Branched end layout分支端头布局
Conductors separate toward different ends, creating individual connection points. Branch lengths and directions can follow the equipment modules.导线向不同端头分出，形成独立接入位置。各支路可围绕设备模块分别安排长度与方向。
Overmolded Cable Assembly包覆成型电缆组件
4-Branch Compact Circular Connector Harness四支路小型圆形接头线束
4-Branch Compact Circular Connector Harness combines branched end layout, circular connection end, plug-in connection end. Interface, circuit and installation data guide dimensions, material selection and sample review.四支路小型圆形接头线束的结构重点包括分支端头布局、圆形连接端、插接式端头。接口、电路与安装资料将作为尺寸、物料和样品制作的确认依据。
- Branched end layout分支端头布局
- Circular connection end圆形连接端
- Plug-in connection end插接式端头
CONSTRUCTION结构解析
Connection structure and design details连接结构与设计要点
Use the 4-branch compact circular connector harness form as a starting point and confirm these design points against drawings and the actual equipment.以四支路小型圆形接头线束的结构形式为起点，结合图纸和实际设备确认以下设计要点。
Circular connection end圆形连接端
The end uses a circular interface form, with connection positions planned around mating direction, retention and cable exit.端头具有圆形接口形式，可围绕对插方向、端部固定和线缆出口规划连接位置。
Plug-in connection end插接式端头
The end uses a plug-in form, with clearance arranged for insertion, removal and cable bends.端头采用插接形式，可围绕安装位置安排插入、退出及线缆弯曲空间。
CONFIGURATION结构与选配
Construction & customization options结构与定制配置
The table describes the construction and available configuration choices. Materials, dimensions, circuits and inspection requirements are agreed for each project.以下说明展示结构与可配置内容。具体材料、尺寸、电路和检验要求按项目确认。
| Molding material, hardness and cable-jacket compatibility包胶材料、硬度与线缆护套相容性 | Assess jacket compatibility, hardness and appearance together.材料与护套相容性、硬度和外观一起评估。 |
|---|---|
| End geometry, exit angle and mold parting line端头3D结构、出线角度与分型线 | Define exit angle, transition and parting positions in the end geometry.3D端头定义出线角度、过渡段和分型位置。 |
| Tooling, molding process window and insert location模具方案、注塑工艺窗口与嵌件定位 | Select tooling location and process conditions for insert tolerance.模具定位与温压条件结合嵌件耐受能力确定。 |
| Strain relief and target sealing test method应力消除与目标密封检验方法 | Set separate validation methods for pull, bend and sealing targets.拉力、弯折与密封目标分别设定验证方法。 |
| Circuit and revision reference电路与版本依据 | Provide both interfaces, pin map, cable construction, jacket material and diameter, required molded geometry, colour, hardness, environmental exposure, bend direction, pull loads, quantity and validation method.建议提供两端接口、针脚、线缆结构、护套材料与外径、所需包胶几何、颜色、硬度、环境、弯曲方向、拉力、数量与验证方法。 |
| Sample and manufacturing configuration样品与制造配置 | Engineering first reviews the electrical assembly and molding feasibility. A drawing defines insert position, datums, parting line, gate-sensitive surfaces and cable exit.工程首先审核电气组件与包胶可行性。图纸定义嵌件位置、基准、分型线、浇口敏感面与出线方向，再依次确认模具、首件、尺寸与电气检查、约定机械测试和生产控制。 |
APPLICATIONS连接的应用
Application directions应用方向
These are connection directions for project discussion. Suitability depends on interfaces, circuits, installation conditions and project validation; configuration can be adapted to the equipment.以下为可讨论的连接方向。实际适用性取决于接口、电路、安装环境和项目验证，可按设备需求调整。
Industrial sensors and actuators工业传感器与执行器
Overmolding can protect compact interfaces and cable exits on sensors, valves, switches and actuators exposed to handling, vibration or contamination. Assess jacket compatibility, hardness and appearance together.包胶可保护传感器、阀、开关与执行器上的紧凑接口和出线，使其适应操作、振动或污染。选配时，材料与护套相容性、硬度和外观一起评估。
Automation and production equipment自动化与生产设备
Molded connectors provide repeatable handling and strain relief for equipment modules, fixtures and replaceable station cables. Define exit angle, transition and parting positions in the end geometry.成型接口为设备模块、工装与可更换工位电缆提供可重复操作和应力消除。选配时，3D端头定义出线角度、过渡段和分型位置。
Machine tools and service cables机床与维修电缆
Defined boots and rigid bodies protect connectors around oil, chips, vibration and frequent technician handling when materials are matched to the exposure. Select tooling location and process conditions for insert tolerance.材料匹配环境后，明确的护套与硬质外壳可保护油污、切屑、振动和频繁操作区域的接口。选配时，模具定位与温压条件结合嵌件耐受能力确定。
Robotics and moving equipment机器人与运动设备
A tuned strain-relief transition can manage repeated cable movement, but flex life still depends on the cable, routing, bend radius and attachment system. Set separate validation methods for pull, bend and sealing targets.经过调整的应力过渡可以管理重复运动，但弯折寿命仍取决于线缆、路径、弯曲半径与固定系统。选配时，拉力、弯折与密封目标分别设定验证方法。
Appliances and commercial equipment电器与商用设备
Molded junctions and plugs can combine touch protection, recognizable geometry, cleanability and repeatable assembly around motors, heaters and controls. Assess jacket compatibility, hardness and appearance together.成型接点与插头可在电机、加热和控制连接中结合触摸防护、识别几何、易清洁和可重复装配。选配时，材料与护套相容性、硬度和外观一起评估。
Instrumentation and test systems仪器与测试系统
Custom exits, shield terminations and compact molded bodies support probes, instruments and fixtures when signal requirements and grounding are defined. Define exit angle, transition and parting positions in the end geometry.在信号与接地明确时，定制出线、屏蔽端接与紧凑成型外壳可支持探头、仪器和测试工装。选配时，3D端头定义出线角度、过渡段和分型位置。
ENGINEERING & PRODUCTION工程与制造
Adapt the connection to your equipment.围绕设备，调整连接细节。
Touched by me, better it’ll beTouched by me, better it’ll be
Custom wire harness manufacturing in China中国工厂 · 定制线束制造
Our China factory supports overmolded cable assembly projects through custom wire harness manufacturing and OEM/ODM development. Interface, circuit and installation data guide material selection, sample builds and manufacturing-document approval before repeat production.Super Smile-Tech 中国工厂围绕包覆成型电缆组件的项目需求提供定制线束制造与 OEM/ODM 支持。我们从接口、电路与安装资料开始，协同物料选配、样品制作和制造文件确认，再按批准要求组织重复生产。
Design from the interface and duty cycle从接口与工作周期开始设计
Mating clearance, user handling, cable pull direction, bending, sealing, chemicals and assembly space define the molded envelope before a tool is selected.插合空间、用户操作、拉线方向、弯折、密封、化学环境与装配空间共同定义成型外形，再决定模具方案。
Review existing tooling without forcing a fit审核现有模具但不强行套用
An existing tool may reduce development work only when insert position, cable diameter, interface clearance, gate, parting line and performance requirements genuinely match.只有嵌件位置、线径、接口空间、浇口、分型线与性能要求真正匹配时，现有模具才可能减少开发工作。
Control insert position and cavity filling控制嵌件位置与型腔填充
Fixtures support connectors, cables, shields and components against injection movement. Gate and vent locations are arranged to fill thin sections without trapping air or displacing wires.工装支撑接口、线缆、屏蔽与元件，抵抗注射位移；浇口与排气位置需要让薄壁充分填充，同时避免困气和推移线材。
PRODUCT QUESTIONS产品问答
Product & customization questions产品与定制常见问题
What is the difference between overmolding and using a separate boot?包覆成型与安装独立护套有什么区别？
Overmolding forms material directly around the insert and cable in a tool, creating a controlled integrated geometry. A separate boot is assembled afterward and may not provide the same retention, sealing or dimensional control.包覆成型在模具中直接围绕嵌件与线缆形成材料，得到受控一体几何；独立护套在之后装配，其保持、密封与尺寸控制可能不同。
Which molding material should be used?应该使用哪种包胶材料？
The choice depends on hardness, flexing, temperature, chemicals, abrasion, flame requirements, colour, cable-jacket compatibility and processing temperature. A material name alone is not enough.选择取决于硬度、弯折、温度、化学、耐磨、阻燃、颜色、护套兼容与加工温度，单一材料名称不足以完成选型。
Can an existing mold be reused?可以复用现有模具吗？
Possibly, after insert position, cable diameter, interface clearance, exit direction, parting line, gate and required performance are compared. Similar appearance does not guarantee fit.可以审核，但需要比较嵌件位置、线径、接口空间、出线方向、分型线、浇口与性能要求，外形相似不代表能够适配。
Start with your interface and installation requirements从您的接口与安装需求开始
Share mating interfaces, a circuit table, target lengths or a sample for the 4-branch compact circular connector harness. We can use them to review configuration and sample requirements.提供四支路小型圆形接头线束的对插接口、回路表、目标长度或参考样品，我们据此梳理选配与样品确认事项。