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Electrical Connectors

This page is a reference for all electrical connectors used on our robots. It covers specifications, crimping tools, installation procedures, and common use cases.

ConnectorTypeMax CurrentMax VoltageWire Range
Anderson PowerPole SB 120High-power two conductor120A600V AC / 900V DC4–2/0 AWG
Anderson PowerPole SB 50High-power two conductor50A50V DC6–10 AWG
Anderson PowerPole PP15/30/45Power single conductor, stackable15–45A50V DC10–20 AWG
Cable Lugs (Ring Terminals)Bolted ring terminalvariesvariesvaries
Molex SLSignal multi-conductor3A/pin250V AC22–28 AWG
Molex Microfit+Signal multi-conductor8.5A/pin600V18–30 AWG
JST-PHSignal multi-conductor2A/pin100V AC24–32 AWG
Wire FerrulesWire end sleevevariesvariesvaries
Weidmuller LSFPush-in spring-cage, wire-to-boardvariesvariesvaries
RJ45 EthernetNetwork plug——22–26 AWG
Wago 221Lever splice32A450V12–24 AWG
Wago 2616PCB terminal block, lever-actuated, high-power76A1000V18–4 AWG
Wago 2606PCB terminal block, lever-actuated41A1000V24–8 AWG
Wago 2601PCB terminal block, lever-actuated, compact17.5A320V26–14 AWG
Wago 250PCB terminal strip, push-in8A320V22–16 AWG
Wago 745PCB terminal block, screwdriver CAGE CLAMP41A1000V24–10 AWG
CAN Lever Connector2-pos lever splice, CAN-coded24A450V12–24 AWG
USB-A PlugUSB Type-A—5V—
USB-C PlugUSB Type-C—20V—
Wire-to-Wire Solder SplicePermanent inline jointvariesvariesvaries
Wire-to-Board Solder SplicePermanent PCB jointvariesvariesvaries

Anderson PowerPole SB 120​

Manufacturer docs: Anderson Power Products — SB Connector Series

The SB 120 heavy-duty connector is rated for high-current battery and main power wiring and features two conductors. Because the connector is genderless, both halves use the same housing and contacts and can mate with each other interchangeably. Note that housings in different colors are keyed differently and cannot be mated with one another.

Specifications​

ParameterValue
ManufacturerAnderson Power Products
Series / StandardSB Series
Conductors2
Max current per contact120A
Max voltage600V AC / 900V DC
Wire range4 AWG – 2/0 AWG
Mating cycles1,000+

Crimping Tool​

Hydraulic crimping tool.

Installation​

Installing the Contact on a Wire​

  1. Strip approximately 13 mm (½ in) of insulation from the wire end.
  2. Select the correct contact variant for your wire gauge.
  3. Slide the contact onto the stripped wire so all strands are fully inside the barrel and none are outside.
  4. Crimp using the hydraulic crimper with the correct die.
  5. Inspect: the barrel should be uniformly compressed, and the wire should not pull out with hand force.
  6. Insert the crimped contact into the SB 120 housing by pushing it straight in from the rear until the spring latch clicks.
  7. Tug gently to confirm the contact is locked.

Connecting to the Mating Connector​

  1. Align the two SB 120 housings — the guide tab on one slides into the slot on the other.
  2. Push firmly until both housings snap together.
  3. To disconnect: pull the housings apart.

Common Uses​

  • Battery main power leads

Anderson PowerPole SB 50​

Manufacturer docs: Anderson Power Products — SB Connector Series

The SB 50 heavy-duty connector is rated for high-current battery and main power wiring and features two conductors. Because the connector is genderless, both halves use the same housing and contacts and can mate with each other interchangeably. Note that housings in different colors are keyed differently and cannot be mated with one another.

Specifications​

ParameterValue
ManufacturerAnderson Power Products
Series / StandardSB Series
Conductors2
Max current per contact50A
Max voltage50V DC
Wire range6 AWG – 10 AWG
Mating cycles1,000+

Crimping Tool​

Hydraulic crimping tool.

Installation​

Installing the Contact on a Wire​

  1. Strip approximately 10 mm (⅜ in) of insulation from the wire end.
  2. Select the correct contact for your wire gauge.
  3. Slide the contact onto the stripped wire so all strands fill the barrel completely.
  4. Crimp using the hydraulic crimper with the correct die.
  5. Inspect: the barrel should be uniformly compressed, and the wire should not pull out.
  6. Insert the crimped contact into the SB 50 housing until the spring latch clicks.
  7. Tug gently to confirm the contact is locked.

Connecting to the Mating Connector​

  1. Align the two SB 50 housings — the guide tab on one slides into the slot on the other.
  2. Push firmly until both housings snap together.
  3. To disconnect: pull the housings apart.

Common Uses​

  • Battery main power leads

Anderson PowerPole PP15/30/45​

Manufacturer docs: Anderson Power Products — PowerPole Connector Series

The PowerPole series are compact, single-conductor connectors designed for moderate-current wiring. Their stackable design allows multiple connectors to be ganged together, and are typically configured in pairs or triples. All three variants — the PP15, PP30, and PP45 — share the same plastic housing; the current rating is determined solely by the contact installed. PowerPole connectors are genderless, meaning both halves use identical housings and can mate with each other interchangeably.

Specifications​

ParameterValue
ManufacturerAnderson Power Products
Series / StandardPowerPole Series
Conductors1
Max current per contactSee contact table below
Max voltage50V DC
Wire rangeSee contact table below
Mating cycles1,000+
ContactMax CurrentWire Range
PP1515A20–16 AWG
PP3030A16–12 AWG
PP4545A12–10 AWG

Crimping Tool​

Powerwerx TRIcrimp tool.

Installation​

Installing the Contact on a Wire​

  1. Strip approximately 8 mm (5/16 in) of insulation from the wire end.
  2. Select the correct contact for your wire gauge and current requirement.
  3. Place the contact in the TRIcrimp at the position marked for that contact type.
  4. Insert the stripped wire into the contact barrel so the conductor fills the barrel and the insulation sits against the strain-relief wings.
  5. Squeeze the TRIcrimp tool fully to simultaneously crimp the barrel and close the strain-relief wings.
  6. Inspect: the wire should not pull out, the wire should not stick past the wire stop, and both the barrel and strain-relief wings should be evenly closed.
  7. Insert the crimped contact into the PP housing from the rear until the retention latch clicks. The contact should sit flush.

Connecting to the Mating Connector​

  1. Align the two PP housings — the front tab on each mates with the slot on the other.
  2. Push together until fully seated.
  3. To disconnect: pull the housings apart.

Common Uses​

  • Motor phase wires
  • Motor controller connections

Cable Lugs (Ring Terminals)​

Cable lugs, sometimes referred to as ring terminals, are crimped wire terminations designed to be secured to a screw post or stud. They provide a robust, low-resistance connection at bolted joints.

Specifications​

ParameterValue
ManufacturerVarious
Series / Standard—
Conductors1
Max current per contactVaries by lug/wire rating
Max voltageVaries by lug/wire rating
Wire rangeVaries by lug/wire size
Mating cycles—

Crimping Tool​

Large wire gauges (8awg+) Hydraulic crimping tool.

Small wire gauges (10awg -) IWS-6 crimping tool.

Installation​

Installing the Lug on a Wire​

  1. Select a lug with the correct wire gauge range and hole size for the target fastener.
  2. Strip insulation to match the lug barrel length — typically 12–16 mm for power lugs.
  3. Twist the strands together lightly to keep them bundled.
  4. Insert the stripped wire fully into the lug barrel — all strands must be inside the barrel with none hanging outside.
  5. Crimp with the crimper using the die for the wire gauge.
  6. Inspect: the barrel should be uniformly compressed and the wire should not pull out.

Connecting to a Terminal​

  1. Place the ring over the screw or stud.
  2. Install any required washer and fasten the nut or screw.
Torque to spec

Always torque the fastener to the manufacturer's specified value. Under-torqued fasteners will loosen from vibration and can cause intermittent connections or arcing. Over-torqued fasteners can crack the lug or strip the thread.

Common Uses​

  • Motor controller power terminals
  • CAN bus terminals
  • Power Distribution stud connections
  • Main breaker

Molex SL​

Manufacturer docs: Molex — SL Series

Molex SL connectors are used for low-current signal and power connections. Available in both male (housing and contacts) and female (receptacle and contacts) versions, they are offered in a variety of conductor counts — most commonly 2, 3, and 4 conductors.

Use gold-plated contacts only

Standard tin-plated Molex SL contacts can corrode the robot controller's input pins over time. Always use gold-plated contacts when connecting to the robot controller or any sensitive electronics.

Specifications​

ParameterValue
ManufacturerMolex
Series / StandardSL (2139)
ConductorsVarious — 2, 3, 4 most common
Max current per contact3A
Max voltage250V AC (600V UL)
Wire range22–28 AWG
Mating cycles—

Crimping Tool​

Molex hand crimper part number 638118700.

Installation​

Installing the Contact on a Wire​

  1. Strip approximately 2 mm of insulation from the wire end.
  2. Place the contact in the crimper at the position specified in the crimper instructions.
  3. Insert the wire into the contact so the conductor sits in the wire barrel and the insulation sits in the insulation grip.
  4. Squeeze the crimper fully until it releases.
  5. Inspect: the wire conductor should be visible at the front of the wire barrel, both crimp wings should be uniformly closed, and the wire should not pull out.
  6. Insert the contact into the housing from the rear in the correct cavity, matching the keying. Push until you hear a click.
  7. Tug gently to confirm the contact is locked.

Connecting to the Mating Connector​

  1. Align the male and female housings — the polarization key prevents incorrect orientation.
  2. Push until both housings seat fully and latch.
  3. To disconnect: depress the latch tab on the female/receptacle housing and pull apart.

Common Uses​

  • PWM signal cables
  • Robot controller signal connections
  • Sensor wiring
  • Can Splices

Molex Microfit+​

Manufacturer docs: Molex — Micro-Fit+ Connectors

Molex SL connectors are used for low-current signal and power connections. They are offered in a variety of conductor counts — most commonly 4 conductors.

Specifications​

ParameterValue
ManufacturerMolex
Series / StandardMicro-Fit+
ConductorsVarious — 4 most common
Max current per contact8.5A
Max voltage600V
Wire range18–30 AWG
Mating cycles—

Crimping Tool​

Molex hand crimper part number 2133094400.

Installation​

Installing the Contact on a Wire​

  1. Strip approximately 2.5 mm of insulation from the wire end.
  2. Place the contact in the crimper at the correct position for the wire gauge.
  3. Insert the wire so the conductor fills the wire barrel and the insulation reaches the insulation grip.
  4. Squeeze the crimper fully until it cycles through and releases.
  5. Inspect: both the wire barrel and insulation grip should be uniformly closed with no strands outside the barrel.
  6. Insert the contact into the 4-pin male housing from the rear in the correct cavity. Push until you hear a click.
  7. Tug gently to confirm the contact is locked.

Connecting to the Mating Connector​

  1. Align the male plug with the female receptacle — the polarization key prevents incorrect insertion.
  2. Push firmly until the housings latch together.
  3. To disconnect: depress the latch tab and pull apart.

Common Uses​

  • Robot contoller power

JST-PH​

Manufacturer docs: JST — PH Connector Series

JST-PH connectors are used for low-current signal and power connections. They are offered in a variety of conductor counts — most commonly 4 and 6 conductors.

Prefer premade cables

JST-PH contacts are very small and difficult to crimp reliably. Use premade JST-PH cables whenever available rather than hand-crimping.

Specifications​

ParameterValue
ManufacturerJST
Series / StandardPH
ConductorsVarious — 4, 6 most common
Max current per contact2A
Max voltage100V AC
Wire range24–32 AWG
Mating cycles—

Crimping Tool​

iCrimp SN-28B ratcheting hand crimper.

Installation​

Installing the Contact on a Wire​

  1. Strip approximately 1.5–2 mm of insulation.
  2. Place the JST-PH contact in the crimper at the correct die position.
  3. Insert the wire so the conductor is in the wire barrel and the insulation just reaches the insulation grip.
  4. Squeeze the crimper fully and allow the ratchet to release.
  5. Inspect: wire barrel and insulation grip should be evenly closed, conductor should be visible at the front, and no strands should be outside the barrel.
  6. Insert each contact into the housing from the rear in the correct position. Push until you hear a click.
  7. Tug gently to confirm each contact is locked.

Connecting to the Mating Connector​

  1. Align the male plug with the female receptacle — the connector is keyed and only inserts one way.
  2. Push until the latch clicks.
  3. To disconnect: gently pull straight out.

Common Uses​

  • Motor encoder cables
  • CAN bus connections on motor controllers

Wire Ferrules​

Wire ferrules are cylindrical metal sleeves crimped onto the end of a stranded wire to bundle the strands into a solid, pin-like end. They prevent frayed strands from causing shorts and ensure a reliable connection in spring-cage or screw terminals.

Specifications​

ParameterValue
ManufacturerVarious
Series / Standard—
Conductors1
Max current per contactVaries by wire gauge
Max voltageVaries by wire gauge
Wire rangeVaries by ferrule size
Mating cycles—

Crimping Tool​

Phoenix Contact CrimpFox 6 hand crimper.

Installation​

Installing the Ferrule on a Wire​

  1. Select the ferrule that matches your wire gauge and the required insertion length for the target terminal.
  2. Strip insulation to the length of the ferrule barrel — typically 8–10 mm for most signal sizes.
  3. Insert the stripped wire fully into the ferrule barrel so all strands are captured inside.
  4. Place the loaded ferrule in the crimper at the position for that wire gauge.
  5. Squeeze the crimper fully.
  6. Inspect: the ferrule should be uniformly compressed, all strands should be captured, and the wire should not pull out.

Connecting to a Terminal​

Insert the ferrule end into the target terminal and secure it per that terminal's instructions (spring-cage push-in, lever actuation, or screw).

Common Uses​

  • Required for all Weidmuller LSF connections

Weidmuller LSF​

Manufacturer docs: Weidmuller — LSF Series

Weidmuller LSF connectors are push-in spring-cage terminal blocks that mount on a PCB. The connector accepts a ferrule-terminated wire and holds it via an internal spring — no screw or tool required for insertion.

Ferrules required

Never insert bare stranded wire directly into an LSF connector. Always terminate with a wire ferrule first. Bare stranded wire risks frayed strands bridging adjacent terminals and creating shorts.

Specifications​

ParameterValue
ManufacturerWeidmuller
Series / StandardLSF
ConductorsVaries — 2 most common
Max current per contactPrinted on housing
Max voltagePrinted on housing
Wire rangePrinted on housing
Mating cycles—

Installation​

Connecting a Wire to the Connector​

  1. Terminate the wire with a wire ferrule (see Wire Ferrules).
  2. Identify the correct slot in the connector — slots are typically labeled on the housing or PCB silkscreen.
  3. Push the ferrule straight into the slot until it stops. The spring grips it automatically — no tool needed.
  4. Tug gently to confirm the wire is held.
  5. To remove: insert a small flat-blade screwdriver into the actuation slot next to the wire entry, press to open the spring, and pull the wire out.

Common Uses​

  • Limelight
  • Radio

RJ45 Ethernet​

Standard: TIA-568C

RJ45 (8P8C) is the standard connector for Ethernet networking. It connects switches, robot controllers, cameras, and other networked devices.

Prefer premade cables

Crimping RJ45 connectors reliably requires practice and a quality crimper. Premade Cat5e or Cat6 patch cables are strongly preferred. Only crimp your own cable when a custom length is required.

Specifications​

ParameterValue
ManufacturerVarious
Series / Standard8P8C / TIA-568C
Conductors8
Max current per contact—
Max voltage—
Wire range22–26 AWG
Mating cycles750

Crimping Tool​

RJ45-specific ratcheting crimper with an 8P8C die.

Installation​

Installing the Connector on a Cable​

  1. Cut the cable cleanly and square.
  2. Remove approximately 25 mm of the outer jacket without nicking the inner conductors.
  3. Untwist the pairs and straighten all 8 conductors.
  4. Arrange conductors in T568B order from left to right (with the tab facing down and contacts facing you): White/Orange, Orange, White/Green, Blue, White/Blue, Green, White/Brown, Brown.
  5. Hold the order and trim all conductors evenly so approximately 13 mm of conductor extends beyond the jacket.
  6. Slide into the RJ45 plug — each conductor must reach the front of its channel and be visible through the end of the plug.
  7. Crimp with the RJ45 crimper to drive the 8 contacts into the conductors.
  8. Test with a cable tester before putting the cable in service.

Connecting to the Mating Connector​

  1. Align the plug with the RJ45 jack — the locking tab must face down toward the tab slot on the jack.
  2. Push firmly until the tab clicks.
  3. To disconnect: press the locking tab down and pull the plug straight out.

Common Uses​

  • Robot controller
  • Cameras
  • Radio
  • Network switch

Wago 221​

Manufacturer docs: Wago — 221 Series

Wago 221 connectors are compact lever-actuated wire splice connectors. They require no crimping or tools — a lever opens the contact, the wire inserts, and the lever closes to lock.

For temporary use only

Wago 221 connectors are for quick fixes and temporary wiring only. Do not use them in permanent robot wiring. Permanent connections must use soldering or a properly crimped connector.

Specifications​

ParameterValue
ManufacturerWago
Series / Standard221
Conductors1
Max current per contact32A
Max voltage450V
Wire range12–24 AWG
Mating cycles—

Installation​

No pre-installation on the wire is required — the lever mechanism is the connection.

Connecting Wires​

  1. Lift the orange lever on the target slot to the open position.
  2. Strip approximately 11 mm of insulation from the wire.
  3. Insert the stripped wire into the open slot until it bottoms out.
  4. Push the lever back down to clamp the wire.
  5. Tug gently to confirm the wire is held.
  6. Repeat for each slot.

Common Uses​

  • Temporary repairs during competitions
  • Quick test connections during troubleshooting
  • Not for permanent use

Wago 2616​

Manufacturer docs: Wago — 2616 Series

Wago 2616 connectors are high-power lever-actuated PCB terminal blocks using WAGO's CAGE CLAMP technology. A lever opens the contact, the wire inserts, and the lever closes to clamp.

Specifications​

ParameterValue
ManufacturerWago
Series / Standard2616
Conductors1 per pole — various pole counts
Max current per contact76A
Max voltage1000V
Wire range18–4 AWG
Mating cycles—

Installation​

No pre-installation on the wire is required — the lever mechanism is the connection.

Connecting Wires​

  1. Lift the orange lever on the target slot to the open position.
  2. Strip approximately 11 mm of insulation from the wire end.
  3. Insert the stripped wire into the open slot until it bottoms out.
  4. Push the lever back down to clamp the wire.
  5. Tug gently to confirm the wire is held.

Common Uses​

  • PDH battery input

Wago 2606​

Manufacturer docs: Wago — 2606 Series

Wago 2606 connectors are medium-power lever-actuated PCB terminal blocks using WAGO's CAGE CLAMP technology. A lever opens the contact, the wire inserts, and the lever closes to clamp.

Specifications​

ParameterValue
ManufacturerWago
Series / Standard2606
Conductors1 per pole — various pole counts
Max current per contact41A
Max voltage1000V
Wire range24–8 AWG
Mating cycles—

Installation​

No pre-installation on the wire is required — the lever mechanism is the connection.

Connecting Wires​

  1. Lift the orange lever on the target slot to the open position.
  2. Strip approximately 11 mm of insulation from the wire end.
  3. Insert the stripped wire into the open slot until it bottoms out.
  4. Push the lever back down to clamp the wire.
  5. Tug gently to confirm the wire is held.

Common Uses​

  • PDH power distribution

Wago 2601​

Manufacturer docs: Wago — 2601 Series

Wago 2601 connectors are compact lever-actuated PCB terminal blocks using WAGO's CAGE CLAMP technology. A lever opens the contact, the wire inserts, and the lever closes to clamp.

Specifications​

ParameterValue
ManufacturerWago
Series / Standard2601
Conductors1 per pole — various pole counts
Max current per contact17.5A
Max voltage320V
Wire range26–14 AWG
Mating cycles—

Installation​

No pre-installation on the wire is required — the lever mechanism is the connection.

Connecting Wires​

  1. Lift the orange lever on the target slot to the open position.
  2. Strip approximately 8 mm of insulation from the wire end.
  3. Insert the stripped wire into the open slot until it bottoms out.
  4. Push the lever back down to clamp the wire.
  5. Tug gently to confirm the wire is held.

Common Uses​

  • Mini-PDH circuits
  • PDH CAN connections

Wago 250​

Manufacturer docs: Wago — 250 Series

Wago 250 connectors are compact push-in PCB terminal strips using WAGO's CAGE CLAMP technology. Solid or ferrule-terminated wires insert directly without a tool; stranded wires require pressing the release button with a small screwdriver to open the spring before insertion.

Specifications​

ParameterValue
ManufacturerWago
Series / Standard250
Conductors1 per pole — various pole counts
Max current per contact8A
Max voltage320V
Wire range22–16 AWG
Mating cycles200 (unloaded) / 100 (loaded)

Installation​

Connecting Wires (Solid wire or ferrule-terminated)​

  1. Strip approximately 8 mm of insulation from the wire end. Terminate with a ferrule if using stranded wire.
  2. Push the wire straight into the slot — the CAGE CLAMP grips it automatically.
  3. Tug gently to confirm the wire is held.

Connecting Wires (Bare stranded wire)​

  1. Strip approximately 8 mm of insulation.
  2. Insert a small flat-blade screwdriver into the release slot next to the wire entry and press to open the spring.
  3. Insert the wire into the open slot while holding the screwdriver in place.
  4. Remove the screwdriver — the spring clamps the wire.
  5. Tug gently to confirm the wire is held.

Disconnecting​

Insert a small flat-blade screwdriver into the release slot and press to open the spring, then pull the wire out.

Common Uses​

  • Mini-PDH circuits
  • PDH CAN connections

Wago 745​

Manufacturer docs: Wago — 745 Series

Wago 745 connectors are PCB terminal blocks using WAGO's CAGE CLAMP technology with screwdriver actuation. A screwdriver inserted into the release slot opens the spring clamp, the wire inserts, and withdrawing the screwdriver allows the spring to clamp down.

Specifications​

ParameterValue
ManufacturerWago
Series / Standard745
Conductors1 per pole — various pole counts
Max current per contact41A
Max voltage1000V
Wire range24–10 AWG
Mating cycles~200

Installation​

Connecting Wires​

  1. Insert a small flat-blade screwdriver into the release slot on the target pole and press to open the CAGE CLAMP.
  2. Strip approximately 8–10 mm of insulation from the wire end.
  3. Insert the stripped wire into the open wire entry while holding the screwdriver in place.
  4. Remove the screwdriver — the spring clamps the wire automatically.
  5. Tug gently to confirm the wire is held.

Disconnecting​

Insert the screwdriver into the release slot to open the clamp and pull the wire straight out.

Common Uses​

  • PDP power distribution

CAN Lever Connector​

CAN lever connectors are compact, lever-actuated wire splice connectors that require no crimping or additional tools — a lever opens the contact, the wire inserts, and the lever closes to lock. Each connector contains two conductors, color-coded to correspond to the CAN bus wire pair.

For temporary use only

Like the Wago 221, this connector is for quick fixes and temporary wiring only. Do not use it in permanent robot wiring.

Specifications​

ParameterValue
ManufacturerWCP
Series / Standard—
Conductors2
Max current per contact—
Max voltage—
Wire range18–24 AWG
Mating cycles—

Installation​

No pre-installation on the wire is required — the lever mechanism is the connection.

Connecting Wires​

  1. Lift each lever to the open position.
  2. Strip approximately 11 mm of insulation from each wire.
  3. Insert the CAN High wire into the yellow slot and the CAN Low wire into the green slot, pushing each until it bottoms out.
  4. Push both levers down to the closed position.
  5. Tug each wire gently to confirm it is held.

Common Uses​

  • Temporary repairs during competitions
  • Quick test connections during troubleshooting
  • Not for permanent use

USB-A Plug​

USB Type-A is the rectangular plug found on the host end of most USB cables.

Specifications​

ParameterValue
ManufacturerVarious
Series / StandardUSB 2.0 / USB 3.x
Conductors4 (USB 2.0) or 9 (USB 3.x)
Max current per contact0.5A–0.9A
Max voltage5V
Wire range—
Mating cycles1,500

Connecting to the Mating Connector​

  1. Orient the plug — USB-A is keyed and only inserts in one orientation. The smooth face (or logo side) faces up toward the internal contacts of the receptacle.
  2. Push firmly into the USB-A receptacle until fully seated.
Secure all USB-A connections

USB-A connectors have no locking mechanism. They will vibrate loose on a robot. All USB-A connections must either use a screw-lock USB adapter or be secured with hot glue after seating.

Common Uses​

  • USB peripherals connected to the robot controller or compute device

USB-C Plug​

USB Type-C is the small oval, reversible connector found on modern devices and cables.

Specifications​

ParameterValue
ManufacturerVarious
Series / StandardUSB 2.0 / USB 3.x / USB4
Conductors24
Max current per contact0.9A–5A
Max voltage5V–20V (USB Power Delivery)
Wire range—
Mating cycles10,000

Connecting to the Mating Connector​

  1. Orient the plug — USB-C is reversible and inserts either way.
  2. Push firmly into the USB-C receptacle until fully seated.
Secure all USB-C connections

USB-C connectors have no locking mechanism in most applications and will vibrate loose on a robot. All USB-C connections must either use a screw-lock USB-C adapter or be secured with hot glue after seating.

Common Uses​

  • Motor controller configuration ports
  • Compute device power input
  • Camera connections

Wire-to-Wire Solder Splice​

A wire-to-wire solder splice is a permanent inline connection between two wire ends. When done correctly it is low resistance and reliable under vibration.

Specifications​

ParameterValue
Manufacturer—
Series / Standard—
Conductors—
Max current per contactLimited by wire gauge
Max voltageLimited by wire insulation
Wire rangeUp to 18 awg
Mating cycles— (permanent)

Installation​

Splicing Two Wires​

  1. Slide a piece of heat-shrink tubing over one wire before joining — it cannot be added after.
  2. Strip approximately 20 mm of insulation from both wire ends.
  3. Interleave or hook the two stripped ends together so the mechanical joint bears any tension (not the solder joint).
  4. Apply the soldering iron to the joint and feed solder in until the joint is fully wetted and smooth.
  5. Do not move the joint until the solder has fully solidified.
  6. Inspect: the joint should be shiny and show full conductor wetting. A dull or grainy surface indicates a cold joint — reheat.
  7. Slide the heat-shrink over the joint and shrink with a heat gun.

Disconnecting​

A solder splice is a permanent, non-separable connection. To separate, cut and re-splice.

Common Uses​

  • Extending motor phase or encoder wires
  • Permanent mid-cable joints where a connector would add unnecessary bulk
  • Repairing a cut or damaged wire

Wire-to-Board Solder Splice​

A wire-to-board solder splice is a permanent connection between a wire and a through-hole or surface-mount pad on a PCB.

Specifications​

ParameterValue
Manufacturer—
Series / Standard—
Conductors—
Max current per contactLimited by wire gauge and device
Max voltageLimited by device
Wire rangeUp to 18 awg
Mating cycles— (permanent)

Installation​

Soldering a Wire to a Board​

  1. Strip approximately 5–8 mm of insulation for a through-hole pad, or 2–3 mm for a surface-mount pad.
  2. Tin the wire end: apply heat and solder to the conductor until it is fully coated.
  3. Clean the PCB pad with isopropyl alcohol if there is any contamination or oxidation.
  4. Through-hole pad: Insert the tinned wire through the hole and bend it slightly to hold position. Apply the iron and add solder until the joint forms a volcano shape filling the hole and wetting both the wire and pad ring.
  5. Surface-mount pad: Hold the tinned wire flat against the pad. Apply the iron and add a small amount of additional solder to flow onto both the wire and pad.
  6. Inspect: the joint should be shiny, fully wetted, and smooth with no bridges to adjacent pads.
  7. Apply strain relief — a dab of hot glue, a cable tie to a nearby standoff, or a purpose-built clamp — so that wire tension is not carried through the solder joint.

Disconnecting​

A solder splice is a permanent, non-separable connection.

Common Uses​

  • Soldering signal connectors directly to a custom PCB
  • CAN or PWM signal wires soldered to pads on boards that lack connectors
  • Power wires directly to a PCB when a connector is not available