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Re: Electrical connectors on control system items
As the teacher on a team that prides itself on clean wiring, I like this thread and feel inclined to comment.
.1inch headers (PWM) - annoying and really time consuming to crimp and/or solder. All the cheap tools suck. I wouldn't be opposed to something better (or maybe I just own the wrong tools).
Weidmuller wire-to-board - has been fine
Wago - Can be tough to access in tight spaces. Need to plan for tool access in the design and assembly processes. The big ones on the PDB are fine. Small ones can be annoying, but workable.
Screw terminals - Not opposed to these in the right application, but the problem with Victors in the past was finding a non-insulated flanged spade terminal for a #12 wire and s #6 screw that was narrow enough in width to properly fit the Victor.
Spade terminals - Works well, fast crimping, can be tough to get off sometimes.
Anderson Powerpole - These work very well. Crimping is not an issue for us. I really wish there was a 4AWG SB50 terminal though. We also sometimes have issues with the PP30/45 and SB/50 series getting the terminal all the way in after crimping if the insulation is large or the crimp is slightly malformed. But once you get the terminals over the clip, it's flawless. It's a training issue more than anything.
IDC connectors - seem fine I guess
USB - Haven't used them in an FRC sense.
Barrel jack - Always concerned about losing contact. We put a lot of thought and effort into properly retaining this connector so it cannot come out.
RJ45 (ethernet) - We do not use off the shelf pre-made cables, to eliminate excessive length. We've had some issues properly crimping these. Also, the clips are fragile, and if there's a stiff boot on it, you risk breaking the port itself if the user does not have the finger strength to fully depress the boot before pulling the cable out. So for that reason, I'm weary.
RJ11 - Similar to what I mentioned above, but I haven't used RJ11s specifically.
Here are some new connectors I would like opinions on.
JST connectors (PH series for example ) - Seems plausible. I'd need to see and try the terminals and crimper.
XT connectors - Never. Short circuit risk on the solder cups and just the fact that you can't crimp it.
Deans connectors - Never. The exposed terminals on an unplugged connection are a serious short circuit hazard for teams who don't know what they're doing and install that half of the connector to the wrong side of the circuit. PowerPoles do not have a male or female side.
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Teacher/Engineer/Machinist - Team 696 Circuit Breakers, 2011 - Present
Mentor/Engineer/Machinist, Team 968 RAWC, 2007-2010
Technical Mentor, Team 696 Circuit Breakers, 2005-2007
Student Mechanical Leader and Driver, Team 696 Circuit Breakers, 2002-2004
Last edited by sanddrag : 15-06-2016 at 22:54.
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