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Cavity-level validation

Connector, terminal, seal, and wire compatibility checks

Check connector cavities, terminal crimp ranges, seal limits, wire size and outside diameter, current ratings, and sealing requirements with traceable results.

Resolve the complete cavity chain

A populated cavity links a connector family, cavity definition, terminal, seal, and wire. The resolver compares family keys and numeric ranges rather than assuming that nearby or similarly named parts are compatible.

  • Terminal family must match the cavity family.
  • Wire conductor area and insulation outside diameter must fit the terminal ranges.
  • Seal family and bore range must fit the cavity and wire.
  • Unused sealed cavities can require a matching cavity plug.

Check the weakest current rating

When rating data exists, the current chain compares the wire, terminal, cavity, and connector limits. A lower terminal rating is reported as the weak link even if the wire itself has spare ampacity.

Worked example

Generic compatibility example. Identifiers and values are illustrative engineering data, not commercial part numbers.
CheckEvidenceResultReason
Terminal to cavityX1 cavity 3: GEN-A family; terminal GEN-T-01: GEN-APASSThe family keys match.
Wire to terminalWire: 1.0 mm², OD 2.2 mm; terminal: 0.75-1.5 mm², OD 1.9-2.5 mmPASSBoth conductor and insulation ranges include the wire.
Seal to wireSeal GEN-S-01 bore: 1.4-1.9 mm; wire OD: 2.2 mmFAILThe wire OD is outside the seal bore range.
Connector ratingCurrent rating not recordedUNKNOWNSafety-critical evidence is missing; release remains blocked.

Important limitations

  • Compatibility depends on complete, trustworthy library or manual data.
  • A generic starter record is not evidence that a commercial part is approved for production.
  • Mating compatibility remains UNKNOWN when the mating half or keying evidence is absent.

Related CircuitTwin Harness workflows

Common questions

Does the starter catalog contain approved manufacturer part numbers?

No. The public starter data is generic engineering sample data. Customers must use verified internal records or import data they are authorized to use.

What happens when a connector rating is missing?

The affected check returns UNKNOWN and identifies the missing evidence. Safety-critical unknowns can block release and export.