What connectors do you use?

May. 13, 2024

What connectors do you use?

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Originally Posted by wizard

Originally Posted by

Here are some ideas or comments that I have!

Many of the cheap connectors mentioned above require crimpers and assembly / disassembly tools. This can add to the expense of these connectors significantly for a small project so look before you leap. Also disassembly tools are required unless you want to throw out a wronly assembled connector. It happens to almost everyone from time to time.

Drag Chain and wire gauge

Hey Ziggy,

you find the definitions and wire sizes in American Wire Gauge, it has a chart for comparison of AWG to cross-section area.

As a quick reminder,

6 mm² corresponds to 9 AWG
5.3 mm² corresponds to 10 AWG
2.5 mm² corresponds to 13 AWG
1.5 mm² corresponds to 15 AWG
0.75 mm² corresponds to 18 AWG
0.5 mm² corresponds to 20 AWG

In engineering, wires are not measured in wire diameter but in cross-section area, because the cross section is directly proportional to its strength and weight, and inversely proportional to its resistance. The cross-sectional area is also related to the maximum current that a wire can carry safely. Wire diameter is not.

There is a nice comparison chart for American Wire Gauge to IEC 60228 in this file:

Link to FSWAdditional reading:
What is the difference between towline cable and ...

Comparison of SWG (red), AWG (blue) and IEC 60228 (black) wire gauge sizes from 0.03 to 200 mm² to scale on a 1 mm grid – in the SVG file, hover over a size to highlight it

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Ziggy:

Also, is it the 60Hz from the AC or the noise from the router that is the problem.

60 Hz is EMI dirt and it is a high current, since it is a .75 kW motor, with 120 V there flows 6.25 A AC. Control signals for the stepper motors are also very dirty and the currents are high, up to 6 A, stepper motors are driven by power electronics. There is nothing that should not be shielded.

Ziggy:

Wouldn’t it just be simpler to shield the control cables?

You mean EMI will disturb stepper signals more than it will disturb router operation?
But shielding does not only prevent EMI to act on a cable but also to come from a cable. So if you don’t want the stepper signals to be disturbed, I believe both should be shielded. Both carry dirty power signals. And you don’t know what additional wires you will drag in your drag chain in the future.

If you replace the cable of the router anyway, why would you use an unshielded cable at all? For cost? But you do this only once and if you have EMI problems it is sometimes very, very hard to find the cause. I’ve learned to avoid them where I can.

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