Easier alternatives for wire-to-board cable attachment - Page 1
Forum section: electronics / general

author: dkonigs
author_rank: Regular Contributor
timestamp: March 02, 2021, 05:21:49 pm
content: So I'm working on a project that involves this "sensor probe" at the end of a captive cable:Right now I'm connecting the cable to the PCB by soldering the wires directly into holes at the edge of the PCB, and using a zip-tie at the unpopulated end of said PCB as a sort-of strain relief. While this does work, the process of assembling it is fiddly and annoying. If I ever want to make more than one or two of these, I can see it becoming a major time/frustration bottleneck.I'm wondering if there are any good solutions for making this process easier. For example, some sort of connector I could crimp onto the wires in one or two actions. (any connector that requires manually fiddling/crimping pins onto each conductor then inserting into a shell would likely be even more annoying than how I'm doing it now) I also understand that the same connector could be easy/difficult depending entirely on tooling, so suggestions along those lines are also welcome.

author: mon2
author_rank: Frequent Contributor
timestamp: March 02, 2021, 05:42:27 pm
content: If your budget permits, have you considered a 'magsafe' style of interconnect?Quote

author: Monkeh
author_rank: Super Contributor
timestamp: March 02, 2021, 05:51:47 pm
content: Outsource the assembly of the cable to someone else?

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: March 02, 2021, 05:56:25 pm
content: 1) Use a connector2) Use a "board-in" connector - something with male pins that get soldered into the PCB - quite common on consumer stuff or where space is limited3) Use surface pads not through-hole, and put paste on them in the stencil design. Pre-tinned wires can tehn be soldered on very quickly, especially if they are positioned so the cable cores get fanned out. If doing a lot, use a solder-pot and wide -blade stripper to strip and tin quickly

author: ANTALIFE
author_rank: Frequent Contributor
timestamp: March 02, 2021, 10:42:14 pm
content: Is that an FTDI cable you have OP? If so why not get one with a header at the end and then just get a mating connector on the PCB?Would still recommend you use the cable tie on the PCB, as I don't think any of the FTDI cable connectors are locking

author: dkonigs
author_rank: Regular Contributor
timestamp: March 02, 2021, 11:02:20 pm
content: Quote from: mikeselectricstuff on March 02, 2021, 05:56:25 pmUsing a connector (JST or Molex, regular or board-in) requires having an easy way to crimp those metal pins onto the end of the cable wires. If doing that requires stripping each one individually, then fiddling with a pair of crimpers and a tiny metal doohickey for each one, then its not any easier than simply soldering the wires directly to the board.Is there some sort of off-the-shelf tool that'll let me attach these connectors as easily as I can crimp an IDC or RJ45 connector onto the end of its cable?

author: dkonigs
author_rank: Regular Contributor
timestamp: March 02, 2021, 11:05:07 pm
content: Quote from: ANTALIFE on March 02, 2021, 10:42:14 pmNo, its not an FTDI cable. The other end of this cable is actually a 6-pin Mini-DIN plug. These are easy to get by simply buying M-M PS/2 cables and chopping them in half, but I'm certainly open to other options for this. (My attempts at researching only really dug up Mini-DIN and M12 connectors as options, and M12 is both too expensive and too chunky on the receptacle side.)

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: March 03, 2021, 12:06:35 am
content: Quote from: dkonigs on March 02, 2021, 11:02:20 pmUsing a decent stripper ( hint : strip all cores in one go) and the proper JST crimp tool, should be well under a minute to strip and crimp.QuoteThere are IDC connectors for JST/.Molex style headers, but crimp tool probably fairly expensive.Another option is SMD single-core IDC connectors like these :https://www.avx.com/products/connectors/wire-to-board/idc-connectors-14-28-awg/The "standard" ones need a press-down tool, with the "capped" ones, you just insert the wire and push teh cap down. Neither require strippingBut if you're doing more than 50 or so I'd be getting quotes from a Chinese cable assembly house

author: dkonigs
author_rank: Regular Contributor
timestamp: March 03, 2021, 12:33:48 am
content: Quote from: mikeselectricstuff on March 03, 2021, 12:06:35 amThanks! I've never seen IDC connectors made for regular wires (as opposed to intended-for-IDC ribbon cables), but I guess everything exists if you know where to look.I'll need to dig into their product line to decide exactly what connector is best for my needs, but this looks like exactly what I need. No real reason to bother with a separate connector/socket arrangement beyond ease of assembly, and these could end up being pretty easy.

author: phil from seattle
author_rank: Super Contributor
timestamp: March 03, 2021, 03:09:05 am
content: I dunno, my first thought after reading m-m mini-DIN was this:It doesn't look like 6 pin but you get the idea.

author: dkonigs
author_rank: Regular Contributor
timestamp: March 03, 2021, 06:07:07 am
content: Quote from: phil from seattle on March 03, 2021, 03:09:05 amThat actually is a 6-pin Mini-DIN female jack. Its what the other end of this cable plugs into.

author: mon2
author_rank: Frequent Contributor
timestamp: March 03, 2021, 11:37:53 am
content: Apply the above right angled din connector on your pcb.Then ship a ps/2 male to male cable with the kit.The ps/2 male to male cable should rather simple to source and inexpensive from Asia.

author: Styno
author_rank: Regular Contributor
timestamp: August 02, 2021, 12:51:02 pm
content: - Stripped wire, crimp ferrule and poke-home connector.- Unstripped wire and idc connector.These kinds of surface mount connectors are used for e.g. led lighting. They are available from e.g. AVX, are cheap and great for automated assembly. As press-down tool a plumbers pliers works fine.Edit: ugh, mikeselectricstuff posted this Way before me already.