The strain relief on the ferrules might help a little bit. Quality of the wire is probably much more important - the higher strand count you can get the better.
I have had good luck with automated test equipment using pogo pins from these guys: https://www.mill-max.com/new_products/pages/spring-loaded-connectors?gclid=Cj0KEQjwwoLHBRDD0beVheu3lt0BEiQAvU4CKjxT3jz0NgQWORAdgmRQnj2p5syZayNVxttDShl626UaAkLC8P8HAQ If you can build a fixture that pushes the equipment into the pins so that the device under test moves rather than the test cables you can make the test station survive much longer. Some of the spring pins are socketed (most?) so replacing a damaged or worn one is easy. Mark > On Apr 2, 2017, at 8:15 PM, Forrest Christian (List Account) > <[email protected]> wrote: > > Question for Jaime or anyone else who has an opinion.... > > I'm in the process of getting the wire harnesses put together for the > automatic test equipment in the manufacturing plant. These are the cables > which go from the test equipment to the actual connectors on our products. > > I have two scenarios I need to figure out a more reliable termination for: > > The first is how best to terminate into a removable terminal block. This > termination would be permanent, but the terminal would end up plugged in and > removed a lot of times. In the past I've just terminated the wire to the > block and potted the whole thing with an adhesive. Works mostly. Until > the adhesive comes off the block or the block itself fails. At which point > you start over on the cable. > > I'm wondering if using crimp ferrules on the wire and terminating the wire in > the terminal block normally would be more or less robust. Having not used > ferrules for a long time, I'm not sure if these will handle the type of > abuse one would expect in this application... Ie repeated motion of the > removable terminal block as it is inserted or removed. > > The second application is where I have a fixed terminal block and need to a > harness which will survive multiple terminations to said blocks. I.e. we > have to hook up each product we manufacture to this harness. I'm not sure > if a typical ferrule will survive repeated terminations or if there's a > better option here as well. > > Any opinions on the above would be helpful
