PCB to wire - would it last? How to help it last?

Hardware inside and outside of the ECU
Post Reply
User avatar
AndreyB
Site Admin
Posts: 11041
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

PCB to wire - would it last? How to help it last?

Post by AndreyB »

Trying to make a PnP adapter using one of our PCB breakout boards. What are the things to consider/tricks etc to make this better rather than worse?
Attachments
20200817_234615.jpg
20200817_234615.jpg (477 KiB) Viewed 500 times
20200817_234606.jpg
20200817_234606.jpg (727.3 KiB) Viewed 500 times
20200817_234554.jpg
20200817_234554.jpg (651.03 KiB) Viewed 500 times
https://rusefi.com/s/howtocontribute
very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions
my skype is arro239

stefanst
contributor
contributor
Posts: 660
Joined: Wed Feb 17, 2016 12:24 am
Location: USA 08530

Re: PCB to wire - would it last? How to help it last?

Post by stefanst »

The most common killer of wires is continued bending. The highest bending stress is where the copper leaves the insulation jacket. This is where ending will occur and where, eventually the wire will fail and break off. The way to deal with it is to eliminate bending at that point.
Crimped connectors achieve this by having two crimps- one on the actual wire and one on the insulation, making sure that no bending can occur.
For wires soldered to PCBs, it's a bit more tricky.
One way to help this is to have the wire weaved through one or two holes in the PCB, thus fixing the location of the insulation.
You could also use crimped ferrules with a plastic sleeve that locates the insulation.
wire_end_crimp.jpg
wire_end_crimp.jpg (288.51 KiB) Viewed 480 times
Lastly, if none of these is available, gobs of hot-glue around the wires will help fixing the insulation in place and avoiding bending.

User avatar
AndreyB
Site Admin
Posts: 11041
Joined: Wed Aug 28, 2013 1:28 am
Location: Jersey City
Github Username: rusefillc
Slack: Andrey B

Re: PCB to wire - would it last? How to help it last?

Post by AndreyB »

Wow, today I've learned!

Speaking about wire itself, I am using six colors from https://www.shamrockcontrols.com/category-s/603.htm those melt around soldering point

Matt has different colors from https://www.waytekwire.com/item/WM20-6/WM20-6-Automotive-Cross-Link-Wire-/ those do not melt from soldering.
https://rusefi.com/s/howtocontribute
very limited telepathic abilities - please post logs & tunes where appropriate - http://rusefi.com/s/questions
my skype is arro239

Post Reply