting through a wired connection to a personal terminal instead of the SLS's wireless point. But for the majority of users, the fear wasn't enough to keep them from their daily login to their favorite worlds. After all, barely even 5% of users could be called glitched victims. The chances that it would happen to any particular person was vanishingly small and the world's governments were quick to reassure people that all efforts were being made to find out why it was happening and stop it.

Personally, I thought the whole thing was silly. It'd been almost two years since the media reported any major glitch incidents after all. Glitching was nothing more than a freak accident. There was no real dangers to logging in and I'd put so many hours into my character, throwing it all away by not logging in seemed like the bigger loss. There hadn't even been one glitched player from my server, so the possibility of glitching seemed about as remote as getting into a plane crash without ever boarding. And besides, I'd finally managed to afford a real Dive Tank. There was no way I was letting it go to waste.

I stretched in the glass enclosure of my tank, warming up for my first deep login. I know it's silly since my avatar and my physical body don't really connect like that, but I can't help it and besides, it makes me feel more relaxed before I login. Just like how the orange-ish nutrient solution feels warm as it washes into the enclosure, even though I know it's only room temperature. Some things are just the way they seem no matter what reality might say.

I settled my oxygen mask over my mouth and nose and took a deep breath of the filtered air as the solution washed over my face. Taking one last glance around my bare room - selling off the last few bits of furniture I had to bankroll this Tank was a big decision - through the orange-ish soup of the solution, I let my eyes close and reached for the familiar command menu of the SLS nestled against my bare back.  The Bested World's logo hovered tantalizing close before my face as I opened my eyes again, the SLS overriding the signals my real eyes were sending my brain with its command menu. I'd been playing in The Bested World for the last five years with my old Suit. Now I was finally going to have an advantage only the top players could meet with my Tank.

Grinning, I reached up with a virtual hand and tapped the logo to login, waiting for the familiar rainbow swirl of connection.

Only for everything to go completely white.

[ecswire]

Connecting Power with Precision: The Importance of Electrical Wire Terminal Connectors

In the complex world of electrical systems, even the smallest components play a crucial role in ensuring safety, efficiency, and performance. Among these vital components are electrical wire terminal connectors—small but powerful parts that make secure, reliable connections between wires and electrical devices. From household appliances to industrial machinery, these connectors are foundational to modern electronics and electrical infrastructure.

What Are Electrical Wire Terminal Connectors?

Electrical wire terminal connectors are devices used to join electrical wires to each other or to terminals on electrical components. They ensure a firm connection, facilitate current flow, and protect the conductors from environmental factors like moisture, dust, and vibration. These connectors come in many shapes, sizes, and materials, and are designed for a wide range of applications.

The main types include:

Ring Terminals – Designed to connect a wire to a post or stud, often used in automotive and industrial settings.

Spade Terminals – Flat, fork-like connectors that can be easily inserted or removed from screw terminals.

Butt Connectors – Used to connect two wires end-to-end securely.

Bullet Connectors – Male and female connectors that allow for quick disconnection, often used in automotive wiring.

Push-On Terminals – Common in household appliances, these offer fast and easy installation without tools.

Each type serves a specific purpose, and choosing the right one is essential for maintaining electrical integrity.

Why Are They Important?

While wire terminal connectors may appear simple, their impact is anything but. A poor or loose connection can lead to overheating, short circuits, or system failures. In critical applications such as automotive wiring or industrial control panels, a failed connection can cause equipment damage, operational downtime, or even safety hazards.

High-quality electrical terminal connectors:

Enhance safety by minimizing the risk of electrical fires or shocks.

Improve durability of electrical systems by resisting corrosion and wear.

Ensure efficient current flow, reducing energy loss.

Simplify maintenance, as components can be easily disconnected or replaced.

In industries where precision and reliability are paramount, such as aerospace, marine, telecommunications, and home automation, these connectors are indispensable.

The Manufacturing Process

Manufacturing electrical wire terminal connectors requires precision engineering. Most connectors are made from metals like copper, brass, or aluminum, often coated with tin or nickel to prevent oxidation and enhance conductivity. The process typically includes:

Stamping – Shaping the metal into the desired form.

Plating – Applying a protective layer to improve corrosion resistance.

Insulating – Adding a PVC, nylon, or heat-shrink sleeve to prevent electrical shorts.

Testing – Ensuring connectors meet safety, conductivity, and durability standards.

Automation has greatly improved production consistency, allowing manufacturers to meet the growing demand for high-performance connectors in both commercial and consumer applications.

Choosing the Right Connector

Selecting the right wire terminal connector depends on several factors:

Wire gauge (AWG) – The connector must fit the wire size correctly.

Current and voltage rating – It must withstand the electrical load.

Environmental exposure – For outdoor or high-humidity applications, corrosion resistance and waterproofing are essential.

Mechanical stress – In high-vibration settings, connectors with strong crimping and locking mechanisms are preferred.

Electricians, engineers, and DIY enthusiasts alike should consider these factors to ensure optimal performance and longevity.

Trends and Innovations

With the rise of smart technology, electric vehicles, and renewable energy systems, the demand for advanced electrical connectors is growing. Modern innovations include:

Quick-connect terminals for faster installation in modular systems.

Color-coded and pre-insulated connectors to improve safety and ease of use.

High-temperature and waterproof terminals for extreme conditions.

Solderless terminals for applications where heat application is not viable.

These advancements are making electrical systems more adaptable, efficient, and easier to assemble or repair.

Electrical wire terminal connectors are essential components that often go unnoticed but are critical to the success of electrical systems everywhere. From improving connectivity to ensuring safety and system performance, their importance cannot be overstated. As technology evolves, so too does the need for advanced, high-quality connectors that can meet the challenges of tomorrow. Whether you're wiring a light switch or building complex machinery, it all starts with the right connection.

[falconerelectronics]

Wire Harness Manufacturing Terms, Tools, and Tips of the Trade

Steps for Wire Harness Manufacturing Success

Superior Quality

Maintaining Impeccable Customer Scorecards

Fast Turnaround Times

Also, Competitive Prices

Highly Skilled and Seasoned Staff

FREE Estimates (click here)

High Productivity

Agility and Flexibility

Company Culture Dedicated to Customer Satisfaction

Lastly, a Commitment to Safety

Helpful Guide of Wire Harness Manufacturing Terms, Tools and Tips

Are you new to the Wire Harness process? Our team created a helpful guide below.

The Wire Harness Manufacturing Guide includes:

Wire Harness Terms

Tools

Tips of the Trade

Additionally, the list below includes a number of Wire Harness Manufacturing Terms and definitions.

Wire Harness Manufacturing IPC/WHMA-A-620 Standard

All of the Wire Harness Manufacturing Terms below are from the IPC/WHMA-A-620. This serves as an industry standard. Therefore, providing criteria for commonly used wire harness assemblies.  Consequently, the standard sets a “collection of visual Quality Acceptability Requirements for Cable, Wire and Harness Assemblies.”

To learn more about the IPC/WHMA-A-620, click here.

A standard system for designating wire diameter. Primarily used in the U.S.

The raised portion at the front and/or back of the wire barrel crimp that provides a gradual entrance and exit for the wire strands without causing damage.

Wire Strands that have separated from the normal lay of the wire.

Woven bare metallic or tinned copper wire used as shielding for wires and cables and as ground wire for batteries or heavy industrial equipment. Also, a woven fibrous protective outer covering over a conductor or cable.

A group of individually insulated conductors in the twisted or parallel configuration under a common sheath.

A cable with plugs or connectors attached.

An uninsulated wire or the conductor of an insulated wire suitable for carrying electrical current.

A tube in which insulated wires and cables are passed.

A device used to physically and electrically join two or more conductors.

The conducting part of a connector that acts with another such part to complete or break a circuit.

A continuous path for the flow of current in an electrical circuit.

Final configuration of a terminal barrel formed by the compression of terminal barrel and wire.

The measurement of the overall wire barrel height after crimping the terminal.

Total current is the combination of resistive and capacitive currents. Resistive current is present in both AC and DC DWV tests. Additionally, the capacitive current is present only with fluctuations in applied voltage (Ex: AC testing).

Any insulating medium that intervenes between two conductors.

The process of two or more mechanical crimping operations on the same location in a single terminal.

A short tube. Used to make solderless connections to shielded or coaxial cable. Also, a terminal crimped onto the stranded wire to allow insertion into terminal blocks.

A rubber seal used on the cable side of multiple contact connector to seal the connector against moisture, dirt or air.

A group of wire and cables, usually made with breakouts. Furthermore, with a rubber or plastic sheath tie them together. A harness also provides interconnection of an electric circuit.

A material that offers high electrical resistance making it suitable for covering components, terminals, and wires. This material also helps to prevent the possible future contact of adjacent conductors and a resulting short circuit.

Area of a terminal, splice or contact formed around the insulation of the wire.

An outer covering, usually nonmetallic, mainly used for protection against the environment.

A device attached to certain connectors that permit uncoupling and separation of connector halves by a pull on a wire or cable.

A combination of two or more conductors cabled together and insulated from one another and from sheath or armor where used.

A mechanical arrangement of inserts and/or shell configuration that prohibits the mating of mismatched plugs and receptacles.

Connector used for connecting or terminating coaxial cable.

A flat cable of individually insulated conductors lying parallel and held together by means of adhesive film laminate.

A technique or item which reduces the transmission of mechanical stresses to the conductor termination.

A predetermined amount of slack to relieve tension in component or lead wires.

A device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another conductor, etc., to establish an electrical connection. Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged.

A tube of extruded non-supported plastic or metallic material.

Slender rod or filament of drawn metal.

The overall conductor plus insulation thickness.

Types of Wire Terminals

The definition of a terminal is:

A device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection.

Wire Terminals come in many different shapes and sizes. This is due to the size of the wire and screw. Also, there are several types of terminals.

Wire Harness Manufacturing Terminals Include:

Ring

Spade

Hook

Quick-disconnect

Bullet

Butt terminals

Flagged

Wire terminals are available in insulated and non-insulated. The insulation provides a protective cover. Therefore, serving as a non-conductor. Furthermore, the type of project that is being done will determine if you need insulated or non-insulated terminals.

The insulation spares the wire from water and moisture as well. Also, it protects against extreme heat or cold. Wire insulation is typically available in vinyl, nylon and heat shrink.  Non-insulated terminals provide much more economic value with its low cost. Also, they are commonly used when extra protection is unnecessary.

When purchasing various Types of Wire Terminals, make sure that your purchase meets industry standards as well as project requirements.

Wire Terminals

A ring terminal is a round-ended terminal that easily allows a screw or stud to be attached. Ring terminals also called ring connectors, come in various sizes. It is crucial that the ring terminal is compatible with the wire gauge and stud size. Ring Terminals are either crimped or soldered to the wire. Available in insulated or non-insulated.

Spade Terminals are also called spade connectors or fork terminals due to the shape of the terminal. A spade terminal is available in various sizes depending on the gauge of the wire and stud size. Additionally, the open-ended spade terminal is convenient to use allowing easy attachment or removal from the screw. Especially for wire harness projects that are tight on space for installation. They are also available in insulated or non-insulated.

Similar to the Spade Terminal, Hook Terminals are convenient to use with an open end (imagine a tiny version of Captain Hook). These terminals are produced as insulated or non-insulated. Hook Terminals offer a simplistic yet durable connection for a variety of projects.

A quick-disconnect terminal provides convenient and reliable usage while also offering an easy connect and disconnect between two wires. They are commonly found in auto, industrial and consumer products. Products can be insulated or non-insulated. Quick-Disconnect Terminals additionally deliver a stable and durable connection.

Bullet Terminals (also called bullet terminals) make an easy, reliable and secure connection. It is simple to disconnect as well. Bullet terminals also connect with the male and open-ended round female connectors creating a high-quality connection. Therefore, the connection with bullet terminals helps prevent corrosion and other potentially harmful materials from entering a wire harness.

A Butt Terminal connects or terminates single or multiple wires. Butt Terminals help prevent abrasion and cutting. Additionally, this extra protection helps keep out moisture, corrosion, and other negative elements. Butt Terminals serve as a simple solution to extend wires due to the ability to mate and connect wires. Simply install each wire on the open end of the connector, then crimp both ends of the terminal to secure the connection.

Flag Terminals also called flag connectors to offer a convenient and secure connection. Flag terminals work well in tight spaces as well as when a quick-disconnect is too large. Provides a quick and easy connection and disconnect. Also available in insulated and non-insulated.

Wire Insulation

Wires can be found… seems like… everywhere. Any electrical product that demands a current flowing will typically require a wire (or cable). Even when you hear something is “wireless”. In this instance wires power the device sending a signal. Electricity traveling through wires bring each of us tremendous joy and pleasure.

Examples of electronics containing wires:

Computers

Internet routers

Also, music players (MP3 and iPods)

Communication devices (Cell Phones)

Vehicles

Appliances

Actually, can you imagine surviving a single day without electricity? Well, in the early stages, electricity did not travel so safely through wires. Thankfully electricity travels safe and sound through wires protected with wire insulation.

The explosive growth of electrical products well over a century ago drastically increased the use of wires carrying electricity. Unfortunately, uncovered or exposed wires were responsible for dangerous situations.

Furthermore, exposed wires led to electrical shocks or fire. However, the addition of a non-conductive cover was a brilliant move to protect and strengthen wires. The application of Wire Insulation protects wires greatly reducing potential hazards and threats.

You can take a look at wire insulation in the 19th century.

Check out this cool video on porcelain insulators. Thanks to Thomas Edison Tech Center.

https://youtu.be/x8ekfxijhuA

Wire Insulation Evolution

Due to increasing demand, electrical products require a solution to protect wires. The solution is affordable and efficient. Also, with the early growth in popularity, wire harness assembly has become necessary. It is much more efficient in harnessing loose wires. This is opposed to a "free for all". Especially for electrical consumer goods and the auto industry. Both of which have exploded since the early 20th century.

Insulation serves as a non-conductor. The Insulation also separates and protects wires within a wire harness assembly. Especially since it is a nasty world out there with many detrimental elements that can cause harm to non-insulted wires.

To save the day, an insulated jacket protects each wire from the elements keeping the wire cozy and safe. Like insulated terminals, wire insulation also protects from moisture and extreme temperatures.

Thankfully wire insulation today is much more efficient. It is also, effective and affordable.  For example, thermoplastic high heat-resistant nylon coated wire (THHN wire) is low in cost. It is also lightweight. Due to these factors, it is an extremely popular wire insulation option.

Now that you know all about terminals and wires you need to know how they come together to create a wire harness.

Crimping Tools

We have over 30 years of wire harness manufacturing experience. Also, we here at Falconer Electronics have accumulated an impressive arsenal of crimping tools. When crimping wires and cables for our customers we have to utilize the proper tools. These allow our team to execute jobs with accuracy and efficiency. As well as, in a safe manner.

Many projects require crimping wires by hand. When producing wire assemblies for prototypes and small volume runs, handheld crimping tools sure come in…well... handy.

It is extremely important to look over the entire assembly when selecting the proper tool. For example, a basic pliers-style crimp tool can fit various wires, connectors, and terminals. Also, matching the right size tool is imperative when terminating wires.

A great brand is Molex. They are a global leader in the manufacturing of high-quality electrical tools. They are also a leader in components and other equipment. Falconer Electronics hax relied on Molex for many years. We trust their products.

The team at Molex declares they solve challenges “through our collaborative process, we take a multi-dimensional approach that brings together engineers, product designers, and manufacturers to ensure the design cycle is smooth and seamless.”

Below is one of the “Bad Boys” from Molex that our team loves to use when tackling tough projects:

Pneumatic Crimping Tool

Not interested in crimping wires by hand? Or do you have a large amount to crimp? No problem. Pneumatic crimping tools are extremely beneficial and efficient. Additionally, a pneumatic tool allows you to work hands-free due to air power. These tools are also fast and accurate. All qualities that will drastically increase your production.

We recently welcomed a new addition to our team. The Pneumatic Crimping Press pictured below. The “Plug’n Play” Pneumatic Press looks fierce, doesn’t it? It is ready and raring to CRIMP!! Especially ideal for wires requiring interchangeable crimping dies:

Tips for Successful Wire Harness Manufacturing

The crimp does not break the insulation.

Also, the crimp fully wraps around and supports insulation (also cannot expose an opening greater than 45 degrees).

Insulation does not have puncturing to the point where tabs penetrate the wires.

Crimp tabs are in contact with the top of the insulation.

Insulation is flush with the crimped wire.

Additionally, identifying damaged insulation that reveals wires.

The wire, connector, assembly process, as well as insulation, are all compatible.

Wire Harness Manufacturing: Crimping Wires Do’s & Don’ts

The IPC/WHMA-A-620  standard provides the necessary guidance on crimping wires. Consequently, this standard shows what is acceptable along with what is considered defective. Here are a few examples of Do’s and Don’ts:

Do’s

Insulation crimp tabs fully wrap and support insulation

Additionally, the insulation fully enters and extends past the insulation crimp tabs

Wires must be in solid working condition – also cannot have scrapes, nicks, severing or other damages

The connector retains the wires

Center the crimp indent

Insulation crimp must provide a minimum side report of 180 degrees

Don’ts

Wires should not have deformities- Flattening untwisting, buckling, or kinking

Insulation should not show any signs of pinching, pulling, fraying, discoloration, or charring

Also, the insulation crimp needs to fully support and wrap insulation without causing any damage or breaking the insulation

No broken insulation- This can expose wires causing safety issues and potential hazards

Wire not secured by crimp

Contact has visible cracks and fractures

Also, no Birdcaging – Wire Separation

These are just a handful of the requirements.

To learn more about the Wire Harness Manufacturer’s Association and A-620 Standards, please click here.

Wire Harness Manufacturing Quality Control  

Wire Harness Quality Control is paramount at Falconer Electronics. We perform testing on cables and wire harness assemblies for every order. Therefore, quality control strongly impacts the bottom line with the wire harness assembly process. Also, our well-guided wire harness quality control and a solid test system prevents unnecessary errors, stress and lost profits.

High accuracy during the assembly process is the key to maintaining competitive pricing and reliability. We take every step to ensure accuracy at the time of assembling and producing the wires. Instituting a strict wire harness quality control system during production brings significant benefits to our customers.

Wire Harness Manufacturing Testing Check List

Safety First! Wire Harness Testing requires extreme caution. This is due to it involving live wires. Unfortunately, electric shock and burns can turn a great day into a really bad day quickly. It is mandatory to use personal protective equipment on the job such as safety glasses when testing a wire assembly.

When performing Wire Harness Testing, our quality control department strictly follows the IPC/WHMA-A-620 Standard. This standard is a collection of visual Quality Acceptability Requirements for Cable as well as Wire and Harness Assemblies.

Wire Harness Manufacturing Checklist for Testing Wires:

Accurate Labeling

Check for Damaged Insulation or Defective Wires

Continuity

Correct Wire Gauge

Also, Check for Proper Crimps

Free of Moisture and Corrosion

Optimum Wire Placement Within Connectors

Pull Test

Test for Broken Wires

Finally, Test for Shorts

Deming Values for Continual Improvement

Going old school, we are big fans of 20th-century management guru Dr. Deming. Dr. W. Edwards Deming created 14 points for management with a quest for continual improvement. We give credit to Dr. Deming for being the master of quality improvement. Particularly with his work in Japan during the 1950’s.

The Deming Institute continues the incredible legacy of Dr. Deming.

Furthermore, one of the core values at the Deming Institute states:

We are dedicated to the Deming philosophy and the belief that working together, with humility, we can make a difference in the quality of life for everyone.

This is a truly inspiring message!

According to Dr. Deming, implementing the 14 points is a philosophical way of conducting business with an unwavering quest for continual improvement. In addition, new tactics and behaviors become habits. Furthermore, those habits eventually form into the core beliefs and culture of a company.

Two particular interesting points from Dr. Deming's 14 points that help drive our wire harness quality control:

1. Create constancy of purpose toward improvement of product and service, with the aim to become competitive and to stay in business, and as a result to provide jobs.

5. Improve constantly and forever the system of production and service, to improve quality and productivity, and thus constantly decrease costs.

Consequences when continual improvement and quality are NOT the top priority:

High defect rates

Underutilized equipment

Poor productivity

Poor inventory management

Safety concerns

Finally, low morale with employees

Wrapping it Up

Thank you for reading our post on Wire Harness Manufacturing Terms, Tools, and Tips of the Trade.

Also, for more information on Wire Harness Manufacturing, click here:

For additional information click on the links below:

Build Your Business Tips: Selecting a Wire Harness Manufacturer

Ground Straps: What Are They And What Are They Used For?

Wire Harness Estimator

Ground Strap Express

[itsworn]

Be The Light You Want To See On Your C5 Corvette

Most Corvettes can benefit from a headlight upgrade. After all, the better your headlights the better you can see at night and the safer you are. For many people, a headlight upgrade means HID or some other conversion that may (or may not) be legal and which often delivers a retina-searing blast of white light toward oncoming drivers, making it difficult for them to see the road. While it may be useful to have a set of driving lights set up like that, for day-in, day-out driving, the better answer is probably somewhere between that and the factory bulbs.

In the case of the C5, it’s not just the inevitable aging and fading of the 20-year-old lamps that hurts them, it’s also because Chevy could have done better at the time. Factory lamps for domestic-market Corvettes were originally designed for the 1992 Cadillac Seville, a fine car I’m sure, but not one expected to be driven enthusiastically through the mountains. The good news is that export C5s came with better lights that combine H4 halogen bulbs with Bosch metal reflectors and glass Guide lenses that provide beams that are wider, brighter and better focused.

However, it’s not just as simple as finding export lamps. The reflector housings are made for both right- or left-hand driving, and using left-hand headlights here in the U.S. is unsafe. To get the correct, right-hand export components, we reached out to Daniel Stern Lighting Consultancy for a pair of the correct housings as well as the bulbs and a relay kit containing the components needed to assemble the wiring harness to power them. While Stern offers professionally built harnesses, we’re wiring nerds and prefer to do it ourselves.

Instructions came with the parts we ordered, but for those who haven’t done much electrical, there are a few things to be aware of and the first is the use of relays. A relay is basically a switch that you turn on, which then allows power to pass through it to go somewhere else. Typically, the power for a pair of headlights goes through the headlight switch that, when turned on, allows the power to go to the headlights. It’s a long path for the electricity to follow and every bit of power that gets to the lights has to go under the dash and through the headlight switch, places where you really don’t want a lot of amperage. This is especially a problem on older cars.

A typical relay setup, however, draws power directly from a source such as the battery or alternator and sends it to the bulbs, with the original output wires from the headlight switch only serving to “turn on” the relay and allow the power to pass through it. The power through the relay usually comes through a shorter, heavier gauge wire, which also helps deliver more power directly to the bulb. For example, the factory wiring to each bulb on a C5 appears to be 16-gauge. We fed the relays with a much larger 10-gauge wire and then each individual bulb with 12-gauge. We used two relays (one for high beam and one for low) and located them on the passenger-side of the car close to the battery box, from which we drew power.

The factory headlights have two plugs on each light: one that goes to the high beam bulb and one to the low, for a total of four plugs. Each plug has two wires, a power wire (green for the high beam bulb, brown for low) and a ground (black on both). The new H4 bulbs, however, use a single bulb per side with a three-wire plug that has a power wire each for high and low beam (green and brown) and a black ground wire. To wire the new plug, the power wires will come directly from each of the two relays and the black ground wire will need to be grounded from the plug to the frame.

Since the relays are located on the passenger-side, that means snaking the long harness of three wires and the plug across the nose of the car to the driver-side. We used zip ties to attach the harness to the bolts protruding downward from the bodywork just forward of where the hood sits when its closed, where it’s out of the way and unobtrusive. You’ll need to measure this distance before wiring the relays so you’re sure to have enough wire length, and don’t forget to include an extra loop of wire on both sides to allow the headlights to go up and down.

Disconnect the battery prior to starting work, and once the lights are installed and working, don’t forget to follow Stern’s instructions and have them corrected aimed to get the most out of them. Vette

1. Headlight disassembly should be familiar for anyone who’s ever changed their bulbs. Start by raising the headlights, which you can do by turning the grooved knob on the headlight motor assembly and then removing the screws that hold the plastic bezel surrounding the lights.

2. With the plastic bezel out of the way, you have access to the Torx screws holding the body-colored headlamp door in place.

3. The headlight assembly has three molded-in alignment studs that fit into holes in its metal bracket and is screwed in place with three self-tapping screws: two on the outboard side, one on inboard. The two outboard ones on the passenger’s side are visible in this photo, shown from the front. The screw heads are hard to get to, so we strongly suggest a ratcheting wrench. Our screws had pieces of the headlight’s plastic housing still stuck in the threads after removal, so make sure the threads are cleaned out prior to reassembly.

4. The upgraded headlight assembly uses an H4 halogen bulb with an entirely different plug than the stock C5 headlight so there’s going to be some wiring involved in getting this to plug in.

5. Although the headlamp housing in our kit came with bulbs already installed, we ordered the upgraded Osram bulbs to go with it. The standard-wattage Osrams offer better seeing distance and beam focus, and run a bit over $40/pair.

6. There are two different types of H4 plugs available from Stern: a phenolic plug with a pigtail that needs to be spliced on and a heat-resistant ceramic plug, which is the one we selected. It’s a bit of a bear to install, as standard crimpers can distort the terminals and the ceramic can be easy to break but we took our time and also soldered the connection. We ordered a spare set to replace the one we bent beyond repair.

7. The Flosser use the standard Bosch designations (30 for power input, 85 for trigger ground, 86 for trigger input, and 87 for power output) and have two output terminals—one for each side of the car. You’ll want to keep an eye on the plug as you wire it to make sure you’re plugging things into the correct terminal, and remember there’s a separate relay for high beam and for low.

8. The plugs are grooved so they can be mounted together as one unit, and the relays come with a thin, bent metal bracket that can be slid into a matching recess on the back of the relay. While we considered mounting the two relays together as a unit, that would have required fabricating a bracket, so we took the easy way out and mounted the relays separately by the metal tabs.

9. Each relay will be fed with a heavy-gauge wire (we used 10) from the battery, and each will need to be fused at 20 amps. The kit came with these weathertight fuse holders. To install them, we clipped the red-insulated wire and spliced one end to the main power wire and crimped a ring terminal on the other.

10. We replaced the terminals that came in the kit with these strain-relief ring terminals, which have a second set of prongs that are crimped onto the insulation for a more secure, longer-lasting connection. After crimping on the terminal, we sealed it up with 3M adhesive-lined shrink tube. The terminals came from Mouser, the tubing from Waytek.

11. The most easily reversible way to wire the lights is to use the included adapters that plug directly into the factory bulb connectors and wire them to trigger the relay. You never cut the harness, and it can just as easily be unplugged and removed if you want to return to the factory lights.

12. The cleaner way, however, is to remove the sub-harness that goes to the bulbs and build a new one that will go from the main lighting harness to the relay. This is where the sub-harness plugs in, right next to the headlight actuator. Note the three visible wires: black, green and brown. These are the ones that matter to us.

13. The three terminals of the sub-harness plug into a five-way Metripack 280 connector: the other ways contain the wiring for the actuator that raises the headlight. We removed the black secondary lock from the connector and used our Metripack pin removal tool to gently remove the three headlight wires, being careful to note which of the pins went into which way.

14. We then created a new sub-harness with 16-gauge wire in the correct colors, using the correct grey wire seal and Metripack 280 terminals so we can plug it right back into the connector. (For those unfamiliar with assembling Metripack connectors, we covered that in the Scarlett project in some depth) The green wire serves as a trigger wire for the high beam relay, brown for the low, and the black wire, which we spliced into two separate wires, serves as a common ground for each of the relays. All wires were then routed through heat-resistant fiberglass conduit similar to what the factory used.

15. This steel bracket is conveniently located directly beneath the passenger-side headlight assembly. We mounted the high beam relay to it by simply removing the existing nut, opening up the hole on our relay mounting tab, then slipping it on the threaded stud and reinstalling the nut. The low beam was about as easy: we added a second nut so the body of the relay would clear the molded lip at the bottom of the bracket.

16. To make the installation as unobtrusive as possible, we routed the power and ground wires through the same type of heat-resistant conduit (we had two sizes on hand) and ran it beneath the surge tank located on the passenger side. The tank is easily removed and should not have to be drained if you’re careful enough not to knock any of the fittings loose. The two main mounting studs are visible in the lower part of the photo, and the two plastic prongs on the lower left of the tank are clamped in place by a third nut visible directly beneath the prongs.

17. The bulb ground wires were connected to this ground stud located beneath the battery box, which should be loosened to give you access to the stud. Note the conduit containing the main power wires for the headlights: it enters the battery box at the same place.

18. The main power wires were routed behind the underhood fuse block located in the battery box and mounted to the stud where power comes into the fuse block. In a perfect world, we’d have powered the lights using one of the two existing, unused Maxi-fuse ways in the fuse block, but that was a bit deeper into the car’s wiring than we wanted to dig.

19. After installing the passenger-side headlight, but prior to replacing the driver-side. The new light produces a much cleaner, brighter light than the dirty yellow illumination from the factory lights, but without blinding those in oncoming lanes.

Sources

Daniel Stern Lighting Consultancy

www.danielsternlighting.com

Mouser Electronics

(800) 346-6873

www.mouser.com

Waytek, Inc.

(800) 328-2724

www.waytekwire.com

The post Be The Light You Want To See On Your C5 Corvette appeared first on Hot Rod Network.

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[forwardassistmechanics-blog]

As a cover all cars mechanic sometimes you get to work on some of the more modern vehicles that are new enough to be great running vehicles but any type of warranty has long expired. The Highlander 3.5 Alternator looks daunting but in reality is just an exercise in time, Its pretty easy to change technically and only requires some basic handtools, Any slightly mechanical person can generally replace one in about 3 hours with a bit of patience.

Tools = drip pan, work light, 10mm 3/8 drive socket, 3/8 ratchet, deepwell 14mm socket, shallow 14mm socket, prybar, 12mm deepwell socket, 10mm wrench for battery terminal, variety of pliers for hose clamps, extra 10mm socket for the one you will drop and a tool to remove the belt (1/2 inch or 13mm long wrench will work…..maybe

)

Step one- make sure its actually broken- most battery tester units and or a multi meter can take care of this, there is information all over the internet so I don’t need to tell you how to get this done, Any parts store generally has the ability to test one for you in or out of the car.

1. Disconnect  negative battery terminal

2. Remove the serpentine belt, I used a 13mm wrench to manipulate the tentioner pully, you rotate it counter clockwise to loosen and remove the belt. turning the tentioner bolt clockwise will loosen the bolt and get you nowhere.

3. remove the plastic on top the engine and the plastic on top of the radiator.

4. take off the radiator hoses (if needed) and make sure to have a drain pan ready to catch the little bit that will come out. the top hose will need removed from the radiator so you can remove the fan assembly.

5. remove the air intake from the top of the radiator that connects to the air intake filter box

5. remove the 3 or 4 10mm bolts from the fan assembly and pull the fan assembly up and rotate it towards the drivers side to get it out of the way, If you don’t remove it there will be no room to take out the uninstalled alternator.

6. remove the alternator positive wire (10mm)

7. Remove the electrical connector from the alternator (squeeze it)

8. Take the 2 or 3 10mm bolts off the exhaust heat-shield and move it to the right (don’t break the o2 sensor wires)

9. Take out the mounting bolts for the Alternator (14mm)

10. Remove the 12 mm nut on the stud on the backside of the Alternator, There is a bracket that connects to the Alternator on the backside (that’s why you move the heat shield)

11. pry out the Alternator a little until you can get a 12 mm socket to that 90 degree bracket on the backside of the alternator and remove that bracket, It has a wire attached to it.

12. rejoice that you have won and pull the alternator out, replace it with a quality new or manufactured unit.

13. reverse process using expletives

Click Here for a link to a video I made to explain things and show whats going on

    Trials and tribulations, How to replace a 2009 Toyota Highlander 3.5 Liter Alternator. (Video) As a cover all cars mechanic sometimes you get to work on some of the more modern vehicles that are new enough to be great running vehicles but any type of warranty has long expired.

[glenmenlow]

10 Obstacles To New Product Success

Many obstacles can slow the spread of new products and services, we’ve identified ten of the most common and categorized them as obstacles to adoption and obstacles to use. Will they or do they impact you?

Obstacles to adoption are barriers that prevent customers from buying your products in the first place. Even customers who might benefit from your product—or otherwise be inclined to buy it—may choose a competitor’s product or non-consumption in the face of these obstacles. Therefore, it is important to find ways to reduce or eliminate them. The following obstacles are some of the most frequent barriers to product purchases:

1. Lack Of Knowledge. One of the most fundamental reasons that customers don’t buy your product is that they don’t know they need it. It’s not that the innovator is making up a job to be done that didn’t actually exist—a tough road to take, for sure—but rather that customers had just gotten used to the old way of doing things. Look at medical records at a physician’s office, which are typically a mess of free-form text, checked boxes, and scans of faxes from diagnostic labs and other doctors. It’s very tough to find useful information quickly, and sometimes critical data gets overlooked. Yet vendors of “golden record” solutions that create a single integrated file have found the market slow to materialize because physicians don’t realize the cost—in terms of both money and sub-optimal medical outcomes—of the current make-do approach. Only by quantifying the situation and evangelizing about the dangers of the typical practice have they made people realize that these jobs can get done in a far better way.

2. Behavior Change Requirement. To no one’s surprise getting people to change their behavior can be quite difficult. Ozon, often referred to as the Amazon of Russia, is the largest e-commerce company in Russia. It started with book sales, moved into movies and music, ventured into consumer electronics, then ultimately became a full-range retailer of virtually every consumer good imaginable. Despite its relative size in Russia, growth has been challenging in Russia’s cash-based economy. In particular, Ozon has had trouble selling its proprietary e-reader (the Ozon Galaxy), e-books, and digital music. With digital content requiring a credit card for purchase and Russian consumers being generally unwilling or unable to move away from cash, these categories have seen lackluster sales.

3. Multiple Decision Makers. Even great ideas can be hindered by the need to bring many disconnected decision makers on board, some of whom may have misaligned incentives. Systems that enable teams of doctors to consult online about shared cases seem to make a ton of sense, but they have grown quite slowly. IT, hospital departments, and individual physicians all need to come on board, or else the system will be stymied. Some of these entities may embrace change, whereas others see mainly risk. Even if the benefits of the solution are clear to all, simply getting people to agree on a proposition and action plan can take far longer than implementing the actual system.

4. High Costs. Costs can be high in a number of ways. The actual cost of a new product can be prohibitively expensive. At around $40,000 (or roughly 80 percent of the median U.S. household income), a Nesmuk diamond-studded knife is simply too expensive for most consumers. A product can also be too costly compared to rival goods. Harrods, the UK department store, launched its £29.95 Pot Noodle in 2008. Although the launch was part of a stunt to celebrate design innovation (while also sending proceeds to charity), one can’t help but wonder whether that price is a bit high for a cup of instant noodles. Finally, the cost of switching to a new solution can be unpalatable. Along this third vein, cell phone carriers decided years ago that they would make it hard to switch carriers by imposing an early termination fee. More recently, as carriers have battled for market share, they have begun buying out termination fees from other carriers and eliminating the idea of a standard two-year contract altogether, thus helping to reduce the costs of switching carriers.

5. High Risk. Customers will be reluctant to adopt a new solution if it involves a lot of risk or a high potential cost of failure. Even with the recent rise in lawsuits by patent trolls, the uptake of patent litigation insurance has been slow. In part, attorneys believe that this is because buying such insurance might actually invite patent suits with liabilities that quickly exceed coverage limits. Even though the insurance could prevent crippling lawsuit damages, the risk of attracting patent troll attention has been too great to allow for fast adoption.

6. Unfamiliar Category. Sometimes, products are so innovative that they define a new category that the customer doesn’t really understand or have a budget for. Consider the Internet of Things (IoT)—a network of potentially millions of connected devices and sensors in a workplace that can keep tabs on just about everything happening in a facility. For all of the hype surrounding the idea, uptake by major corporations has been slow. There typically isn’t anyone with IoT in the job title or with an IoT line item in the annual budget. IoT vendor en-Gauge has addressed this challenge in a clever way, focusing tightly on monitoring the readiness of fire extinguishers. Fire safety usually is someone’s responsibility, and few people dissent from spending modestly to improve a company’s readiness in this area. Once en-Gauge introduces its IoT solution through this route, it plans to be in prime position to sell much more expansive offerings later.

Obstacles To Use

A second set of obstacles to consider are obstacles to use. These are the reasons that customers stop using your product or service after initial adoption. Obstacles to use can take a few different shapes. You may see an early wave of enthusiasm with a rapid falloff of purchases. Or, more straightforwardly, people simply stop repurchasing your product, buying add-on features, or upgrading to later editions. Obstacles to use present a major hurdle to creating a sustainable business model. The following categories represent some of the most common reasons a customer will not use a product:

7. Limited Supporting Infrastructure. Sometimes a product can be great on its own, but lacks value without a system to support it. Imagine downloading a peer-to-peer app but having no peers! Similarly, electric vehicles offer a number of benefits for both drivers and the environment. Yet even ecofriendly consumers who are willing to buy electric cars are often dissuaded by the lack of available charging stations. Those who drive long distances arguably have the most to save (assuming the price of gas stays high relative to the price of electricity in your area), but they are the ones for whom the solution is least viable. Without the infrastructure that allows you to get the full potential out of your purchase, use becomes prohibitively difficult.

8. Use Creates Pain Points. Customers will not continue to use a product that is overly complex or difficult to use. Yet companies often insist on overloading their new products with features rather than focusing on satisfying important jobs well. According to an NPD Group survey of over 1,500 consumers, 13 percent of consumers had returned an electronic device due to frustration when trying to get it to work. Windows Vista, launched by Microsoft in 2007, was surrounded by high expectations from both consumers and the company. As incessant compatibility and performance problems plagued the product, even some of Microsoft’s most loyal customers defected for Apple.

9. It’s Cool, Not Better. Many times, a new product sounds really exciting, but it ultimately doesn’t do a better job than the existing solution. Generally, customers rush to try these products but stop using these solutions when they realize that they don’t excel along the dimensions that they find most important. The technology that allows you to purchase items using a cell phone has been around for a relatively long time. Although a number of people tried it once or twice, they ultimately found that it didn’t perform any better than a standard swipe of the credit card. In fact, it often took longer. As Google and Apple reignite the race to get mobile payments off the ground, this second wave is focusing on jobs that are now top of mind for customers, such as data security.

10. Offering Isn’t Targeted. Similarly, new offerings need to be targeted to specific jobs and customer types. The Segway was another fun device that was launched without much purpose or direction. Once the company stopped trying to sell the Segway to the general public—who couldn’t afford it and didn’t know what to do with it—it found success among customer types with undersatisfied jobs, including police forces, urban tour guides, and warehouses.

Getting customers to even consider your product in the first place can often be quite the challenge, but finding ways to overcome obstacles to long-term use can be just as important a task. Without opportunities to resell to past purchasers, you may find that your business model is simply unsustainable.

More of this approach is featured in my new book JOBS TO BE DONE: A Roadmap for Customer-Centered Innovation.

The Blake Project Can Help: The New Product Co-Creation Workshop

Branding Strategy Insider is a service of The Blake Project: A strategic brand consultancy specializing in Brand Research, Brand Strategy, Brand Licensing and Brand Education

FREE Publications And Resources For Marketers

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[markjsousa]

10 Obstacles To New Product Success

Many obstacles can slow the spread of new products and services, we’ve identified ten of the most common and categorized them as obstacles to adoption and obstacles to use. Will they or do they impact you?

Obstacles to adoption are barriers that prevent customers from buying your products in the first place. Even customers who might benefit from your product—or otherwise be inclined to buy it—may choose a competitor’s product or non-consumption in the face of these obstacles. Therefore, it is important to find ways to reduce or eliminate them. The following obstacles are some of the most frequent barriers to product purchases:

1. Lack Of Knowledge. One of the most fundamental reasons that customers don’t buy your product is that they don’t know they need it. It’s not that the innovator is making up a job to be done that didn’t actually exist—a tough road to take, for sure—but rather that customers had just gotten used to the old way of doing things. Look at medical records at a physician’s office, which are typically a mess of free-form text, checked boxes, and scans of faxes from diagnostic labs and other doctors. It’s very tough to find useful information quickly, and sometimes critical data gets overlooked. Yet vendors of “golden record” solutions that create a single integrated file have found the market slow to materialize because physicians don’t realize the cost—in terms of both money and sub-optimal medical outcomes—of the current make-do approach. Only by quantifying the situation and evangelizing about the dangers of the typical practice have they made people realize that these jobs can get done in a far better way.

2. Behavior Change Requirement. To no one’s surprise getting people to change their behavior can be quite difficult. Ozon, often referred to as the Amazon of Russia, is the largest e-commerce company in Russia. It started with book sales, moved into movies and music, ventured into consumer electronics, then ultimately became a full-range retailer of virtually every consumer good imaginable. Despite its relative size in Russia, growth has been challenging in Russia’s cash-based economy. In particular, Ozon has had trouble selling its proprietary e-reader (the Ozon Galaxy), e-books, and digital music. With digital content requiring a credit card for purchase and Russian consumers being generally unwilling or unable to move away from cash, these categories have seen lackluster sales.

3. Multiple Decision Makers. Even great ideas can be hindered by the need to bring many disconnected decision makers on board, some of whom may have misaligned incentives. Systems that enable teams of doctors to consult online about shared cases seem to make a ton of sense, but they have grown quite slowly. IT, hospital departments, and individual physicians all need to come on board, or else the system will be stymied. Some of these entities may embrace change, whereas others see mainly risk. Even if the benefits of the solution are clear to all, simply getting people to agree on a proposition and action plan can take far longer than implementing the actual system.

4. High Costs. Costs can be high in a number of ways. The actual cost of a new product can be prohibitively expensive. At around $40,000 (or roughly 80 percent of the median U.S. household income), a Nesmuk diamond-studded knife is simply too expensive for most consumers. A product can also be too costly compared to rival goods. Harrods, the UK department store, launched its £29.95 Pot Noodle in 2008. Although the launch was part of a stunt to celebrate design innovation (while also sending proceeds to charity), one can’t help but wonder whether that price is a bit high for a cup of instant noodles. Finally, the cost of switching to a new solution can be unpalatable. Along this third vein, cell phone carriers decided years ago that they would make it hard to switch carriers by imposing an early termination fee. More recently, as carriers have battled for market share, they have begun buying out termination fees from other carriers and eliminating the idea of a standard two-year contract altogether, thus helping to reduce the costs of switching carriers.

5. High Risk. Customers will be reluctant to adopt a new solution if it involves a lot of risk or a high potential cost of failure. Even with the recent rise in lawsuits by patent trolls, the uptake of patent litigation insurance has been slow. In part, attorneys believe that this is because buying such insurance might actually invite patent suits with liabilities that quickly exceed coverage limits. Even though the insurance could prevent crippling lawsuit damages, the risk of attracting patent troll attention has been too great to allow for fast adoption.

6. Unfamiliar Category. Sometimes, products are so innovative that they define a new category that the customer doesn’t really understand or have a budget for. Consider the Internet of Things (IoT)—a network of potentially millions of connected devices and sensors in a workplace that can keep tabs on just about everything happening in a facility. For all of the hype surrounding the idea, uptake by major corporations has been slow. There typically isn’t anyone with IoT in the job title or with an IoT line item in the annual budget. IoT vendor en-Gauge has addressed this challenge in a clever way, focusing tightly on monitoring the readiness of fire extinguishers. Fire safety usually is someone’s responsibility, and few people dissent from spending modestly to improve a company’s readiness in this area. Once en-Gauge introduces its IoT solution through this route, it plans to be in prime position to sell much more expansive offerings later.

Obstacles To Use

A second set of obstacles to consider are obstacles to use. These are the reasons that customers stop using your product or service after initial adoption. Obstacles to use can take a few different shapes. You may see an early wave of enthusiasm with a rapid falloff of purchases. Or, more straightforwardly, people simply stop repurchasing your product, buying add-on features, or upgrading to later editions. Obstacles to use present a major hurdle to creating a sustainable business model. The following categories represent some of the most common reasons a customer will not use a product:

7. Limited Supporting Infrastructure. Sometimes a product can be great on its own, but lacks value without a system to support it. Imagine downloading a peer-to-peer app but having no peers! Similarly, electric vehicles offer a number of benefits for both drivers and the environment. Yet even ecofriendly consumers who are willing to buy electric cars are often dissuaded by the lack of available charging stations. Those who drive long distances arguably have the most to save (assuming the price of gas stays high relative to the price of electricity in your area), but they are the ones for whom the solution is least viable. Without the infrastructure that allows you to get the full potential out of your purchase, use becomes prohibitively difficult.

8. Use Creates Pain Points. Customers will not continue to use a product that is overly complex or difficult to use. Yet companies often insist on overloading their new products with features rather than focusing on satisfying important jobs well. According to an NPD Group survey of over 1,500 consumers, 13 percent of consumers had returned an electronic device due to frustration when trying to get it to work. Windows Vista, launched by Microsoft in 2007, was surrounded by high expectations from both consumers and the company. As incessant compatibility and performance problems plagued the product, even some of Microsoft’s most loyal customers defected for Apple.

9. It’s Cool, Not Better. Many times, a new product sounds really exciting, but it ultimately doesn’t do a better job than the existing solution. Generally, customers rush to try these products but stop using these solutions when they realize that they don’t excel along the dimensions that they find most important. The technology that allows you to purchase items using a cell phone has been around for a relatively long time. Although a number of people tried it once or twice, they ultimately found that it didn’t perform any better than a standard swipe of the credit card. In fact, it often took longer. As Google and Apple reignite the race to get mobile payments off the ground, this second wave is focusing on jobs that are now top of mind for customers, such as data security.

10. Offering Isn’t Targeted. Similarly, new offerings need to be targeted to specific jobs and customer types. The Segway was another fun device that was launched without much purpose or direction. Once the company stopped trying to sell the Segway to the general public—who couldn’t afford it and didn’t know what to do with it—it found success among customer types with undersatisfied jobs, including police forces, urban tour guides, and warehouses.

Getting customers to even consider your product in the first place can often be quite the challenge, but finding ways to overcome obstacles to long-term use can be just as important a task. Without opportunities to resell to past purchasers, you may find that your business model is simply unsustainable.

More of this approach is featured in my new book JOBS TO BE DONE: A Roadmap for Customer-Centered Innovation.

The Blake Project Can Help: The New Product Co-Creation Workshop

Branding Strategy Insider is a service of The Blake Project: A strategic brand consultancy specializing in Brand Research, Brand Strategy, Brand Licensing and Brand Education

FREE Publications And Resources For Marketers