Manufacturing Insulation Piercing Needle Clusters

These needle clusters are used not only in E-Z-Hook products, but sold as raw material components to many of our clients. We even sell them to “competitors” for use in their products! While we are known for finished goods, many of our raw material components are available for sale. Over 20 years ago we started making these needle clusters for our p/n 82-2.

Since then we have developed variations with 23 to 33 needles. These are hand assembled in our plant in California by the thousands.  Contact us to meet your design requirements with our needle cluster technology. This product technology is popular with our Aerospace and Defense clientele.

E-Z-Hook needle cluster products : XB, 82-2, 8507

 

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Test Leads and Kits for the Automotive Market

Blog3_16In 1980 E-Z-Hook entered the automotive sector with our XJL insulation macro-hook connected to a lead with a standard alligator connector on the other side. This product 619XJL was offered in a black and red set of 18″, 36″ , and 60″ standard lead lengths. Today, 36 years later, this product can still be found in most automotive jobber trucks (think Matco, Snap-On, MacTool, etc). We have sold thousands of this product, which single handedly helped us enter the automotive after market for repair and testing.

Today the 619XJL remains a staple, and one of our most popular automotive leads. Variations of this test lead set include a straight banana plug connector or a shrouded right angle connector. All of these products work with most standard Digital Multi-Meters. For environments that require a higher heat resistance and more durability than our standard PVC wire provides, we do offer all test leads with silicone wire if requested.

In the early 90’s we introduced our XEL piercing hook into the automotive market. This narrower hook has an angled front to navigate through wire bundles, as well as a v-shaped design for grabbing and centering the wire or cable prior to piercing. It was introduced as an alternative lead set combination to the XJL options. In addition we designed it to be available without a factory installed lead. This XEL version offers a shrouded banana socket on either handle side, allowing easy flexibility to use with any standard banana plug lead. Much like our XJL versions, the XEL has become a popular staple in most auto repair and test mechanics tool boxes.

So, what next? As we spoke to distributors and automotive jobbers we realized that the automotive repair and test aftermarket really lacked in the “accessory” area. For most equipment companies the test leads and components were an after thought – and often not well designed or manufactured products. Automotive technicians would purchase fabulous multi-meters but the test cables supplied with these were often junk, couldn’t carry a proper signal, and needed replacement within a year. At E-Z-Hook these test leads, test cables, and connectors are our specialty. That is what we focus our manufacturing quality on so we could easily compete with great replacement products and test kits.

That is exactly what we have continued to do in these past 10+ years. Today in addition to our standard XJL and XEL test lead sets we offer various banana plug lead sets and individual leads specifically designed for automotive use. One of my personal favorites is our 9183-144BLK banana plug jumper test lead. Why do I like it – because while learning about our products for this industry I asked why in the world would we make something so long? 144 inches? 12 Feet? I was reminded that this length (the approximate length of a car) would allow a technician to be on one side and connect to something on the other. Made sense to me, and obviously to a lot of automotive test and repair technicians. Due to it’s popularity in the field we now bundle this test jumper in with many of our automotive kits. It can be purchased individually or is part of our popular 3519 and 3520 test lead sets. In addition to leads we offer various kits including our insulation piercing hooks as well as alligator clips, back probe needles and other connectors. All kits include various lead options and are offered with either our XJL or XEL piercing macro-hooks or the 8064 needle back probes which we just introduces to the market in late 2015.

Testing was never so easy. Over 35 years of PROVEN EXPERIENCE IN THE FIELD.

Defense and Security Applications

These handy little devices represent the XB product line created for the defense and security industries. Originally a “modification” to our 82-2 harness board product, these wire piercing devices are fully insulated on the exterior and offer a screw down clamp to ensure a secure and solid connection upon engagement with the wire. Once the XB is hooked on you can rest assured that it isn’t coming off until you decide to physically unclamp the device. The V-grove above the nailbed allows for various sized wire dimensions and ensures they can easily be directed over the wire bed for optimal connection. We understand there is often no room for technician error in the field- and this product was made with that requirement in mind.

The XB parts are available in red, yellow and black with factory installed leads. The most preferred lead is an 18 gauge PVC wire to a shrouded banana plug, but contact us for various connector options. This product is also available as a lead set or kit for specific industry requirements.

82-1 Harness Board Connector Makes Wire Testing E-Z!

In response to many customer inquiries, E-Z-Hook has developed a new product allowing for quick release of wires after testing.  This new design, our 82-1 series, is based off our popular 82-2 product line.

The 82-2 product has a bed of piercing nails allowing for testing of wire connections without requiring any wire stripping.  The clamp or lever holds the wire against the bed of nails, forcing the needles into the wire so that contact can be made through the insulation.

In many customer applications, the wire being used was already pre-striped. While pre-striped wire can be used with the 82-2, we recognized that the same “insulation piercing” needle bed wasn’t a requirement for positive connectivity. In talking with clients using pre-stripped wire an important feature was easy wire removal after testing. The 82-2 piercing design requires the clamp to be opened or released to free the wire and disengage from the nails. For pre-striped wire ends the nails aren’t needed to create a connection. The individual wires tended to get caught or stuck in the bed of nails, which lengthened the time requirements for the testing process.

“Voila,” the flat pad 82-1 product! We listened to our customer feedback and recognized we could provide a better solution specific to environments using pre-stripped wire. We designed a “flat metal pad” harness connector. This flat metal pad provides contact with the striped wire once the clamp is closed. Unlike the bed of needles, the wire removal from the connection is as easy as simply pulling on the wires. The clamp or lever does not need to be lifted to free the wire. When multiple  wire connections are being tested this new design saves valuable time.

The new harness board connector, 82-1, will be available at the beginning of January, 2016.  Picture coming soon!

Insulation Piercing Harness Board Connector

Our latest product, P/N 8507 has been nominated for a King Award.  We’re particularly excited about the innovative solutions this product delivers.  We’re certain it will help many other harness board environments, too.

Insulation piercing connector designed for harness board applications. Accepts wire diameters up to .20” (5mm).  Wire can be inserted from multiple angles within the 180 degree opening. Spring tension of 7 pounds actuates product into open position. Product available with 4 different threaded studs and is offered in 10 colors.

Insulation Piercing Harness Board Connector, 8507 Line Up                        Insulation Piercing Harness Board Connector, Part Number 8507

Quick Solution for a Complex Hook Problem

A Government and Defence client needed an effective solution that had to fulfil specific space and material requirements.  The client was looking for a minimally invasive micro piercing connector that makes a mid-line connection. Upon connection, the device needed to remain engaged until removed.

Leveraging our automotive macro piercing technology we designed and manufactured two micro piercing connectors with thumb screw action for secure connection.

Less than one inch long, the micro-sized XEP and XEPA piercing connectors are ideal in environments where size and reliability of connection are essential. Features include the V shaped tip design for separating wire bundles and a .030″ pin plug that connects to any standard .030″ diameter socket. XEP features a straight contact angle and XEPA features a slanted contact angle. (XEP & XEPA shown).

E-Z-Micro Hook Insulation Piercing, XEP and XEPA Gray