Connector opinions?

[IncrdblHulk7]

I am beginning planning for a modular panel setup.  I was just wondering what kind of connectors people are using and any advice.  For the setup I am planning, I would need somewhere between 15-25 connectors on the largest connector - this kinda rules out RJ45 (unless I do multiple jacks)

I have mainly been pricing out D-Sub and Molex connectors.  I have worked with solder-cup D-Sub connectors before - and while they might be cheap, soldering the wires on can be a pain (any tricks to make it easier?).  It seems like the crimp D-Sub connectors all require a very expensive crimper tool.  

I figure I will just use Molex connectors for any internal break-away wiring I do between panel housing Ipac and OptiPac.  But, I like the fancier look of the D-Sub connector for the interface to the modular panels.  I guess I could always use the panel mount Molex connectors - as they seem to be alot easier to work with.

Also, has anyone tried the Molex solder-tail terminals - wondering if they are easier to use the crimp style - and it would save money on crimper.

Any advice?  

 

[Landstander]

I would need somewhere between 15-25 connectors on the largest connector - this kinda rules out RJ45 (unless I do multiple jacks)

Are your modules going to each take up the full control panel? If not, I actually think it helps your flexibility if you use multiple jacks for connecting panels. Splitting out the buttons from the joystick directions allows you to mix and match different pieces as needed. Plus, making cables and connectors with RJ45 jacks is pretty easty.
Here are visio drawings of the setup I am going to use that I think will allow easy mixing and matching of components.
http://www.aracnet.com/~stigmata/mame/ipac.gif
http://www.aracnet.com/~stigmata/mame/optipac.gif
I linked to them since they are pretty wide....

[NoOne=NBA=]

The absolute "must-have" piece of equipment for soldering those connectors is a small project vise from Radio Shack.

It has two little arms on it that are articulated, like a robot arm, and end in alligator clips.
That lets you put the connector in one arm, and the wire in the other, and move them both around, to get them into position for soldering.

Also, fill ALL the solder cups with solder, and tin the ends of the wires before you insert them.
That lets you melt the solder in the cup really quickly, and push the wire in until it sets up.

[Tiger-Heli]

I am beginning planning for a modular panel setup.  I was just wondering what kind of connectors people are using and any advice.  For the setup I am planning, I would need somewhere between 15-25 connectors on the largest connector - this kinda rules out RJ45 (unless I do multiple jacks)

I have mainly been pricing out D-Sub and Molex connectors.  I have worked with solder-cup D-Sub connectors before - and while they might be cheap, soldering the wires on can be a pain (any tricks to make it easier?).  It seems like the crimp D-Sub connectors all require a very expensive crimper tool.  

I figure I will just use Molex connectors for any internal break-away wiring I do between panel housing Ipac and OptiPac.  But, I like the fancier look of the D-Sub connector for the interface to the modular panels.  I guess I could always use the panel mount Molex connectors - as they seem to be alot easier to work with.

Also, has anyone tried the Molex solder-tail terminals - wondering if they are easier to use the crimp style - and it would save money on crimper.

Any advice?  

DB 25's or DB37 will be your best bet.  

Look for RS-232 M/F serial extension cables (not null-modem which may not have all pins wired.)  They used to be on pricewatch.com for $2-3 for ten foot cables.  Cut it in half and wire one end to the panel and the other to the encoder - no soldering or crimping.

Another option is a cut flat ribbon HD cable and IDC DB25 connectors, but thess get pricey ($5-7 per connector, usually).

[Sapper]

I used a thirty-seven pin solder connector for my panel, and I have regretted it ever since.  Although the controls are working now, the soldering process must have melted some of the plastic within the connector, causing me unbelievable shorting problems with my IPAC.  It took a lot of diagnostic time and resoldering to solve this problem.   Sometimes I still get little problems here and there where pressing a button will give me a surprise result.  

Nothing sucks more than trying to play R-Type and launching your rover unexpectedly and without intent...

If and when I rewire the panel, I think I will use a ribbon wire, cut it in half, and solder the individual wires to the switches.  Instant connections.

Cheers.

[IncrdblHulk7]

I was checking out the D-Sub 37 and 50 connector plugs.  I hadnt thought about buying prefab cables and chopping in half.  The only trouble is that on the modular CP end - I wanted panel mounted receptacles for the panels to plug into.  Buying prefab cables would not allow me to do this!  

A side question:  Do I need to run all the Ground wires from Ipac and OptiPac to respective controls - or could I just run a single ground line directly from Computer PS?  Would that cause any problems?

[Sapper]

The only trouble is that on the modular CP end - I wanted panel mounted receptacles for the panels to plug into.  Buying prefab cables would not allow me to do this!  

Why not?  Most ribbon connectors have holes on the sides where screw connectors would hold them together.  You could use these to screw into a panel of some nature, or use hot glue or epoxy to affix the end through a hole onto the panel.

Further bonus...multiple ribbon cables of the same type will allow you to run several control panels with the same male end into the one female on your panel.  Just ensure you map the connections well....

AS for the ground, I don't know if you could run the gnd from the PS, but I think you would be better off completing the IPAC circuit from its ground.  

PS...attached is a pic of the rat's nest caused by a thirty-seven pin connector...

Cheers.

[IncrdblHulk7]

I dont plan on screwing the Dsub connectors together when connecting a panel - therfore would Molex provide a better connection?

Here is what I planned to do:

BreakOut Junction from Ipac,OptiPac, DruinRotary Boards -
requires about 72-80 connections
1) 2xDsub37
2) 4xMolex24

Modular CP Hookup
This is a previous post showing the modular panels I plan on building
http://www.arcadecontrols.org/yabbse/index.php?board=1;action=display;threadid=20670
Player1 Controls - 12 inputs + Gnd, 5v, 12V = 15
Player2 Controls - 12 inputs + Gnd, 5V, 12V = 15
P1 Rotary - 12 Inputs = 12
P2 Rotary - 12 Inputs = 12
TB1 = 6 inputs + GND, 5V, 12V = 9
TB2 = 6 inputs + GND, 5V, 12V = 9
Spinner1 = 5 inputs + GND, 5V, 12V = 8
Spinner2 = 5 inputs + GND, 5V, 12V = 8
4-Way = 7inputs + GND = 8

Using DSub - I could combine the respective player and rotary hookups into a single DB25.  So that would result in an interface with DB25x2 and DB9x5.

Using Molex - would result in M15x2, M12x2, M9x5.

Either way it seems like it really just comes down to what connector would provide the best connection and ease of use in this application.

I think I am leaning toward the Molex connectors (solder or crimp connectors???)