Connectors - Revision history

FsaeIllumina at 07:02, 22 May 2021

2021-05-22T07:02:14Z

Satiric: /* Removable */

2020-09-08T23:32:06Z

Removable

Satiric: /* Solder */

2020-09-02T09:25:45Z

Solder

Satiric: /* Standard Connectors */

2020-09-01T22:17:49Z

Standard Connectors

Satiric: /* Screw Down */

2020-09-01T22:08:30Z

Screw Down

Satiric: /* Housing */

2020-09-01T22:00:31Z

Housing

Reshovsky at 04:17, 19 May 2020

2020-05-19T04:17:58Z

Reshovsky: /* Solder */

2020-05-19T04:08:21Z

Solder

Reshovsky at 04:07, 19 May 2020

2020-05-19T04:07:27Z

Reshovsky at 03:44, 19 May 2020

2020-05-19T03:44:34Z

@@ Line 35: / Line 35: @@
 ===Connection Method===
 ====Crimp====
 A crimp is a mechanical connection between wire and terminal. The terminal is deformed tightly around the wire conductors, often with additional points secured to the jacket for strain relief. When done properly, this can be an incredibly strong connection - sometimes stronger than the wire itself. For this reason, most professional motorsport wiring harnesses will only use crimped joints. To achieve a reliable crimp, terminals must be properly designed for the wire gauge being used. The correct tools are also necessary; using pliers or a vise will almost always result in a weak connection that is more likely to fail.
 ====Solder====
-Soldering is the process of joining two or more parts by melting solder around the connection. When the solder cools, it creates a good electrical connection and a weak mechanical connection. Solder joints are much more brittle than crimped joints, so they are unreliable in high-vibration environments. Solder connections are often found on panel mount connectors in the form of solder cups. Soldering can also be used to reinforce a crimped connection.
+Soldering is the process of joining two or more parts by melting solder around the connection. When the solder cools, it creates a good electrical connection and a weak mechanical connection. Solder joints are much more brittle than crimped joints, so they are unreliable in high-vibration environments. Solder connections are often found on panel mount connectors in the form of solder cups. Soldering can also be used to reinforce a crimped connection. Always make sure solder is completely wetted out both components in the joint.
 ====Screw Down====

@@ Line 32: / Line 32: @@
 ====Resistance====
 ===Removable===
-Some connectors have terminals permanently fixed in the housing (such as most D-subminiature connectors), while others have removable terminals. Removable terminals allow for easier assembly and maintenance, but may increase the size of a connector. Many connectors require specialized tools to remove terminals, and can be damaged by attempting to remove a terminal without the required tool.
+Some connectors have terminals permanently fixed in the housing (such as most D-subminiature connectors), while others have removable terminals. Removable terminals allow for easier assembly and maintenance, but may increase the size of a connector. Many connectors require specialized tools to remove terminals, and can be damaged by attempting to remove a terminal without the required tool. Many times, however, you can just use a flathead screwdriver - when in doubt, look up tutorials on YouTube.
 ===Connection Method===
 ====Crimp====

@@ Line 37: / Line 37: @@
 A crimp is a mechanical connection between wire and terminal. The terminal is deformed tightly around the wire conductors, often with additional points secured to the jacket for strain relief. When done properly, this can be an incredibly strong connection - sometimes stronger than the wire itself. For this reason, most professional motorsport wiring harnesses will only use crimped joints. To achieve a reliable crimp, terminals must be properly designed for the wire gauge being used. The correct tools are also necessary; using pliers or a vise will almost always result in a weak connection that is more likely to fail.
 ====Solder====
-Soldering is the process of joining two or more parts by melting solder around the connection. When the solder cools, it creates a good electrical connection and a weak mechanical connection. Solder joints are much more brittle than crimped joints, so they are unreliable in high-vibration environments. Solder connections are often found on panel mount connectors in the form of solder cups.
+Soldering is the process of joining two or more parts by melting solder around the connection. When the solder cools, it creates a good electrical connection and a weak mechanical connection. Solder joints are much more brittle than crimped joints, so they are unreliable in high-vibration environments. Solder connections are often found on panel mount connectors in the form of solder cups. Soldering can also be used to reinforce a crimped connection.
 ====Screw Down====

@@ Line 56: / Line 56: @@
 ==Standard Connectors==
 ===USB===
-===RJ45===
+Used for connecting to computers, e.g. for tuning the car or downloading data from a datalogger.
 ===D-Subminiature===
 ==RF Connectors==
 ===BNC===

@@ Line 40: / Line 40: @@
 ====Screw Down====
-Screw terminals use a screw to clamp onto wires. Unlike crimp and solder connections, screw terminals do not permanently or semi-permanently fasten wires, and therefore are good solutions for applications such as an engine dyno or test bench.
+Screw terminals use a screw to clamp onto wires. Unlike crimp and solder connections, screw terminals do not permanently or semi-permanently fasten wires, so they are most useful for wiring that won't leave the shop, like for an engine dyno or a test bench. Because they can loosen under vibration, they should not be used on vehicles.
 ==Types==
 ===Free Hanging===

@@ Line 2: / Line 2: @@
 ==Housing==
 ===Material===
-Connector housings are usually made from plastic or metal. Plastic connectors are usually cheaper and lighter, but will be less durable and with a lower lifespan than metal connectors.
+Connector housings are made from either plastic or metal. Plastic connectors are usually cheaper and lighter, but are less durable and generally have a lower lifespan than metal connectors.
 ====Durability====
 ====Chemical Resistance====
@@ Line 23: / Line 23: @@
 ====Push-Pull====
 Push-pull connectors require that a sleeve on the connector be pulled back in order to release the locking mechanism. Some connectors require the mechanism to be unlocked when connecting or disconnecting the connector, while others only require this during disconnection. The most common push-pull connectors are made by LEMO.
 ==Contacts==
 ===Material===

@@ Line 10: / Line 10: @@
 All connectors feature some sort of retention method. For most connections in a FS car, strong retention methods (locking or tight friction-fit) are required. Only a few applications (e.g. connection between ECU and computer for tuning) may benefit from connectors with weak retention.
 ====Friction Fit====
 ====Locking Tab====
 ====Screw Lock====
 ====Twist Lock====
 ====Cam Lock====
 ====Push-Pull====
 ==Contacts==
 ===Material===
@@ Line 32: / Line 38: @@
 ==Types==
 ===Free Hanging===
-This is probably the most common type of connector on an FSAE car. These connect wires to other wires, and can interface either with other free hanging connectors or with panel mount connectors. In FSAE these will usually need to be weather resistant. The Deutsch DT and DTM series are popular in FSAE, although many varieties exist.
+This is probably the most common type of connector on an FSAE car. These connect directly to wires or cables, and can interface either with other free hanging connectors or with panel mount connectors. In FS these will usually need to be weather resistant. The Deutsch DT and DTM series are popular in FS, although many varieties exist.
 ===Panel Mount===
-Panel mount connectors are used to allow a circuit to interface with the rest of the car. In FSAE these will usually need to be resistant to the weather. They can either be soldered directly to a PCB, or they can be connected to a circuit via wires.
+Panel mount connectors are often used to allow a circuit inside of a housing, such as a PCB, to interface with external devices. In FSAE these will usually need to be resistant to the weather. They can either be soldered directly to a PCB, or they can be connected to a circuit via wires.
 ===PCB Mount===
 These are connectors that are soldered to PCBs. They are usually not weather resistant, and are only used inside a housing - either to connect two PCBs, or to connect a PCB to a standalone panel mount connector.
@@ Line 40: / Line 46: @@
 PCBs can be directly connected together inside a housing without the use of wires. This is usually done for modularity (so that you can use a PCB for multiple functions), interfacing with a premade part (e.g., a microcontroller), or for packaging reasons. Care needs to be taken so that the solder joints on the connectors are not being overly stressed with the weight of a PCB.
 ==OEM Connectors==
-Many off-the-shelf parts either come with a pre-attached connector, or have a connector integral to the part itself. Some parts include a mating connector, while others will require one to be sourced.
+Many off-the-shelf parts either come with a pre-attached connector, or have a connector integral to the part itself. Some parts include a mating connector, while others will require one to be sourced. OEM connectors intended for mass production often have significantly lower connect/disconnect cycle ratings than other connectors.
 ==Standard Connectors==
@@ Line 55: / Line 61: @@
 ==Considerations==
 ===Density===
-Connectors can vary greatly in how close together the pins are. A connector with a higher density will usually be lighter, but they can be harder to assemble.
+Connectors can vary greatly in how close together the pins are. A connector with a higher density will usually be lighter and easier to package, but they can be more expensive and harder to assemble.
 ===Connect/Disconnect Cycle Rating===
-As connectors are connected and disconnected, the contacts and components will deteriorate. The cycle rating is how many times this can happen while still meeting the specifications for maximum resistance and pull force. Many connectors (like board to board connectors) are only rated to tens of cycles, while some (like USB connectors) are rated for thousands of insertions.
+As connectors are connected and disconnected, the contacts and components will deteriorate. The cycle rating is how many times this can happen while still meeting the specifications for minimum resistance and pull force. Many connectors (like board to board connectors) are only rated to tens of cycles, while some (like USB connectors) are rated for thousands of insertions.
 [[Category:Electronics]]