Dreadful DIN plug...

B

bitrex

Guest
This DIN plug has 8 or 9 components to assemble:

<https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly>

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!
 
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!
Click to expand...

The wires are there. They are just invisible. LOL.

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
 
On Tue, 13 Oct 2020 17:50:14 -0400, bitrex <user@example.net> wrote:

This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!
Click to expand...

\'You will hear it click as it snaps into place.\'

I\'ve been hear that click all my life.

Now I want a disassembly/rework instruction that doesn\'t require
special tools.

RL
 
On 10/13/2020 6:55 PM, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!

The wires are there. They are just invisible. LOL.

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
Click to expand...

These are little tricky to get right but once it\'s wired up seems a
pretty rugged connector.

The video is a bit silly because it shows you how to build a useless
object! once it\'s assembled there\'s no way to connect the cable!
Building it on the bench there are certain parts you have to slip over
the cable and if you mess it up you\'re in the classic
forgot-to-put-the-heat-shrink-over-the-wire-first situation.

The pins to connect are tiny, no lugs, and the wire I\'m using is for a
power connector, the best I could do is tin both pin and wire and use
3rd hands to align them and solder together straight-in, then wrap in
heat shrink (which you must also put over all three internal wires in
the cable...first)

DIN power connectors seem more common on European stuff. Detusche
Industrie Norm was used a lot in Soviet Bloc countries for all sorts of
stuff like audio connectors too, must be why they called it Deutshce
Industrie Norm.
 
On 10/13/2020 7:12 PM, legg wrote:
On Tue, 13 Oct 2020 17:50:14 -0400, bitrex <user@example.net> wrote:

This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!

\'You will hear it click as it snaps into place.\'

I\'ve been hear that click all my life.

Now I want a disassembly/rework instruction that doesn\'t require
special tools.

RL
Click to expand...

I was lucky and did it right on the first try, if I hadn\'t IDK how I\'d
fix my mistake other than snippers and the trash bin.
 
On 14-Oct-20 9:55 am, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!

The wires are there. They are just invisible. LOL.

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
Click to expand...

I\'ve sometimes wondered whether the entire market for such plugs
consists of people who try to solder them, fail, and eventually abandon
the attempt.

Sylvia.
 
On Tuesday, October 13, 2020 at 4:16:05 PM UTC-7, Sylvia Else wrote:
On 14-Oct-20 9:55 am, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!

The wires are there. They are just invisible. LOL.

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.

I\'ve sometimes wondered whether the entire market for such plugs
consists of people who try to solder them, fail, and eventually abandon
the attempt.
Click to expand...

Well, they are good enough to make a prototype, with the specific wire size, length and color, then send it to the manufacturer. They probably mold the plastic with the pins and wires together.
 
Ed Lee wrote:

============
Anyway, the difficult part is soldering the wires without
melting the plastic holding the pins together. I tried to
solder wires to a 12 pins plug. After a few wires,
the plastic get deformed and not mating well.
Click to expand...

** You need to plug the male insert into a socket while soldering.

Pre- tin the wires and solder quick with a temp controlled iron at about 300C.


...... Phil
 
On 2020/10/13 3:55 p.m., Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!

The wires are there. They are just invisible. LOL.

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
Click to expand...

Have a DIN 12 pin socket to help keep the plug pins in place...and heat
sink (alligator clip) the socket pin you are working on!

John :-#)#
 
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
Click to expand...

You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...
 
On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...
Click to expand...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.
 
On Wednesday, October 14, 2020 at 10:47:37 AM UTC-4, Ed Lee wrote:
On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...
I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.
Click to expand...

It helps to pre-tin the solder cup contacts before soldering the wires to them. Add a drop of liquid rosin flux after that, and pre-tin the wires. then you only have to heat the pre-tinned end to flow them together. That takes much less heat. Start with the lowest row of pins with the solder cup openings to the top. These are much smaller wire count than repairing cables for old studio cameras. Some military manuals had great drawings of how to assemble and wire circular connectors.
 
On Wed, 14 Oct 2020 07:47:28 -0700 (PDT), Ed Lee
<edward.ming.lee@gmail.com> wrote:

On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.
Click to expand...

You can buy all sorts of cable assemblies. Why go to all that trouble?



--

John Larkin Highland Technology, Inc

Science teaches us to doubt.

Claude Bernard
 
On Wednesday, October 14, 2020 at 9:03:14 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 07:47:28 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.

You can buy all sorts of cable assemblies. Why go to all that trouble?
Click to expand...

That\'s what i am saying. I am just building a few prototype with the right size and length color coded cables, then order the rest from someone.
 
On Wed, 14 Oct 2020 09:28:40 -0700 (PDT), Ed Lee
<edward.ming.lee@gmail.com> wrote:

On Wednesday, October 14, 2020 at 9:03:14 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 07:47:28 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.

You can buy all sorts of cable assemblies. Why go to all that trouble?

That\'s what i am saying. I am just building a few prototype with the right size and length color coded cables, then order the rest from someone.
Click to expand...

Even better, try to use a stock cable assembly.

I use ribbon cables when I can. And buy stock cables, or make up a
part number according to Digikey rules and let them make it for me.
For less than I can buy the parts.



--

John Larkin Highland Technology, Inc

Science teaches us to doubt.

Claude Bernard
 
On Wednesday, October 14, 2020 at 9:53:43 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 09:28:40 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Wednesday, October 14, 2020 at 9:03:14 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 07:47:28 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.

You can buy all sorts of cable assemblies. Why go to all that trouble?

That\'s what i am saying. I am just building a few prototype with the right size and length color coded cables, then order the rest from someone.
Even better, try to use a stock cable assembly.

I use ribbon cables when I can. And buy stock cables, or make up a
part number according to Digikey rules and let them make it for me.
For less than I can buy the parts.
Click to expand...

I don\'t think ribbon cables can handle 5A as these plugs. I need 22 AWG wires as well.
 
On Wed, 14 Oct 2020 10:44:35 -0700 (PDT), Ed Lee
<edward.ming.lee@gmail.com> wrote:

On Wednesday, October 14, 2020 at 9:53:43 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 09:28:40 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Wednesday, October 14, 2020 at 9:03:14 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 07:47:28 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.

You can buy all sorts of cable assemblies. Why go to all that trouble?

That\'s what i am saying. I am just building a few prototype with the right size and length color coded cables, then order the rest from someone.
Even better, try to use a stock cable assembly.

I use ribbon cables when I can. And buy stock cables, or make up a
part number according to Digikey rules and let them make it for me.
For less than I can buy the parts.

I don\'t think ribbon cables can handle 5A as these plugs. I need 22 AWG wires as well.
Click to expand...

I\'m using three parallel wires of a 28ga ribbon cable for 48 volts at
5.4 amps into my class-D power amps, which is super conservative. Just
one wire barely gets warm at 5 amps. Picking the pins right spreads
out the heat in the cable too.

https://www.dropbox.com/s/rdejxjz8a6vbny7/P900_FA_Jun_15.jpg?raw=1

The mating connectors are cheap shrouded boxes on the PCBs, and
Digikey makes the ribbon cables.
 
On Wednesday, October 14, 2020 at 12:12:33 PM UTC-7, John Larkin wrote:
On Wed, 14 Oct 2020 10:44:35 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Wednesday, October 14, 2020 at 9:53:43 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 09:28:40 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Wednesday, October 14, 2020 at 9:03:14 AM UTC-7, jla...@highlandsniptechnology.com wrote:
On Wed, 14 Oct 2020 07:47:28 -0700 (PDT), Ed Lee
edward....@gmail.com> wrote:

On Tuesday, October 13, 2020 at 6:55:30 PM UTC-7, whit3rd wrote:
On Tuesday, October 13, 2020 at 3:56:00 PM UTC-7, Ed Lee wrote:
On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly
Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
You can solder to some of those connectors by putting the mating connector in a vise, and
plugging the subject into it (increases heat capacity of pins), then if it takes lap-joints, prep
with a tiny coil of bare copper wire, just big enough to hold the cable strand and the connector
back-shank. I\'ve found mini-DIN connectors can be workable, if you have a #50 drill shank
to wind the copper around...

I am trying this:

https://www.ebay.com/itm/SP21-12Pin-Waterproof-Circular-Connector-Panel-Mount-Electrical-Connector-5A400V/263517120554?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I\'ll try a couple more. I would have to destroy a pair by heat sinking the mating connectors, perhaps with conductive metal glue, binding all the pins together.

It\'s difficult to get to the center pins, i wish they make the center pins longer.

In the long run, for more than a few pieces, it\'s probably more cost effective to ask the manufacturer to do it.

You can buy all sorts of cable assemblies. Why go to all that trouble?

That\'s what i am saying. I am just building a few prototype with the right size and length color coded cables, then order the rest from someone.
Even better, try to use a stock cable assembly.

I use ribbon cables when I can. And buy stock cables, or make up a
part number according to Digikey rules and let them make it for me.
For less than I can buy the parts.

I don\'t think ribbon cables can handle 5A as these plugs. I need 22 AWG wires as well.

I\'m using three parallel wires of a 28ga ribbon cable for 48 volts at
5.4 amps into my class-D power amps, which is super conservative. Just
one wire barely gets warm at 5 amps. Picking the pins right spreads
out the heat in the cable too.
Click to expand...

28ga should be fine for 2A, but not constant 5A.

I need each wire to handle constant 5A, and a couple of parallel wires for 10A. These SP21 connectors max out at 12 pins; so i can\'t parallel too many of them.
 
On Tue, 13 Oct 2020 15:55:53 -0700 (PDT), Ed Lee
<edward.ming.lee@gmail.com> wrote:

On Tuesday, October 13, 2020 at 2:50:23 PM UTC-7, bitrex wrote:
This DIN plug has 8 or 9 components to assemble:

https://www.digikey.com/en/videos/k/kycon/kmdlax-assembly

And they show you the assembly procedure (why is it narrated by a
teenager?) but they assemble it without connecting a cable. WTF! How you
gonna show how to assemble a cable connector with no cable!

The wires are there. They are just invisible. LOL.

Anyway, the difficult part is soldering the wires without melting the plastic holding the pins together. I tried to solder wires to a 12 pins plug. After a few wires, the plastic get deformed and not mating well. So, i gave up.

I am still looking for better heat resistive plastic, or perhaps pre-soldered with wires.
Click to expand...

You need a hot (800F) temperature-controlled iron, so you can solder
the wires into the cups instantly, a puff of smoke and done.

Joe Gwinn
 
On 10/14/20 00:47, Phil Allison wrote:
Ed Lee wrote:

============

Anyway, the difficult part is soldering the wires without
melting the plastic holding the pins together. I tried to
solder wires to a 12 pins plug. After a few wires,
the plastic get deformed and not mating well.


** You need to plug the male insert into a socket while soldering.

Pre- tin the wires and solder quick with a temp controlled iron at about 300C.


..... Phil
Click to expand...

Similar method here, but pretin the pins as well as the wires,
fast, so not all the flux has evaporated. Then insert plug into
socket and typically less than a second touch to bring the
two together.

Cheap D connectors and many others have the same problem...

Chris
 
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