Software options for designing electrical connector / wiring adapters - Page 1
Forum section: electronics / projects

author: weirdaljr
author_rank: Contributor
timestamp: February 16, 2015, 09:34:27 pm
content: Hello,I am a hobbyist interested in learning what software would be best for designing basic electrical wiring connectors and adapters. I am willing to learn any software and invest in purchasing if need be, but I do not even know what software would be best for this, whether it be a CAD program or derivative or electronic schematic/prototyping type of software, or something else? I wanted to ask this community for recommendations so I spend my time and money (if need be) on the proper solution for this.So give a basic example, lets say I want to design a adapter, or power supply connector from one type or another to submit to manufacturing companies for quotes. For a more specific example let me use a common one I see all the time... a ATX power supply to? Adapter. For giggles lets say a Xbox Power Brick to a proprietary electric shaver power plug port (I know this is impractical, just for a example of the basic level of software I am looking for). Something that can handle completely proprietary custom electrical connectors that could export manufacturing schematics.I am new her, and a beginner in any form of engineering, but I am willing to learn and I wanted to ask for your recommendations.Thanks for your time.

author: moffy
author_rank: Super Contributor
timestamp: February 16, 2015, 10:52:04 pm
content: Any electrical/electronic schematic software will do the job:1. Free: KiCAD2. Purchase and Popular: Eagle CAD3. Free from RS Components: DesignSpark

author: Falcon69
author_rank: Super Contributor
timestamp: February 16, 2015, 11:36:15 pm
content: SolidWorks is probably your best bet for actually designing the connector as it gives you a simulation and 3D. It is expensive though, but if you are in school, like me, you can get a student copy and your local college will probably offer a CAD course for SolidWorks. There are other programs of course, AutoCAD Rhino, AutoDesk, etc. There are free programs which aren't too bad, but not as in depth as SolidWorks or other professional version. I haven't used it yet, but Google Sketchup I've heard isn't it bad, and you can export/import .dxf files as well.

author: Mechatrommer
author_rank: Super Contributor
timestamp: February 17, 2015, 12:07:19 pm
content: Quote from: weirdaljr on February 16, 2015, 09:34:27 pmyou are in mechanical design domain. you only liase with ee person on metal contact dimension to avoid electrical specific failure. the robustness of the connection and material type lie in you as mechanical designer. solidworks, autodesk autocad or inventor may cost you an arm, for a simple extruded, subtracted shapes or the like as an adapter, maybe the free googlesketchup or blender will do the job...

author: SL4P
author_rank: Super Contributor
timestamp: February 17, 2015, 12:53:00 pm
content: Yes - the spec for an adapter would typically come from the project / electronics design team - and the electrical / electronic schematic would already be defined as a part of the larger product project. Only then would the adapter assembly come into focus for a production design.If using existing 'standard' connectors - you can (probably) access reference drawings for each connector family - and document the specific characteristics of the assembly (wire types, strain relief etc). Worst case - you create special connectors and parts within your nominated CAD package.Then the adapter schematic and your mechanical/physical assembly drawings would be sent to the manufacturer along with the BOM.If you are doing both - depending on the complexity of the schemaic and mechanical drawings - you may choose one r more packages suited to the task.I've used - ACAD, Visio, Altium/Protel, Excel, pen & paper - and others at different times to do all or part of what you're asking.The recent versions of Altium include various moduies to do all of what you want, but have a steep learning curve and entry price - and may over complicate simple cabling/adapter projects.

author: Falcon69
author_rank: Super Contributor
timestamp: February 18, 2015, 09:56:41 am
content: The other thing you would want to consider in the design phase of a connector, is the ease of adapting your design.What I mean by this is, for example, in SolidWorks, you can configure a part so that the part itself kinda redesigns itself based on perimeters you input. Like, you design/draw it up for say a 3 pin connector, but later you want it to be a 14pin connector, but with the same design basically. This is where configuring the part comes in. SolidWorks recalculates the 3 pin part, and makes it into a 14 pin part (or any amount of pins you want). It's quick and easy, and the part becomes a 14pin and all files, including .DXF, imports as a 14 pin part.With the configuration tool, the part can change more than just its pin count. It can also change it's overall size. So if you desire the pins to handle more current than the original design, which means the pins will need to be a larger diameter. You can input that configuration, and the part will stretch and conform to the new perimeters.I have not used the free cad programs, like Google Sketchup, but this is one feature of SolidWorks I REALLY like.

author: weirdaljr
author_rank: Contributor
timestamp: February 19, 2015, 03:01:25 pm
content: Thanks so much for the replies guys! They have been really helpful.Based on your suggestions and research I am doing with the software companies I am going to try to get trial versions of Altium and Soldworks this week to get a feel for them.Since each companies offer multiple software solutions and suites, I just want to be sure would it be Altium Designer and Solidworks Electrical that would be appropriate for this?Thanks again all!

author: free_electron
author_rank: Super Contributor
timestamp: February 19, 2015, 04:29:38 pm
content: There is a special module for Solidworks and Catia that will exactly do that.You pick the connectors and wire up the connection as a schematic.then you go to the mechanical CAd module and you place the connectors and tell the tool the distances.you create the wiring loom by stringing the wires. and specifying : for this wire i need this thicknes that color. etc.At the end you get a bill of materials how many meters of what wire you need , how many zip ties,and the tool create diagrams so some person can actually build these things. it will even spit out a design for a peg-board so you can build these harnesses.http://www.solidworks.com/sw/products/3d-cad/electrical-cable-harness-and-conduit-design.htmVeSys is another such a toolhttp://www.mentor.com/products/electrical-design-software/Here is a tutorial using SolidEdge:http://support.industrysoftware.automation.siemens.com/training/se/en/ST3/pdf/spse01696.pdf

author: weirdaljr
author_rank: Contributor
timestamp: February 20, 2015, 02:06:50 pm
content: Quote from: free_electron on February 19, 2015, 04:29:38 pmThanks for this, these were great suggestions! I have like 4 trials installed and tried a tutorial, but I wanted to ask about molded cables. I noticed you mentioned cable ties, and the Solid works site for harnesses seems like it mainly just for similar harnesses, made with cable ties or wire loom.Are any of the mentioned software better if I have a end goal of molded wiring with molded connectors is one of the software packages better for that?Thanks again.

author: weirdaljr
author_rank: Contributor
timestamp: June 12, 2015, 05:07:12 pm
content: Quote from: weirdaljr on February 20, 2015, 02:06:50 pmI just wanted to follow up and see if anyone had a recommendation for me to be able to design a production grade molded wire connector or adapter such as this? Or can you do from the suggestion solutions and not just end up with a wire tied type of harness design?

author: daedalus
author_rank: Regular Contributor
timestamp: June 13, 2015, 03:39:45 am
content: +1 for solidworks and Altium.With regards to overmoulding, the best bet would be to model the cable harness in solidworks, then model the overmould volumes, then contact a few suppliers. Don't get too deep into the design until you have talked to a few people who actually do this on a production scale. There is usually a sizable tooling cost attached with overmoulding, but depending on the volume there are some less expensive options.On the one job I had to do this for I prototyped with rapid prototyped shells of the moulding, and back-filling with epoxy resin, then ended up getting help from a specialist with the mould design. I haven't used these guys, but they might be a good starthttp://www.overmoldtooling.com/iscmold.html.oh one more thing, you don't need anything more then solidworks standard for this, the solidworks routing module wont be much help in a job like this, its more for when you need to route cables around a complex assembly then work out the run lengths.RE tool costs, Altium does academic pricing, as does solidworks. Solidworks also rent seats out, talk to a VAR for the best options. If you cant do academic, then Altium also have a less advertised "startup program" where you get full AD15 for a year for £2000, then pay remainder after Y1 for perpetual seat, if you are a new company (they have been known to be flexible on terms). If its a one-off job, there are lots of consultants out there who could do this with their tools for a fee (its a couple days a harness depending on complexity)