Sorry if this is in the wrong Category.
I am trying to reduce visible cabling within my project. I currently have several sections that need to connect, but I want to use a single, multi-strand cable to connect them, rather than the messy alternative.
The major part I am having issue with, is that one section has 25 cables running to another section. I obviously would like to reduce this to a single cable if possible, so I need advice on 25+ core cable, and 25+ pin plugs and matching connectors, and ip69 rated.
This section actually consists of 3 sub-sections, each running 9 cables (one of each will be spliced together, reducing the 27 to 25), so it may be easier if I consider using 3/4 cables instead, though I would rather avoid that.
I also have a section with 7 cables, and 2 sections with 2 cables each, all of which I would rather reduce visibly with multicore.
Any advice anyone can offer on where to search, or where would be better to ask this question, it would be appreciated.
It will need to be replicated, yes. Making a one off as a prototype for now, before exploring replication.
To be a bit more clear, I have an Arduino Mega 2560, and 3 8-channel relay boards. Currently, I am just using some basic Jumper Cables to connect 24 pins on the Arduino to the 24 relays, and then the relays also connect to GND on the Arduino.
To provide an IP69 rating you will need some sort of sealed bushing on a round cable. You could try a ribbon cable with IDC connectors but you will have to be creative for a barrier seal.
I guess I don't understand your project. You have a Mega and what sounds like a generic 8-channel relay card, but for some reason they are not in the same housing.
My first though was the same as @79galinakorczak but when you said you wanted to replicate the project I dismissed that option. But for initial concept testing it might be perfect.
Again, not knowing your project criteria I would consider:
Putting a nano or pro micro at the relay board.
Communication between the mega and nano with a serial signal.
Without being too specific, the bulk of the project will be submerged in resin, with just the plugs accessible, and all of this will be mounted inside a cabinet on the side of the truck. I am being instructed to ensure the plugs are IP69 waterproof in case the cabinet is ever left open.
I realise it is probably massive overkill, but those were my instructions.
I have been having a bit of a look, and this could possibly be what I am after?
I have no idea about how to install plugs/connectors, having never done it myself. Would this be a good plug for what I am intending (based on the little info I have provided) and do you have any tips for installing the plug/connector?
With the right options it could work. I think TE Connectivity has a lower cost circular connector.
But lets say you went with the referenced Amphenol connector.
You would have to crimp each wire from your cable to a connector pin then push the wires through the connector seal (see the orange area). The connector pin will go in beyond the seal and the seal will seal to the OD of each wire.
You also have to be sure you can find a mating connector, usually with a flange for box mounting.
Oh.... don't go with any system that requires you to POT the connector to wires for sealing. Can't be done neatly when doing only a few. I've tried.
Another lesson I learned, when you are making the cables, make a short "extension" with every wire brought out to a prototype board for trouble shooting. You might as well make it right away instead of making one in a panic when things aren't working right.
For a quick education on water proof/resistant automotive connectors, study the electrical wiring on any current production automobile. Yours will have to be similar.
Paul
Hi,
What signals will you have in the cable, you have to possibly consider cross-talk if there are any wires carrying significant current or switching loads.
You will be best to consult a supplier of plugs and cables to ensure you will have IP69 and suitable signal isolation.
Especially if you are aiming for production/sales.
The IP69K Rating
What is an IP69K rating?
The IP69K rating is for applications where high pressure and high temperature washdown are used to sanitise equipment. The IP69K test specification was initially developed for road vehicles, especially those that need regular intensive cleaning, such as dump trucks and cement mixers but has been widely adopted in the Food and Beverage industries as a test of products to withstand sanitary washdown.
In the IEC 60529 rating system, IP6 refers to the product’s ability to resist ingress of dust. The 69K refers to the product’s ability to resist ingress of high temperature (Steam) / high pressure water.
How is the product usually tested?
Products rated to IP69K must be able to withstand high-pressure and steam cleaning.
The test specifies a spray nozzle that is fed with 80 °C water at 80–100 bar (~1160-1450) and a flow rate of 14–16 L/min.
The nozzle is held 10–15 cm from the tested device at angles of 0°, 30°, 60° and 90° for 30 seconds each.
The test device sits on a turntable that rotates once every 12 seconds.
IP69 rating is very close to you typical coin operated carwash.
The connector the OP chose should withstand the IP test. The backshell and extended grommet will slow the water down and the internal seal will keep the water (soap etc) out of the contact volume.
