Panel Wiring that Is Tool-free, Ferrule-free and Automation-ready

The key benefits of Snap-In technology include:

• Eliminates the need for ferrules on stranded wire
• Provides audible, visual and tactile confirmation of a secure connection
• Allows for quick wire termination without tools
• Supports easy installation on DIN rails.

Machine design engineers and panel builders work with many electrical components to create machines and controls systems, so they often look for wiring solutions that simplify panel assembly, reduce installation time and minimize wiring errors. Weidmuller USA’s Snap-In technology provides a method to terminate standard wires quickly and securely without requiring ferrules or tools. Its design offers clear confirmation of proper wire insertion, which helps improve installation reliability and efficiency.

This technology provides an alternative to push-in wiring systems and is identified by green pushers compared to the orange pushers used in standard push in systems. Hannah Witopil, product manager at Weidmueller USA, told Machine Design as she demonstrated the technology.

Traditional push-in systems require ferrules on stranded wires to pass through the spring and complete the connection. To connect a wire using Snap-In technology, the wire is inserted into a termination point until a click is heard. The green pusher rises visibly and a tactile feedback can be felt, providing three forms of indication that the wire is properly terminated.

Each terminal block is preloaded with a spring mechanism that holds the wire securely once inserted. The terminal blocks are designed to be mounted on a DIN rail and can be wired using one hand without the need for tools.

Witopil demonstrated an expanded product range that includes the following options:

• Knife blade disconnect blocks for safely interrupting current flow to allow testing or troubleshooting
• Fuse terminal blocks that use standard 5×20 mm fuses to provide circuit protection
• Larger cross-section terminal blocks with side entry to accommodate wires up to 4 AWG. Side entry reduces bending radius stress on larger wires. The available wire size range now spans from very small 22 AWG wires up to 4 AWG.

Automation Compatibility

Snap-In technology enables automated assembly and wiring processes. Robots equipped with grippers can pick terminal blocks from magazines and place them on DIN rails. The zero insertion force required by this technology allows automated wire termination as the wire can be inserted. Without applying significant force or needing tools, sensors in these systems measure wire length and bending radius to ensure proper preparation before stripping and termination.

Snap in technology is designed with flat sides on terminal blocks for easy robot handling and is currently a patented technology. It is one of the few wiring technologies that supports fully automated terminal block installation and wiring according to Witopil.