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apelly
What are your favourite wire to board connectors?
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on: September 09, , 12:38:54 pm »
As a couple of projects come closer to fruition, I'm starting to look at wire to board connectors.
Man there's a lot. And it often isn't obvious which is the mating part.
There are a bunch of guys with years more experience than me here, and you've all been through this before.
What's the collective wisdom on parts that are:
- Readily available
- Reasonably priced
- Not orientation agnostic
- A bit clippy, or with some kind of retention
- Good for a few tens of insertions
- Hand solderable
- Available in a few spacings, for the occasional higher voltage connection
- Fairly small, or at least short when parallel to the board
I don't really want to crimp a lot either. Some sort of pressure fit like the old IDE cables would be nice.
DenzilPenberthy
Re: What are your favourite wire to board connectors?
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Reply #1 on: September 09, , 02:15:38 pm »
Molex KK are always my standard thing for this. Cheap, ubiquitous, secure.
Buy the crimp tool and never look back
metalphreak
Re: What are your favourite wire to board connectors?
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Reply #2 on: September 09, , 02:17:21 pm »
Molex minifit junior or equivalent. Move up to the larger version for higher current (ie PC ATX style, PCI-E style and bigger).
It seems to be a fairly common standard amongst manufacturers as far as the keying of pins goes, so there's heaps to choose from.
http://www.molex.com/molex/products/group?key=wire_to_board_connectors&channel=products
Just look at the current rating and pin pitch you want. They do the connectors in various versions (ie latching, PCB mounting holes, with clips, gold plated, with drain holes (?!))
« Last Edit: September 09, , 02:19:29 pm by metalphreak »
ajb
Re: What are your favourite wire to board connectors?
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Reply #3 on: September 09, , 07:13:38 pm »
If you might find yourself doing a large number of terminations, it's worth considering IDC options. TE's MTA series IDC connectors intermate with Molex KK and equivalents, and the hand tool is reasonably priced (in the realm of non-generic tooling, anyway) at a couple hundred bucks. The same ratcheting handle works with a number of different heads that will accomodate the .100" and .156" MTA connectors as well as a bunch of others. In the same vein, JST's XH connectors (and their ubiquitous knockoffs) have an IDC equivalent in the NR series, which also has an interchangeable head hand tool available for a few hundred bucks.
German_EE
Re: What are your favourite wire to board connectors?
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Reply #4 on: September 09, , 07:27:31 pm »
I hate to go against the grain here but my favorite wire to board termination is a turret terminal and some solder. No problem with dirty or loose connections.
Should you find yourself in a chronically leaking boat, energy devoted to changing vessels is likely to be more productive than energy devoted to patching leaks.
Warren Buffett
penfold
Re: What are your favourite wire to board connectors?
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Reply #5 on: September 09, , 10:25:28 pm »
If its coming from a wiring harness that I have no control over I rather like the molex mini-fit jr range, they're chunky enough to avoid hack handed service technicians pulling on the wires to release them and come with strain relief options
For everything else, I try and use as much ribbon cable as possible, for 'outside world' connectors that have to be mounted away from the main boards i aim to get them on small PCBs with ribbon cable for internal interconnections.
I really like turret terminals and tags because they big, easily inspected, nice to work with (and look pretty), but I'd struggle to work them into a product because of assembly time and field replacement targets
mikeselectricstuff
Re: What are your favourite wire to board connectors?
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Reply #6 on: September 09, , 10:31:10 pm »
JST XH (2.5mm) and PH(2mm)
very cheap, well designed, good retention polarisation, SMD and TH versions, PH available in 1 and 2 row versions.
Crimp tools are very good, though expensive.
Way better than Molex's overpriced, poorly retaining, single-side contact KK
Youtube channel:Taking wierd stuff apart. Very apart.
Mike's Electric Stuff: High voltage, vintage electronics etc.
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T3sl4co1l
Re: What are your favourite wire to board connectors?
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Reply #7 on: September 09, , 10:45:08 pm »
Molex SL. But KK are good too.
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hamdi.tn
Re: What are your favourite wire to board connectors?
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Reply #8 on: September 10, , 12:06:53 am »
Molex KK are a good choice for this
apelly
Re: What are your favourite wire to board connectors?
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Reply #9 on: September 10, , 01:23:41 am »
The tips here have provided surprisingly useful search criteria. Thanks guys. There's no doubt you've saved me days of annoyance, link loops, frustration, unreliable notes and worry.
While I think of it; thanks for nothing Mister Manufacturer-Part-Number-Creator. I'm sure they mean well, and I realise the numbers mean something, but bloody hell. At least you'll get relevant google hits when searching for one I suppose.
The JST XH/PH connectors do indeed appear to be cheaper for a whole connection in reasonably small quantities.
Anyway, whatever I choose from this thread I'll probably buy a selection of and stick with for some time. So I have a couple of follow up questions:
The consensus is crimping. Crimping annoys me. Probably because I can never trust my cheap crimpers and connectors. The next obvious (over asked) question is do you use the recommended crimper? Without getting into a protracted discussion with the pedants about the pros and cons of using the manufacturers specified crimper; has anyone experienced good results with an after market one? I'll be buggered if I'm going to pay $500+ for a crimper. (but maybe this is a stupid attitude)
The MTA and NR IDC connectors are cool, and what I asked for, but not what I wanted; they still require a special tool.
Maybe I'm making too much of this. Maybe crimping isn't a big deal when you have the hang of it. Does it take long to get good at making, say, a 5 wire connection that's tidy and secure?
I hate to go against the grain here but my favorite wire to board termination is a turret terminal and some solder. No problem with dirty or loose connections.
I've just been looking at these for test points. Maybe I'm searching in the wrong place, but they seem to be 25-30 cents in lowish volumes. This seems outrageous. Where are you buying them from?
penfold
Re: What are your favourite wire to board connectors?
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Reply #10 on: September 10, , 08:45:17 am »
For molex KK and similar connectors, I have had good results with a cheap generic crimper, as long as one uses an appropriate wire size for the terminal and gets the stripping distance right, its fine. But that being said, the official molex crimper is very nice, it has a little tab to hold the terminal before you insert the wire and crimp.
deephaven
Re: What are your favourite wire to board connectors?
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Reply #11 on: September 10, , 09:01:03 am »
If you want a small connector, the Molex PicoBlade is pretty good (1.25mm pitch). You can buy pre-crimped wires for them which sidesteps the requirement for a crimping tool.
I use the Molex KK series if size is less of an issue. Very handy to have straight and right-angled versions available. I have never had a problem with poor connections using them,
JST make very good connectors but, as you have found out, the crimper's price makes my eyes water. They do have an excellent free sample facility where you just go to their website and make up a 'basket' of samples you want and you get them in a couple of days. This is in England, YMMV.
DenzilPenberthy
Re: What are your favourite wire to board connectors?
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Reply #12 on: September 10, , 09:44:23 am »
This is an interesting thread. Thumbing through a catalogue of connectors is a pretty bewildering experience. It's interesting to see what everyone else uses.
I was just looking at those JST connectors and thinking 'yeah, they look pretty handy' but oh my god! £895 for the crimp tool!!! That's over a grand with the VAT! I thought I was really treating myself when I shelled out for the KK crimper
metalphreak
Re: What are your favourite wire to board connectors?
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Reply #13 on: September 10, , 11:07:22 am »
For relatively cheap multipurpose crimpers, the Engineer Japan PA-21 (and others depending on which crimps you are doing) are pretty versatile. You have to crimp the wire and insulation separately in two steps, but for small volume stuff they're adequate.
PA-21 http://www.engineer.jp/en/products/pa21e.html
Application Chart http://www.engineer.jp/en/products/pa21applicatn_chart.html
Similar info on their site for the PA-20 and PA-09. I've just got a set of PA-09s and PA-21s to cover everything.
mcinque
Re: What are your favourite wire to board connectors?
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Reply #14 on: September 10, , 11:15:23 am »
JST for me like mike said.
Dago
Re: What are your favourite wire to board connectors?
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Reply #15 on: September 10, , 11:38:29 am »
JST XH (2.5mm) and PH(2mm)
very cheap, well designed, good retention polarisation, SMD and TH versions, PH available in 1 and 2 row versions.
Crimp tools are very good, though expensive.
Way better than Molex's overpriced, poorly retaining, single-side contact KK
I have recently been using 2 pin PH-series connectors as my go-to board power connector. I like the size and the retention and all but damn they are tedious to crimp, at least with my 15€ eBay crimping tool. Main problem is getting the contact seated in the jaws so that the wire is the right way in (can't really see inside the jaw and cannot really position the wire beforehand). Never used the genuine crimping tool.
Come and check my projects at http://www.dgkelectronics.com ! I also tweet as https://twitter.com/DGKelectronics
mikeselectricstuff
Re: What are your favourite wire to board connectors?
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Reply #16 on: September 10, , 12:43:35 pm »
JST XH (2.5mm) and PH(2mm)
very cheap, well designed, good retention polarisation, SMD and TH versions, PH available in 1 and 2 row versions.
Crimp tools are very good, though expensive.
Way better than Molex's overpriced, poorly retaining, single-side contact KK
I have recently been using 2 pin PH-series connectors as my go-to board power connector. I like the size and the retention and all but damn they are tedious to crimp, at least with my 15€ eBay crimping tool. Main problem is getting the contact seated in the jaws so that the wire is the right way in (can't really see inside the jaw and cannot really position the wire beforehand). Never used the genuine crimping tool.
This is why the proper JST tool is so good - you insert the contact into a carrier plate, which then hinges into place it in the crimping jaws ready to insert the wire & crimp - very quick and hard to mis-place/misalign anything. Hard to see in most catalogue pictures but you can see it in the instructions :
http://www.farnell.com/datasheets/.pdf
Youtube channel:Taking wierd stuff apart. Very apart.
Mike's Electric Stuff: High voltage, vintage electronics etc.
Day Job: Mostly LEDs
Dago
Re: What are your favourite wire to board connectors?
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Reply #17 on: September 10, , 01:13:47 pm »
JST XH (2.5mm) and PH(2mm)
very cheap, well designed, good retention polarisation, SMD and TH versions, PH available in 1 and 2 row versions.
Crimp tools are very good, though expensive.
Way better than Molex's overpriced, poorly retaining, single-side contact KK
I have recently been using 2 pin PH-series connectors as my go-to board power connector. I like the size and the retention and all but damn they are tedious to crimp, at least with my 15€ eBay crimping tool. Main problem is getting the contact seated in the jaws so that the wire is the right way in (can't really see inside the jaw and cannot really position the wire beforehand). Never used the genuine crimping tool.
This is why the proper JST tool is so good - you insert the contact into a carrier plate, which then hinges into place it in the crimping jaws ready to insert the wire & crimp - very quick and hard to mis-place/misalign anything. Hard to see in most catalogue pictures but you can see it in the instructions :
http://www.farnell.com/datasheets/.pdf
I wonder how these would work: http://www.ebay.com/itm/
Come and check my projects at http://www.dgkelectronics.com ! I also tweet as https://twitter.com/DGKelectronics
Re: What are your favourite wire to board connectors?
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Reply #18 on: September 10, , 01:30:04 pm »
That looks like a "convertible" version of the PA-09 / PA-20. They're reasonable crimpers but I'm not sure I really see the benefit of the interchangeable dies - especially at that price.
david77
Re: What are your favourite wire to board connectors?
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Reply #19 on: September 10, , 01:52:58 pm »
I mainly use this generic sort of connector: https://ec.setron.de/products/--2pybeige.aspx
Cheap generic crimpers are available for these, I've recently acquired one from Hong Kong. Before I used to solder them, not good for production use I guess but in a hobbyist environment not a big deal.
One thing I like about them is you can easily remove the pins without any special tool.
poorchava
Re: What are your favourite wire to board connectors?
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Reply #20 on: September 10, , 03:26:27 pm »
For low pin count interconnects I use generic 2.54mm crimped "goldpins", for larger pin counts or higher currents generic 2.54mm IDC connectors. IDC connectors can be easily crimped using an ordinary vise, and for crimped ones I use my generic $10 crimp tool. All this works very well and is really cheap.
I love the smell of FR4 in the morning!
Corporate666
Re: What are your favourite wire to board connectors?
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Reply #21 on: September 10, , 09:22:43 pm »
The consensus is crimping. Crimping annoys me. Probably because I can never trust my cheap crimpers and connectors. The next obvious (over asked) question is do you use the recommended crimper? Without getting into a protracted discussion with the pedants about the pros and cons of using the manufacturers specified crimper; has anyone experienced good results with an after market one? I'll be buggered if I'm going to pay $500+ for a crimper. (but maybe this is a stupid attitude)
I said the same thing as I spent countless frustrating hours messing with cheaper crimpers. After getting the real thing (Molex in this case), it was a breeze. It comes down to two paths... either you are crimping a lot of wires, or you aren't. If you aren't, then doing a few by hand isn't that big of a deal, and/or you can have a local wire company make up the wires for you (Squires in the USA is great for this). If you are doing a lot, then you can again either outsource the crimping or buy a higher volume crimper - in Molex's case they had a pneumatic unit.
But having the right crimping tool and die makes all the difference, not only in ergonomics (holding the terminal correctly), but also in correct crimps which means less warranty work down the line.
It's not always the most popular person who gets the job done.
eneuro
Re: What are your favourite wire to board connectors?
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Reply #22 on: September 10, , 10:52:38 pm »
I like those 3mm screws with additional soldered copper wires for power tracks when needed
It require some "art work" but quite nity
12oV4dWZCAia7vXBzQzBF9wAt1U3JWZkpk
“Let the future tell the truth, and evaluate each one according to his work and accomplishments. The present is theirs; the future, for which I have really worked, is mine” - Nikola Tesla
-||-|-
Alex30
Re: What are your favourite wire to board connectors?
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Reply #23 on: September 11, , 01:00:32 am »
Before everyone starts buying crimpers I would see how you go just using needle nose pliers. I have a crimper but I often just grab my pliers because they're closer and I can do the job just as good provided it's just thin wire (not too thin, not too thick).
mikeselectricstuff
Re: What are your favourite wire to board connectors?
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Reply #24 on: September 11, , 11:52:31 am »
Before everyone starts buying crimpers I would see how you go just using needle nose pliers. I have a crimper but I often just grab my pliers because they're closer and I can do the job just as good provided it's just thin wire (not too thin, not too thick).
..and you don't care too much about long-term reliability.
Crimping is all about achieving an airtight compression of wire and contact. Using a totally wrong tool is unlikely to achieve this
Youtube channel:Taking wierd stuff apart. Very apart.
Mike's Electric Stuff: High voltage, vintage electronics etc.
Day Job: Mostly LEDs
If you're diving into PCB design, one of the most critical decisions you'll make is choosing the right connectors. Whether you're looking for PCB connector types, a connector selection guide, or specifics on board-to-board connectors, wire-to-board connectors, or RF connectors, this guide has you covered. We'll break down the essentials of each connector type, their applications, and tips for selecting the best option for your project. Let's explore everything you need to know to ensure reliable and efficient connections in your printed circuit board designs.
Why Connectors Matter in PCB Design
Connectors are the unsung heroes of PCB design. They create the vital links between components, boards, and external devices, ensuring seamless transmission of power, signals, and data. A poorly chosen connector can lead to signal loss, mechanical failure, or even complete system breakdowns. On the other hand, the right connector enhances performance, durability, and ease of assembly. With countless options available, understanding PCB connector types and their specific uses is the first step to a successful design.
What Are the Main Types of PCB Connectors?
PCB connectors come in various shapes, sizes, and configurations, each tailored for specific functions. Below, we’ll explore the most common types, focusing on their structure, purpose, and typical applications.
1. Board-to-Board Connectors
Board-to-board connectors are designed to link two PCBs together, often used in compact devices where space is limited. These connectors allow for direct communication between boards without the need for external wiring, reducing clutter and improving reliability.
- Key Features: Available in pin headers, sockets, and mezzanine styles. They often support high-density connections with pitch sizes as small as 0.4mm.
- Applications: Found in smartphones, tablets, and multi-board systems where stacking is necessary.
- Advantages: Compact design, high signal integrity, and support for high-speed data transfer (up to 10 Gbps in some cases).
- Considerations: Ensure proper alignment during assembly to avoid connection issues. Mating cycles (typically 10 to 100) should match the expected usage.
2. Wire-to-Board Connectors
Wire-to-board connectors facilitate connections between a wire or cable and a PCB. They are essential for bringing external power or signals into the board and are widely used across industries.
- Key Features: Often feature crimp terminals or insulation displacement contacts (IDC). Available in pitches ranging from 1.0mm to 5.08mm.
- Applications: Common in automotive systems, home appliances, and industrial equipment.
- Advantages: Easy to install and replace, with secure locking mechanisms to prevent disconnection.
- Considerations: Pay attention to current and voltage ratings (e.g., some handle up to 10A at 250V) to match your circuit's requirements.
3. RF Connectors
RF (Radio Frequency) connectors are specialized for high-frequency signals, typically in the range of 3 kHz to 300 GHz. They are built to maintain signal integrity with minimal loss or interference, making them crucial for communication devices.
- Key Features: Designed with controlled impedance (often 50 ohms or 75 ohms) to prevent signal reflection. Common types include SMA, BNC, and MCX connectors.
- Applications: Used in wireless devices, antennas, GPS modules, and test equipment.
- Advantages: Low signal loss and high-frequency performance (some support up to 18 GHz).
- Considerations: Choose connectors with proper shielding to avoid electromagnetic interference (EMI). Mating durability (often 500 cycles for SMA types) is also a factor.
4. Other Notable PCB Connector Types
Beyond the primary categories, several other connectors play vital roles in PCB design:
- Wire-to-Wire Connectors: Used to join two sets of wires without involving a PCB, often in power distribution systems.
- Edge Connectors: Found in plug-in cards, these connect directly to the edge of a PCB, common in older computer hardware with mating cycles around 25-50.
- Power Connectors: Designed for high-current applications, supporting up to 40A in some industrial setups.
A Connector Selection Guide for PCB Design
Selecting the right connector for your PCB design can feel overwhelming with so many options. However, focusing on a few key factors can simplify the process. This connector selection guide will help you make informed decisions tailored to your project needs.
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1. Understand Your Electrical Requirements
Start by evaluating the electrical demands of your circuit:
- Current and Voltage: Ensure the connector can handle the required load. For example, a power connector for industrial use might need to support 20A at 600V, while a signal connector may only need 1A at 5V.
- Signal Type: For high-speed data or RF signals, prioritize connectors with low impedance mismatch and minimal insertion loss (e.g., under 0.5 dB for RF connectors).
- Frequency Range: RF connectors must match the frequency of your application. A connector rated for 6 GHz won’t perform well in a 12 GHz system.
2. Consider Mechanical Constraints
The physical aspects of your design also influence connector choice:
- Size and Pitch: In compact designs, opt for connectors with smaller pitches (e.g., 0.5mm for board-to-board connectors) to save space.
- Mating Cycles: If frequent connections and disconnections are expected, choose a connector with a high mating cycle rating (e.g., 100 cycles for wire-to-board connectors).
- Mounting Type: Decide between through-hole or surface-mount connectors based on your assembly process. Surface-mount options are often preferred for automated production.
3. Evaluate Environmental Factors
The operating environment can impact connector performance:
- Temperature Range: Some connectors are rated for extreme conditions, such as -40°C to 105°C, ideal for automotive or outdoor applications.
- Moisture and Dust: For harsh environments, look for connectors with IP ratings (e.g., IP67 for waterproofing) to ensure reliability.
- Vibration and Shock: In applications like aerospace, connectors with locking mechanisms or rugged designs prevent disconnection under stress.
4. Budget and Availability
Cost and supply chain factors are practical considerations. High-performance connectors, such as those for RF applications, often come with a higher price tag (sometimes $5-$10 per unit compared to $0.50 for basic headers). Balance performance needs with budget constraints, and ensure the chosen connector is readily available to avoid production delays.
Best Practices for Integrating Connectors in PCB Design
Choosing the right connector is only part of the equation. Proper integration into your PCB layout is equally important for performance and reliability. Here are some best practices to follow:
- Optimize Placement: Position connectors near the edge of the board for easy access, especially for wire-to-board types. For board-to-board connectors, ensure alignment with mating boards.
- Minimize Signal Interference: For RF connectors, keep traces short and use ground planes to reduce EMI. Maintain a 50-ohm impedance path if possible.
- Secure Mechanical Stability: Use mounting holes or brackets for connectors under mechanical stress. This is crucial for heavy-duty power connectors handling currents above 10A.
- Test Thoroughly: Simulate your design under real-world conditions to check for signal integrity, thermal performance, and mechanical durability before production.
Common Challenges with PCB Connectors and How to Avoid Them
Even with careful planning, connector-related issues can arise. Here are some common challenges and tips to mitigate them:
- Signal Loss in RF Applications: Use connectors with low insertion loss and ensure proper impedance matching. Avoid sharp bends in traces near RF connectors.
- Mechanical Failure: Over-mating or misalignment can damage connectors. Choose designs with guiding features or higher mating cycle ratings for frequent use.
- Thermal Overload: High-current connectors can overheat if undersized. Select connectors with adequate current ratings and consider heat dissipation in your layout.
Future Trends in PCB Connector Technology
The world of PCB connectors is evolving rapidly to meet the demands of modern electronics. Here are a few trends to watch:
- Miniaturization: As devices shrink, connectors with pitches below 0.3mm are becoming more common, especially in wearables and IoT devices.
- High-Speed Data: Connectors supporting data rates above 25 Gbps are emerging to handle next-generation communication standards like 5G.
- Sustainability: Manufacturers are focusing on eco-friendly materials and designs that reduce waste during production and disposal.
Conclusion: Mastering Connector Selection for PCB Success
Understanding PCB connector types and following a solid connector selection guide are foundational to creating reliable and efficient printed circuit board designs. Whether you're working with board-to-board connectors for compact systems, wire-to-board connectors for power delivery, or RF connectors for high-frequency signals, each type has unique benefits and considerations. By carefully assessing electrical, mechanical, and environmental needs, you can choose connectors that enhance your project's performance and longevity.
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