Thingiverse
Digital Caliper Data Port Connector by Masterkookus
by Thingiverse
Last crawled date: 4 years, 2 months ago
I used the data connector as a starting port, though this is a new model, I wanted to be sure to give credit for the original idea.
I am trying to get the pictures in the correct order, but the assembly follows below:
Use four wires from a multi-conductor cable, (cat3/5 work well), cut the remaining wires off.
a. Total wire length should be around 22mm (7/8")
b. Strip wires back 12mm (1/2")
c. Use a pair of fine pliers to straighten wires
Insert striped wires into the holes at the end of the connector, then carefully fold them down.
Find the approximate bend point ~3mm that would create the bottom to make contact with the circuit board. Keep your finger at this point and remove the wires from the holes, create this bend with the pliers.
If the above step was correct, inserting the wires into the holes again should create a nice wrap around the end of the connector and fall into the slots underneath.
Ensuring that the bare and insulated wires are in slots, carefully insert the cap using a pair of pliers. This cap will be a tight fit as to make sure the wires stay in place. *See note 10
Next hold the bare wires against the connector and if necessary slide the cable sheath up so that it will make contact with the Strain relief.
Using M3, 4-40, or 6-32 screws and nuts, tighten the strain relief down over the cable sheath to ensure the cable will not pull out of the connector.
Using a multi-meter or ohmmeter test to make sure no cables are shorted together using the following checklist:
a. wire 1 to 2
b. wire 1 to 3
c. wire 1 to 4
d. wire 2 to 3
e. wire 2 to 4
f. wire 3 to 4
Test cable for proper operation using a micro controller, oscilloscope, or a logic analyzer.
Remove cap and add some adhesive to keep cables and cap in place permanently, can be done during assembly if certain everything is correct.
Add a small layer of non-conductive adhesive to the end of the connector where the wires are inserted to the holes.
I am trying to get the pictures in the correct order, but the assembly follows below:
Use four wires from a multi-conductor cable, (cat3/5 work well), cut the remaining wires off.
a. Total wire length should be around 22mm (7/8")
b. Strip wires back 12mm (1/2")
c. Use a pair of fine pliers to straighten wires
Insert striped wires into the holes at the end of the connector, then carefully fold them down.
Find the approximate bend point ~3mm that would create the bottom to make contact with the circuit board. Keep your finger at this point and remove the wires from the holes, create this bend with the pliers.
If the above step was correct, inserting the wires into the holes again should create a nice wrap around the end of the connector and fall into the slots underneath.
Ensuring that the bare and insulated wires are in slots, carefully insert the cap using a pair of pliers. This cap will be a tight fit as to make sure the wires stay in place. *See note 10
Next hold the bare wires against the connector and if necessary slide the cable sheath up so that it will make contact with the Strain relief.
Using M3, 4-40, or 6-32 screws and nuts, tighten the strain relief down over the cable sheath to ensure the cable will not pull out of the connector.
Using a multi-meter or ohmmeter test to make sure no cables are shorted together using the following checklist:
a. wire 1 to 2
b. wire 1 to 3
c. wire 1 to 4
d. wire 2 to 3
e. wire 2 to 4
f. wire 3 to 4
Test cable for proper operation using a micro controller, oscilloscope, or a logic analyzer.
Remove cap and add some adhesive to keep cables and cap in place permanently, can be done during assembly if certain everything is correct.
Add a small layer of non-conductive adhesive to the end of the connector where the wires are inserted to the holes.