Electrical Connection Head for Sensors and Probes

Product Specifications

Technical details and manufacturing context for Electrical Connection Head

Definition

The electrical connection head is a critical sub-component of sensors and probes that serves as the termination point for electrical wiring. It houses the terminals, connectors, or pins that establish the electrical pathway between the sensing element and the external measurement, control, or data acquisition system. Its primary role is to ensure a secure, reliable, and often environmentally sealed connection for signal transmission and/or power supply. This component is typically used in industrial automation, process control, and instrumentation applications where sensors must interface with control systems. The connection head is designed to accommodate various cable types and termination methods, including screw clamps, spring clamps, plug connectors, or solder points. It provides a robust mechanical interface that protects the internal electrical connections from environmental factors such as moisture, dust, and vibration. The housing is often made from thermoplastic materials like PBT or PPS, or metals such as stainless steel, brass, or nickel-plated brass, depending on the required corrosion resistance and mechanical strength. Key electrical parameters include rated voltage (24–250 V AC/DC), rated current (5–10 A), contact resistance (≤5 mΩ), insulation resistance (≥100 MΩ), and dielectric strength (1.5–3 kV). The operating temperature range is -40 to 85 °C, and the IP rating can vary from IP54 to IP67, indicating the degree of protection against dust and water ingress. Connection threads are commonly M12 to M20, and the weight ranges from 0.05 to 0.2 kg. These specifications are reference values and must be verified with the manufacturer for the specific model. The connection head is selected based on the sensor type, cable specifications, environmental conditions, and electrical requirements. Proper installation and maintenance are essential to ensure reliable operation and to prevent failures such as short circuits, signal loss, or insulation breakdown.

Working Principle

The connection head functions by providing a physical and electrical interface. Internal terminals are connected to the sensor's internal leads. External cables are then attached to these terminals via screw clamps, spring clamps, plug connectors, or solder points. This creates a continuous conductive path, allowing electrical signals (e.g., voltage, current, resistance) generated by the sensor to be transmitted out, or allowing power to be supplied to the sensor. The housing provides mechanical protection and may include sealing elements to achieve the specified IP rating. The design ensures that the electrical connections are secure and that the signal integrity is maintained under normal operating conditions.

Common Materials

Thermoplastic (e.g., PBT, PPS), Stainless Steel, Brass, Nickel-Plated Brass

Technical Parameters

Parameter	Typical range	Notes & selection driver
Rated Voltage	24–250 V AC/DC	Exceeding rated voltage may cause arcing or insulation failure.IEC 60664
Rated Current	5–10 A	Higher current requires larger conductor cross-section.IEC 60512
Contact Resistance	≤5 mΩ	Higher resistance leads to power loss and heating.IEC 60512-2
Insulation Resistance	≥100 MΩ	Lower insulation resistance may cause leakage current.IEC 60243
Dielectric Strength	1.5–3 kV	Test voltage for 1 minute without breakdown.IEC 60243-1
Operating Temperature	-40–85 °C	Outside this range, sealing and insulation degrade.IEC 60068-2-1/2
IP Rating	IP54–IP67	Higher IP for dusty or wet environments.IEC 60529
Material	316L	Corrosion-resistant stainless steel for harsh media.ASTM A276
Connection Thread	M12–M20	Common sizes for sensor mounting.DIN 13
Weight	0.05–0.2 kg	Affects handling and installation torque.

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Housing Part
Provides mechanical protection, environmental sealing, and mounting structure for internal components.

Material: Thermoplastic or Metal
Terminal Block
The internal assembly with screw clamps or spring clamps to secure wire conductors.

Material: Thermoplastic with metal (brass, steel) terminals
Cable Gland
Secures and seals the entry point of the external cable into the housing.

Material: Nitrile Rubber, Neoprene, or Metal
Sealing Gasket/O-Ring Part
Creates a seal between the housing and the sensor body or mounting surface.

Material: Silicone, Viton, EPDM

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Sensor/Probe

View system integration details

Manufacturers of Electrical Connection Head

Manufacturer profiles associated with Electrical Connection Head.

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Compiled and source-reviewed by the CNFX editorial team. Each manufacturer above links to the page on that company's own website where the product is listed, with the date we checked it. How we source and review · Page last updated 6 September 2026

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Frequently Asked Questions

What is the purpose of an electrical connection head?

It provides a secure and reliable electrical interface between a sensor or probe and external systems, allowing signal transmission or power supply.

What materials are commonly used for connection heads?

Common materials include thermoplastics like PBT or PPS, stainless steel, brass, and nickel-plated brass, depending on environmental requirements.

What is the typical IP rating for these components?

The IP rating can range from IP54 to IP67, indicating protection against dust and water. The specific rating depends on the model and application.

How do I choose the right connection head?

Consider the sensor type, cable size, electrical ratings (voltage, current), environmental conditions (temperature, moisture), and required IP rating. Always verify specifications with the manufacturer.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification

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pressure:	0 to 100 bar (1450 psi)
other spec:	IP67 ingress protection, 1000V AC/DC dielectric strength
temperature:	-40°C to +150°C

Electrical Connection Head

Product Specifications

Applied To / Applications

Industrial Ecosystem & Supply Chain Structure

Application Fit & Sizing Matrix

Reliability & Engineering Risk Analysis

Compliance & Manufacturing Standards