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How to Terminate Machine Vision Cables Properly

Machine vision cables – like CoaXPress (CXP), Camera Link, GigE Vision, or USB3 Vision – are lifelines for industrial imaging systems. A faulty termination means signal loss, noise interference, and costly downtime. Follow these steps to terminate them correctly and ensure peak performance:

1. Identify Cable & Connector Specifications

Match standards: Confirm whether it’s shielded coaxial (e.g., CXP), twisted-pair (e.g., GigE), or hybrid. Verify connector types (Hirose, MDR, micro-BNC, etc.).
Check pinouts: Never assume wiring schematics. Use manufacturer datasheets for pin assignments and shield requirements.

2. Gather Essential Tools & Materials

Precision wire strippers (calibrated for insulation thickness)
Crimping tool with dies for your contacts
Quality soldering iron (for solder-type contacts)
Multimeter / continuity tester
Strain relief boots, shrink tubing
Manufacturer-specified connector housings and contacts

3. Strip Cable Layers Carefully

Remove the outer jacket using a rotary tool or sharp knife—avoid nicking inner conductors.
Unwrap or cut back shielding foil/braid neatly. Keep it intact for grounding.
Strip inner conductor insulation with a stripper adjusted to exact depth. No exposed strands!

4. Prepare Conductors & Shield

Coax Cables: Slide shrink tube onto cable. Expose the center conductor to match contact depth. Trim shielding to ensure contact with the connector’s shell.
Twisted Pair: Untwist minimally. Strip each wire to the pin contact length. Group drain wires for grounding.
Tin wires sparingly if soldering: Apply only enough solder to prevent fraying.

5. Crimp or Solder Contacts Securely

Crimp Contacts: Insert each conductor into the contact cup. Crimp firmly using the correct die size. Tug-test gently to confirm no slippage.
Solder Contacts: Heat the contact cup, flow solder into it, then insert the pre-tinned wire. Avoid cold joints or excess solder causing shorts.
Ground Shields: Crimp/solder shields to designated connector shells/ground pins. This is critical for EMI protection.

6. Assemble the Connector

Insert contacts into their labeled slots in the connector housing until they audibly click.
Route cables through the strain relief boot.
Tighten the backshell or crimp ring to anchor the cable jacket. Strain relief must grip the outer jacket, NOT the conductors.
Apply heat shrink over the boot-jacket junction if needed.

7. Validate with Testing

Continuity Test: Use a multimeter to verify all pins connect correctly—no shorts, crosses, or open circuits.
Shield Verification: Ensure shields have continuous grounding paths without contact to signal pins.
System Test: Connect to the camera/PC under real-world conditions. Check for flickering, artifacts, or dropouts.

Critical Tips for Success

Work Clean: Keep workspaces dust-free. Contamination causes intermittent faults.
Avoid Over-Bending: Never exceed the cable’s bend radius during or after termination.
Use Strain Relief: Always secure cables mechanically to prevent tugging on contacts.
Label Both Ends: Note cable type, length, and termination date for maintenance.

Conclusion

Proper termination preserves signal integrity, minimizes noise, and prevents failures in demanding machine vision applications. Rushing this process risks calibration errors, data corruption, and unplanned downtime. By investing in the right tools, adhering to pinouts, and methodically validating connections, you ensure your vision system runs reliably for thousands of operational hours. Always prioritize manufacturer guidelines—when in doubt, consult certified specialists.