Let’s talk about wiring, cabling and connectors. The past cabling efforts, while very good in some areas, such as diagramming, have not been properly assembled. The final vehicle will need to use proper waterproof environmentally sealed automotive connectors. The department was nice enough to buy us top of the line Deutsch DT automotive connectors. Lets use them!
Deutsch DT Connectors
The Deutsch DT series connectors were selected for their high current carrying capabilities, ease of assembly, waterproof design. They are already present in the Huff Dynamometer system, so selecting them was a logical decision. They are high quality connectors for use in harsh environments.
DT Connector Assembly Videos
Below are some videos which are useful for learning how to use the DT series connectors, and associated tools.
DT Purchase Information
Below is the purchase information for the Deutsch DT series connectors which we ordered. If you need to order more of something, this is the place to look.
Cables, Wire, Gauge
This section gives a brief overview of some common wiring concepts. Gauge is the diameter of a wire, smaller numbers mean the wire is bigger. Wire is a single conductor, which usually comes in two types stranded and solid. Stranded is capable of carrying less current through the same diameter but is more flexible. Cable is a series of wire connected together. Cable has a specified conductor count, stranding, and insulation.
Connectors come in all shapes and sizes, search Digikey, Mouser, Amazon and eBay when looking. Like tools, you should the the right connector for the right job. Connectors have several important features: contact count, contact current, and wire guage. Every connector has a specialized crimp tool, but sometimes you can get away with a generic crimper and a soldering iron. Consider three things when picking a connector (in order of importance): wire gauge, contact current rating, and future expansion.
Wire gauge selection is important! Higher current applications must use lower gauge wires. A chart is shown below to help select the proper wire gauge for a given application.
http://www.offroaders.com/tech/12-volt-wire-gauge-amps.htm
Wire/Cable Purchase
Three main types of wire/cable were purchased over the Fall 2015 semester. CAN Bus Cable, 16 gauge – 4 Conductor Trailer Wire, and general purpose 18 Gauge Wire.
20 gauge wire should be purchased Spring 2016 for running inside the battery pack.
Wire Purchase Order
2015-11-06 Waytek Wire Purchase Request
CAN Bus Cable
CAN Bus Cable should be used to route the CAN bus throughout the vehicle. It is shielded cable, which is less susceptible to EMI.
16 Gauge Trailer Cable
16 Guage 4 Conductor Trailer Cable should be used to route both Safety Loop and GLV. It was selected because it is cheap, and meets the gauge requirements for Deutsch DT connectors.