Views: 0 Author: Uly Hong Publish Time: 2024-07-07 Origin: LenoRF
In the current situation of involution, I often encounter customers demanding lower prices, who usually do not understand the production process and cost differences of a RF connector. Pursuing low prices naturally sacrifices quality, leading to many quality issues. This results in a lose-lose situation for both customers and suppliers. Due to intense involution, individuals and organizations often invest significant resources (time, money, energy, etc.) in ineffective competition, leading to huge waste of resources. These resources could be used for more valuable innovation and development.
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To fully understand the price differences of RF connectors, one must first have a basic understanding of the performance parameters of RF
connectors. This way, you can choose the best cost-effective RF connector suitable for your project, rather than just pursuing low prices.
An RF connector is a passive electronic component. Its performance is determined by mechanical processing precision, materials, and assembly precision. It is a mechatronic product. Generally, we measure the quality of a connector by key parameters such as VSWR (Voltage Standing Wave Ratio), insertion loss, PIM (Passive Intermodulation), mating force, operating temperature, and salt spray resistance. In practice, the most critical parameters are VSWR, retention force, mating and separation force, mechanical compatibility (interface dimensions), salt spray resistance, and mechanical durability. Below is a simple and understandable explanation of these parameters, which are closely related to the product's price.
Operating Frequency: Higher frequencies require higher precision in parts and assembly. [Factors: design, processing precision, assembly precision]
VSWR: The smaller the VSWR, the smaller the signal reflection interference. [Factors: design, processing precision, assembly precision]
Retention Force: High retention force means longer service life and lower contact resistance. [Factors: materials, assembly precision]
Mechanical Compatibility (Interface Dimensions): Ensures the connector can be mated with other manufacturers' connectors of the same model with stable performance. [Factors: processing precision, assembly precision]
Mating and Separation Force: The force required to insert and remove the connector, affecting user comfort. [Factors: processing precision, materials]
Salt Spray Resistance: The product's ability to resist corrosion in its operating environment. [Factors: plating quality]
Mechanical Durability: The ability to withstand collisions, vibrations, and impacts. [Factors: assembly precision, materials]
Production Process of Connectors:
Demand analysis and design
Raw material procurement
CNC processing
Plating
Finished product assembly
Inspection
Packaging and shipment
Main Materials List:
Material Name | Suitable Connector Parts | Classification |
Brass | Housing, inner conductor | New material, recycled rod |
Phosphor Bronze | Inner conductor, elastic connector | Multiple grades |
Beryllium Bronze | Housing, inner conductor, elastic connector | Multiple grades |
Stainless Steel | Housing | 303, 304, 316L |
PTFE (Teflon) | Insulator | First grade, second grade, recycled |
PEEK | Insulator | First grade, second grade, recycled |
PEI | Insulator | First grade, second grade, recycled |
Plating Processes List:
Plating Name | Suitable Connector Parts | Remarks |
Imitation Gold | Housing, inner conductor | Not real gold, looks like gold, but poor corrosion resistance |
Silver | Housing, inner conductor, elastic connector | Different thicknesses (3um, 5um), good conductivity, easy to oxidize, suitable for low intermodulation scenarios |
Gold | Housing, inner conductor, elastic connector | Different thicknesses (0.025um, 0.05um, 0.1um for civilian use, 1.27um, 3.0um for military use), salt spray resistance (24h, 48h) |
Nickel | Housing | Low cost, wear-resistant, easy to solder |
Ternary Alloy | Housing | Medium cost, good salt spray performance, suitable for low intermodulation scenarios |
High Temperature Ternary Alloy | Housing | High salt spray resistance(720 hours) |
High Phosphorus Chemical Nickel | Housing, inner conductor | High salt spray resistance(720 hours), can be used as a base layer for gold plating. |
Tin-Nickel Alloy | Housing | High salt spray resistance (720 hours) |
Parts Processing Equipment List:
Equipment Name | Processing Cost (USD/min) |
Instrument Lathe | Obsolete |
Cam Lathe | 0.01 |
Gang Tool CNC Lathe | 0.03 |
Swiss Type CNC Lathe | 0.25 |
Engraving Machine | 0.04 |
Machining Center | 8.5 |
Summary: The use of different materials, plating, and processing equipment directly affects the performance and price of the product.
Finished Product Processing Equipment List:
Equipment Name | Function |
Manual Press | Mechanical compatibility, ensuring interface dimensions |
Automatic Wire Stripper | Precise wire stripping |
High Voltage Tester | High voltage testing |
High Frequency Welder | Welding |
Vibration Tester | Mechanical durability |
Waterproof Tester | IP6X testing |
Network Analyzer | VSWR, insertion loss testing |
Height Gauge | Interface dimension detection |
Vernier Caliper | Dimension detection |
Micrometer | Dimension detection |
Coordinate Measuring Machine | Dimension detection |
CCD Microscope | Appearance detection, welding quality detection |
Jigs and Fixtures | Custom-made according to product type |
These are some basic finished product production and testing equipment, not a complete list. Although these equipment are not direct costs, they need to be included in management costs when pricing products. Without this equipment, it is difficult to produce high-performance RF connectors and jumpers.
Due to the wide variety of RF connectors and jumpers, with about 40 types defined by IEC standards and some custom standards by enterprises, it is impractical to analyze each one. SMA is one of the most widely used RF connectors with moderate cost. Comparing and analyzing the price and cost of SMA connectors is representative.
Basic Knowledge of SMA:
SMA (SubMiniature version A) connectors were initially designed to meet the needs of high-frequency microwave systems. Over time, they have been widely used in radio communications, microwave systems, antennas, radar, and testing equipment.
Main Parameters and Characteristics of SMA:
Frequency Range: 0 - 18 GHz, extendable to 26.5 GHz.
Characteristic Impedance: 50 ohms.
Threaded Connection: Ensures stable mechanical connection and good electrical contact.
Miniaturized Design: Small size, suitable for space-constrained applications.
High Reliability: Excellent weather resistance and mechanical shock resistance, suitable for harsh environmental conditions.
Price Comparison Analysis for SMA Male Crimping for RG58 Coaxial Cable:
Part | Low-Cost Option | High-Quality Option |
Nut | Recycled brass, simple process, mass production, imitation gold plating | New brass, milled hex surface, sharp edges, real gold plating passing 48-hour salt spray test |
Sealing Ring | Recycled silicone rubber | New silicone rubber |
Retaining Ring | Iron | Beryllium copper |
Insulator | ABS injection molding | New PTFE |
Housing | Recycled brass, imitation gold plating | New brass H59, real gold plating passing 48-hour salt spray test |
Inner Conductor | Brass, imitation gold plating | Brass H59, 0.1um gold plating |
Crimp Tube | Brass, nickel plating | H62 copper, nickel plating |
Processing Precision | 5-10 microns | 1-5 microns |
Finished Product Assembly Precision | 5-10 microns | 3-5 microns |
Maximum Operating Frequency | 3 GHz | 6 GHz Can work for 18Ghz,but RG58’s maximum working frequency is 6 GHz |
Salt Spray Resistance | 24 hours | 48 hours |
Mechanical Compatibility | Loose fit, poor hand feel | Smooth fit, good hand feel |
Price | 0.13 ~ 0.17 USD | 0.5~0.65 USD |
Low-cost options can be used in less demanding scenarios such as consumer electronics. High-cost options can be applied in all scenarios. Therefore, before procurement, it is essential to fully understand the project's actual needs and choose the correct cost plan. Otherwise, blindly pursuing low prices while ignoring quality will result in manufacturers excessively lowering costs to win orders, leading to a market situation where inferior products drive out superior ones.
The End.
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