When working on electronics projects, especially in automotive diagnostics or similar fields requiring robust connections, the fragility of thin gauge wires at termination points becomes a significant concern. Many DIYers and professionals alike grapple with wire breakage, particularly when using standard Dupont ribbon cables for power and ground distribution. While these cables are convenient for prototyping, their 22 gauge wires often fail under mechanical stress at solder joints or terminal blocks. This article explores solutions to enhance wire connection strength, focusing on the benefits of utilizing PCB headers for a more durable and reliable setup.
Direct soldering of 22 gauge wires, while seemingly straightforward, creates stress points where flexing occurs, leading to eventual breakage. Tinning the wire ends before inserting them into terminals doesn’t eliminate this issue; the inherent weakness of the 22 gauge wire remains. Moving to heavier gauges, such as 20 or ideally 18 gauge wire, offers a substantial improvement in mechanical strength, addressing the core problem of wire breakage at the termination. The goal here is not necessarily to handle high current or voltage, but to achieve robust mechanical connections that withstand movement and vibration.
For low-cost and efficient termination solutions, especially in consumer product development where both time and component costs are critical, various options exist. Ferrules are a good starting point, providing a more secure termination than bare wires in screw terminals. However, ferrules need a reliable connection point, and this is where the complexity often increases. Traditional breadboard areas, like those found on some development boards, are insufficient for robust, long-term wire connections. Direct soldering to these areas still leads to wire breakage due to lack of strain relief. Screw terminals offer improved security but often don’t fit standard 0.1″ grid breadboard layouts, and can be cumbersome for multiple power and ground connections.
termstrip termstrip639×653 358 KB
A more integrated and professional solution lies in designing custom PCB terminal boards. Instead of relying on general-purpose breadboards or directly soldering wires, creating a dedicated PCB with terminal blocks offers several advantages. Imagine a PCB designed specifically to act as a robust terminal strip, similar to the concept visualized in the image above. This approach allows for:
- Organized and Secure Connections: Dedicated terminal blocks on a PCB provide a secure and organized method for connecting multiple wires, especially for power and ground distribution.
- Mechanical Strength: Soldering heavier gauge wires to PCB pads and then using screw terminals or robust headers on the PCB significantly reduces strain on the wires themselves, minimizing breakage.
- Customization: PCBs can be designed to fit specific project requirements, incorporating the exact number and type of terminals needed. This includes options for various PCB headers, including SMD (Surface Mount Device) headers for compact designs. While the initial thought might not be directly about an “18 Pin Smd Obd2 Pcb Header”, the principle of using robust PCB headers for reliable connections is broadly applicable. Different pin counts and configurations of PCB headers cater to diverse needs in electronic projects, and considering SMD headers allows for space-saving implementations in compact devices.
- Streamlined Assembly: Using PCBs with pre-designed terminal layouts simplifies assembly and reduces labor time in production, particularly important for consumer products where cost-effectiveness is paramount.
For those considering this approach, readily available and free PCB design software makes creating custom terminal boards accessible. This shift from directly terminating wires to utilizing PCB-based terminal solutions offers a significant step up in terms of connection reliability and overall project robustness, addressing the persistent issue of wire breakage and enhancing the durability of electronic assemblies.
