Quick disconnect test connectors

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Discussion Overview

The discussion revolves around finding more durable quick disconnect test connectors for products with flying leads. Participants explore various connector types, durability issues, and potential designs for improved testing setups.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Experimental/applied

Main Points Raised

  • Some participants express dissatisfaction with existing connectors due to durability issues, particularly with plastic clips that wear out over time.
  • One suggestion involves using pogo pin contacts with a hold-down actuator for each lead, though concerns about complexity arise due to the number of leads.
  • Another participant proposes using solid copper bus wire with wire nuts as a more durable solution, emphasizing the ease of replacing worn components.
  • Some participants mention specific products and connectors, such as Fahnestock clips and pushbutton terminal blocks, while others question their suitability for the application.
  • There is a suggestion to consider using alligator clips mounted to a solid surface to facilitate easier connections.
  • One participant raises the idea of using an A/B switch to allow for simultaneous testing with two sets of connectors, potentially enabling the use of more robust connectors.
  • Concerns are raised about the size of some suggested connectors, with participants noting that smaller connectors may complicate the testing process.
  • A later post mentions a specific product that could serve as a solution, though it is noted to be expensive and not suitable for all applications.

Areas of Agreement / Disagreement

Participants generally agree that existing connectors are inadequate for their needs, but multiple competing views on potential solutions remain. The discussion does not reach a consensus on a single best approach.

Contextual Notes

Some limitations include the lack of detailed specifications for suggested connectors, the dependence on specific product designs, and the unresolved nature of the proposed solutions.

Who May Find This Useful

Individuals involved in product testing, engineering design, or those seeking durable connector solutions for similar applications may find this discussion relevant.

tfr000
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Looking for ideas...
At my work, we test a number of products that come with flying leads, using this kind of connector:
http://www.digikey.com/product-detail/en/33-1404/GC400-ND/258507
I'm looking for something a little more durable. These things have plastic clips to hold the leads in the connector, and they tend to grind down with many insertions until they no longer have enough material to hold a lead in place. I have searched around for a higher quality version of this, without much luck.
 
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tfr000 said:
Looking for ideas...
At my work, we test a number of products that come with flying leads, using this kind of connector:
http://www.digikey.com/product-detail/en/33-1404/GC400-ND/258507
I'm looking for something a little more durable. These things have plastic clips to hold the leads in the connector, and they tend to grind down with many insertions until they no longer have enough material to hold a lead in place. I have searched around for a higher quality version of this, without much luck.

Can you make something based on pogo pin contacts? Some sort of a hold-down actuator for each lead that pushes it down on a spring-loaded pogo pin...
 
berkeman said:
Can you make something based on pogo pin contacts? Some sort of a hold-down actuator for each lead that pushes it down on a spring-loaded pogo pin...
It might get a bit complicated. The products have up to 12 leads.
I should probably mention that we have many test boxes like this - maybe 100-200 of them. So an off-the-shelf solution is probably the way to go, rather than having to do a mechanical design.
 
tfr000 said:
It might get a bit complicated. The products have up to 12 leads.
I should probably mention that we have many test boxes like this - maybe 100-200 of them. So an off-the-shelf solution is probably the way to go, rather than having to do a mechanical design.

Can you post a picture of typical leads? What wire gage? Solid or stranded wire? How far back are they stripped?
 
berkeman said:
Can you post a picture of typical leads? What wire gage? Solid or stranded wire? How far back are they stripped?
Typically 22AWG, but some products vary, maybe 24 to 18 ga. Stranded wire, stripped 1/4 to 1/2 inch, sometimes tinned, usually not. The leads are generally 6 or more inches long. The products are built in batches of just a few to hundreds.
I'm sure you can see how this would be hard on the crappy plastic connectors...
 
tfr000 said:
Typically 22AWG, but some products vary, maybe 24 to 18 ga. Stranded wire, stripped 1/4 to 1/2 inch, sometimes tinned, usually not. The leads are generally 6 or more inches long. The products are built in batches of just a few to hundreds.
I'm sure you can see how this would be hard on the crappy plastic connectors...

Hmm. How about using solid copper bus wire, about 18AWG, and just quickly wire nutting each wire onto a bus wire? The bus wires would be captured in something (wood or plastic) so they are rigid and don't move, and they are spaced far enough apart to make room for your hands twisting the wire nuts.

After you use a wire nut for about 100 times, you can toss it. They are cheap. And make the capture fixture for the copper bus wires so that it's easy to replace the bus wire pieces when they wear out. Actually, you could start with the bus wire pieces about 5" long, and trim 1/2" off every few hundred tests to get longer life...
 
How about using solid copper bus wire, about 18AWG, and just quickly wire nutting each wire onto a bus wire?
I like this idea.

Would this be an option? May be a little more expensive (?)

alligator-clip-test-leads.jpg
 
  • #10
Gator clips... been there, done that. The leads on which the clips are mounted wear out very quickly.
Those Fahnestock clips are a thought... haven't seen those in years.
Most of the "pushbutton terminal block" stuff is just too small for this kind of thing. Production would scream if they had to use some little tool and squint in order to connect and disconnect 12 leads on 100 units.
 
  • #11
tfr00 I don't think you get it. Concerning post #8 you would fasten the alligator clip to something solid then the lead attached to it would never move. You just push on the alligator clip and it opens up to accept the lead. I have built a lot of test fixtures over the years for production and the alligator clip mounted solid to a surface is a good idea.
 
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  • #12
Averagesupernova said:
tfr00 I don't think you get it. Concerning post #8 you would fasten the alligator clip to something solid then the lead attached to it would never move. You just push on the alligator clip and it opens up to accept the lead. I have built a lot of test fixtures over the years for production and the alligator clip mounted solid to a surface is a good idea.
You're right I didn't get it... when I see a picture of alligator clips on the end of leads, without further explanation, that what I think of. But yes, that also seems like a good idea.
Thanks for the ideas, folks.
 
  • #13
Also - how long is the test process - can you use an A/B switch and have 2 sets of connectors, one is being connected/disconnected - as the other is under test? - This may allow the use of a more robust connector, I have to think that there a good / better solution out there for this - but I am not finding one.
 
  • #15
Windadct said:
I have to think that there a good / better solution out there for this - but I am not finding one.
Exactly. I have been looking off and on for months.

meBigGuy said:
What is wrong with this?
http://www.newark.com/wago/261-104-341-000/terminal-block-pushbutton-4pos/dp/73C4061
I can't find any dimensions for that particular one, but most of those are too small. You would need a pointy tool to push the little buttons.
 
  • #16
Do you have an in-house machine shop available as a resource? If so, it would be pretty straightforward to make easy-to-use hold-down assemblies based on standard test fixture clamps like these:

http://cloudfront.zorotools.com/product/large/3CWX7_AS01.JPG
http://cloudfront.zorotools.com/product/large/3CWX7_AS01.JPG


EDIT -- Use a non-conducting bolt/hold-down, pressing the stripped wire end down on a conducting pogo pin or spring finger.

EDIT 2 -- And in case it's not obvious, the receiving fixture should have V-grooves to accept/guide the wires into the hold-down part...
 
Last edited:
  • #17
So anyway, we finally came up with this:
http://www.pomonaelectronics.com/pdf/d4995_100.pdf

They are expensive, so they won't get used on everything. They are an answer to the original question, however.
 

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