Re: [AFMUG] Ferrules

[Chuck McCown]

"The idea is that poisons such as arsenic are, of course, poisonous – that is, 
if one ingests too much they will produce sickness or death. But arsenic and 
other toxins in very low doses, below an amount deemed harmful, repeatedly have 
been shown to benefit the functions of organs, the optimal growth of the 
organism or longevity.

From: Mark Radabaugh 
Sent: Sunday, April 02, 2017 6:59 PM
To: af@afmug.com 
Subject: Re: [AFMUG] Ferrules

None of these cables are cheap, but they will take a lot of abuse - like being 
slammed in the door of a dishwasher and run through a wash cycle day after day. 
   

http://www.belden.com/products/industrialcable/flexible-automation-cable.cfm



Mark Radabaugh
Amplex
22690 Pemberville Rd
Luckey, OH 43443
419-837-5015 x1021
419-261-5996 (cell)
m...@amplex.net

  On Apr 2, 2017, at 8:15 PM, Forrest Christian (List Account) 
<li...@packetflux.com> 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

Re: [AFMUG] Ferrules

[Chuck McCown]

It does seem to be good as it is malleable and will squish in the terminal.  

From: Lewis Bergman 
Sent: Sunday, April 02, 2017 6:35 PM
To: af@afmug.com 
Subject: Re: [AFMUG] Ferrules

I think soldering the stripped end of the wire the last 1/4 inch last longer 
than anything. 



On Sun, Apr 2, 2017, 7:31 PM Chuck McCown <ch...@wbmfg.com> wrote:

  I have the same problems.  I just make extra cables and toss them when they 
start getting intermittent.  Like to find some stranded cat5 with a high strand 
count.  


  From: Jaime Solorza 
  Sent: Sunday, April 02, 2017 6:28 PM
  To: Animal Farm 
  Subject: Re: [AFMUG] Ferrules

  We rarely use ferrules If the wires are moved allot they will 
breakThere are different types of terminal blocks which can help...Deep 
recess ones like Phoenix Contacts hold up well... Good quality wire is also 
important...cuts are key...Make sure all strands are intact and not nicked...A 
simple twist is all that is needed.  I will share part numbers tomorrow.  
  On Apr 2, 2017 6:15 PM, "Forrest Christian (List Account)" 
<li...@packetflux.com> 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

Re: [AFMUG] Ferrules

[Mark Radabaugh]

None of these cables are cheap, but they will take a lot of abuse - like being 
slammed in the door of a dishwasher and run through a wash cycle day after day. 
  

http://www.belden.com/products/industrialcable/flexible-automation-cable.cfm 




Mark Radabaugh
Amplex
22690 Pemberville Rd
Luckey, OH 43443
419-837-5015 x1021
419-261-5996 (cell)
m...@amplex.net

> On Apr 2, 2017, at 8:15 PM, Forrest Christian (List Account) 
>  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

Re: [AFMUG] Ferrules

[Jaime Solorza]

We have used that method and silver coated wire as well for some jobs...
Just like Cat5 cable quality types , same with signal wire.You pay what
you get forLol.

On Apr 2, 2017 6:36 PM, "Lewis Bergman" <lewis.berg...@gmail.com> wrote:

> I think soldering the stripped end of the wire the last 1/4 inch last
> longer than anything.
>
> On Sun, Apr 2, 2017, 7:31 PM Chuck McCown <ch...@wbmfg.com> wrote:
>
>> I have the same problems.  I just make extra cables and toss them when
>> they start getting intermittent.  Like to find some stranded cat5 with a
>> high strand count.
>>
>>
>> *From:* Jaime Solorza
>> *Sent:* Sunday, April 02, 2017 6:28 PM
>> *To:* Animal Farm
>> *Subject:* Re: [AFMUG] Ferrules
>>
>> We rarely use ferrules If the wires are moved allot they will
>> breakThere are different types of terminal blocks which can help...Deep
>> recess ones like Phoenix Contacts hold up well... Good quality wire is also
>> important...cuts are key...Make sure all strands are intact and not
>> nicked...A simple twist is all that is needed.  I will share part numbers
>> tomorrow.
>> On Apr 2, 2017 6:15 PM, "Forrest Christian (List Account)" <
>> li...@packetflux.com> 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
>>
>>

Re: [AFMUG] Ferrules

[Mark Radabaugh]

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) 
>  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

Re: [AFMUG] Ferrules

[Lewis Bergman]

I think soldering the stripped end of the wire the last 1/4 inch last
longer than anything.

On Sun, Apr 2, 2017, 7:31 PM Chuck McCown <ch...@wbmfg.com> wrote:

> I have the same problems.  I just make extra cables and toss them when
> they start getting intermittent.  Like to find some stranded cat5 with a
> high strand count.
>
>
> *From:* Jaime Solorza
> *Sent:* Sunday, April 02, 2017 6:28 PM
> *To:* Animal Farm
> *Subject:* Re: [AFMUG] Ferrules
>
> We rarely use ferrules If the wires are moved allot they will
> breakThere are different types of terminal blocks which can help...Deep
> recess ones like Phoenix Contacts hold up well... Good quality wire is also
> important...cuts are key...Make sure all strands are intact and not
> nicked...A simple twist is all that is needed.  I will share part numbers
> tomorrow.
> On Apr 2, 2017 6:15 PM, "Forrest Christian (List Account)" <
> li...@packetflux.com> 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
>
>

Re: [AFMUG] Ferrules

[Chuck McCown]

I have the same problems.  I just make extra cables and toss them when they 
start getting intermittent.  Like to find some stranded cat5 with a high strand 
count.  


From: Jaime Solorza 
Sent: Sunday, April 02, 2017 6:28 PM
To: Animal Farm 
Subject: Re: [AFMUG] Ferrules

We rarely use ferrules If the wires are moved allot they will 
breakThere are different types of terminal blocks which can help...Deep 
recess ones like Phoenix Contacts hold up well... Good quality wire is also 
important...cuts are key...Make sure all strands are intact and not nicked...A 
simple twist is all that is needed.  I will share part numbers tomorrow.  

On Apr 2, 2017 6:15 PM, "Forrest Christian (List Account)" 
<li...@packetflux.com> 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

Re: [AFMUG] Ferrules

[Jaime Solorza]

We rarely use ferrules If the wires are moved allot they will
breakThere are different types of terminal blocks which can help...Deep
recess ones like Phoenix Contacts hold up well... Good quality wire is also
important...cuts are key...Make sure all strands are intact and not
nicked...A simple twist is all that is needed.  I will share part numbers
tomorrow.

On Apr 2, 2017 6:15 PM, "Forrest Christian (List Account)" <
li...@packetflux.com> 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
>

[AFMUG] Ferrules

[Forrest Christian (List Account)]

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