Splitting 12V high current DC wire

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1. May 21, 2016

MisterX

A large number (56) of 18 gauge-ish connection pins are presented by the connector. They are wired together in large groups on the "client" side of the connector (4 electrodes). We wish to re wire these groups together and then split them off into 24x 18 AWG a few feet removed from the connector. The current through the connector could approach 100 A at 12 V DC. I am looking for easy and elegant solutions to accomplish this in a sturdy way. One idea is to use a covered bus bar. Let me know if you have any ideas about wiring.

2. May 21, 2016

anorlunda

I don't understand what you are trying to accomplish. Can you elaborate?

3. May 21, 2016

MisterX

I am looking to construct a cable or series of cables.

56 pin input (28 ground 28 +12V) --> 2 wire conducting path -> split off multiple 18 AWG paths. I am inquiring about what construction methods to use.

4. May 21, 2016

nsaspook

Last edited: May 21, 2016
5. May 22, 2016

MisterX

This is the solution I have been considering. Unfortunately the cost is getting to be too much perhaps. It's over $50 if I use multiple wires per screw on the busbars and more if I don't. This includes the price of two busbars and crimp ring terminals. I am not sure how good the contact would be in that case with the ring terminals stacked on top of each other. I am considering a mere soldering and shrink wrap solution. A bad connection here could cause damage to ~$500 in equipment so perhaps an investment in connectors is warranted. Nonetheless bit by bit things like this add significantly to overall cost.

6. May 22, 2016

nsaspook

Stacked terminals per screw should not be a problem at your current levels and the results will be far superior electrically than soldering.

The conductor Ampacity for 18 gauge is ~7amps. For 24 equal resistance conductors at 100A that's about 5.5 A per wire.
Typical ring terminal contact resistance should under 1 milliohm for these types of terminals causing minimal losses per terminal connection.

http://www.te.com/usa-en/product-60772-2.html
Contact test data. http://www.te.com/commerce/DocumentDelivery/DDEController?Action=showdoc&DocId=Specification+Or+Standard502-1285ApdfEnglishENG_SS_502-1285_A.pdf61588-1

7. May 23, 2016

jim hardy

Maybe a golf cart connector ?