Better Connectors

     In that scale, 3M insulation displacement connectors are
often a good choice.  Take a look at

      http://www.mouser.com/catalog/623/941.pdf

     In general, complex wiring should go on boards, not in
cables.  If you need to, design a custom PC board that has
nothing but connectors on it and connections between them,
so each cable just plugs in.  You can also build such a board
with wire wrap, although that's kind of retro and takes up
more space.  That's a good way to fan out all the stuff
that has to connect to J1 on that controller board.

     Then you can use ribbon cables and IDC connectors, instead
of making wiring harnesses one wire at a time.  Your cables
will be far less fragile.

     If wires are slipping out, you have the wrong wire size,
the wrong type of wire, the wrong connector size, or the wrong
tool.  Read the connector data sheets carefully.
You can find most connector data sheets on line at Digi-Key or Mouser.

                John Nagle

Dale T Stewart wrote:

OK thanks John

How do you connect your wiring to these connectors. The data sheet
didn't help much

:-]

Dale

John Nagle wrote:

<snip>


Modular connectors are actually among the best, though the solder-on
type have offset rows of terminals. It's easier to use the wired
terminals if you aren't producing your own board or using an adapter.

I'd suggest most any crimp-on connection scheme. Some are more expensive
than others. I used to hassle about this until I ponyed up for a real
terminal crimper. Now I use standard, cheap 0.100" header terminals on
most everything. One advantage is ease of breadboarding. The only
soldering I do, if I'm not using a solderless breadboard, is the pin
headers on copper boards. Everything else is crimp-on.

-- Gordon

On Mon, 21 May 2007 13:03:34 +1000, Dale T Stewart


I use a mix of header pins, which I once used almost exclusively and
modular connectors. The modular connectors are really easy to work
with. In my latest set of robots I have used 4P4C and 6P6C modular
connectors to interconnect all subsystems, using the vertical header
pins and sockets only for the motors. The modular plugs make it easy
to make a cable, just cut, strip, poke, crimp and presto! Plus
orientation and polarity is automatic. The only problem is the pins on
the sockets won't fit a breadboard but I make my own PCBs so I have no
problem. I'm not sure why the metal would be coming out of your
plastic casings, I've never found that problem. The tiresome thing
with the header sockets is attaching each metal spring thingy to a
wire. I crimp and solder cause I don't have a proper crimper. I also
use AT style connectors for the keypads, because the ones I've made
use AT keyboard curly cords, though PS/2 style would also work.


____________________________________________________
"I like to be organised. A place for everything. And everything all over the
place."

Crimps are best if there is vibration or any kind of pull on the wires.
For crimps and screw terminals you should use the recommended size of
stranded cable not solid core.

For crimps and Cat-5 you need a good quality tool.

Ribbon cable has a poor reputation...

If you must solder then you can use heat-shrink tubing and rubber
sleeves to support the joints.

I know it all seems a pain but otherwise things tend to fall apart :)

Cheers
Rich

    Ribbon cable and its connectors come in different qualities. The good
"rainbow" stuff from 3M is fine, especially when used with connectors
that have strain relief.  Some of the no-brand stuff is unreliable.
Simple though those parts seem, the tolerances on the wire and the
connectors are tight.

                John Nagle

I get most of my connectors from Hansen Hobbies:
http://hansenhobbies.com/products/connectors/ . They're inexpensive and
work very well. They ship internationally. The crimper sold there also
works very well.

-Michael

   Gold? Don`t wipe it though.

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Ashley Clarke
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