# Design Electrical Power Connectors | Hello!

• closepet
In summary, the conversation involves a person in the design and manufacturing of electrical power connectors seeking guidance on how to design a connector based on required current rating. They mention that all their connectors are made of Aluminium alloy and ask if there is a formula to determine parameters such as length and thickness. They specify that the connectors are used in transmission lines and substations. The other person asks if they have test results for their current units or if they are trying to do theoretical calculations. The response is that they have test results but need guidance for designing newer sizes, and suggest calculating resistance to determine ohmic heating as a first level approximation.
closepet
Hello!

I am in design and manufacturing of electrical power connectors. I need to know if there is any precise formula to design a connector, i.e. given the required current rating, is there a particular formula that gives the parameters of the connector, like length and thickness??

All our connectors are made of Aluminium alloy. So resistivity, material density and Specific heat remain constant.

Looking forward for a help...

What kind of connectors are you talking about?

hi!

these are power connectors, like tee-connectors, parallel grove connectors used in transmission lines and substations...

closepet said:
hi!

these are power connectors, like tee-connectors, parallel grove connectors used in transmission lines and substations...

Do you have test results for your units? Or are you trying to do theoretical calculations to back up what you have?

yeh we do have test results. But for newer sizes, we require some kind of a guiding factor for the design...

Can you not just calculate the simple resistance and then determine ohmic heating?

EDIT: At least, as a first level approximation?

## What is the purpose of designing electrical power connectors?

The purpose of designing electrical power connectors is to provide a secure and efficient way to connect power sources to electronic devices. This allows for the safe transfer of electricity to power and operate various devices.

## What are the different types of electrical power connectors?

There are several types of electrical power connectors, including AC power connectors, DC power connectors, audio and video connectors, and data connectors. Each type has its own unique features and specifications depending on the specific application and power requirements.

## What factors should be considered when designing electrical power connectors?

When designing electrical power connectors, factors such as voltage and current ratings, temperature and environmental conditions, mechanical strength and durability, and compatibility with different types of devices should be taken into consideration. Safety and ease of use are also important factors to consider.

## How are electrical power connectors tested for safety and reliability?

Electrical power connectors undergo various safety and reliability tests before being approved for use. These tests include checking for proper insulation, voltage and current ratings, temperature resistance, and durability. They are also tested for compatibility with different devices and to ensure they can handle the expected amount of power without overheating or short-circuiting.

## What are some common uses for electrical power connectors?

Electrical power connectors are used in a wide range of applications, including household appliances, industrial equipment, computers and electronic devices, and automotive vehicles. They are also commonly used in power distribution systems for buildings and infrastructure.

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