CRIMPING Introduction This presentation is the companion to “Background / Resources / Crimping Guide” slide show For more detailed instructions, watch the slide show

CRIMPING Overview In this presentation you will learn: How to use crimping pliers How to create custom cables and connectors for Vex How to determine your cable / connector needs In this presentation you will make: A 7½ foot motor extension cable Will connect a motor to the Vex microcontroller

CRIMPING Making custom cables Why? Standard Vex cables are limited Might need different lengths Might need more extension wires than included in your kit How? Manufacturing your own cable is simple! You will use a crimping tool

CRIMPING Determine your needs Ask yourself: What are you trying to do? What materials do you have or need? What is the configuration of the cable needed to complete your task? What length of cable do you need?

CRIMPING Gather tools You will need: Crimping tool Molex 11-01-0208 Hand Crimper Supports 22 – 24 and 30 – 36 AWG Wire strippers Tape measure

CRIMPING Gather materials Vex cable parts: 22 AWG wire, 3 conductor cable Male Molex pins Female Molex pins Crimp housing

CRIMPING Gather materials More on your cable: AWG (American Wire Gauge) is simply a measure of the wire’s thickness Notice the conductor cable has 3 wires inside (all 22 AWG) This type of cable is used for input and output in the Vex system If you do not have this wire available, substitute with 3 (22 AWG) differently colored wires

CRIMPING Prepare the cable Measure the length of cable you need Make sure to leave yourself 6” of extra length, in case of a mistake For this example, we need a cable 7½ feet long; so it should be 8 feet total after adding the 6 inches If your cable needs to be a more exact length, be very accurate; once the pins have been locked into position, they cannot be removed

CRIMPING Cut cable Cut the length of cable you measured Wire strippers usually double as wire cutters; look for a cutting edge on the blade

CRIMPING Separate wires Use wire strippers to remove 1/8” of insulation from each conductor (wire) Make sure to leave 1½ inches from the end so that you can strip them This cable has PVC tubing around the three wires (the grey covering) Trim this PVC covering 1½ inches around the three wires After trimming the covering, separate the three wires manually

CRIMPING Strip wires Use wire strippers to remove 1/8” of insulation from each conductor (wire) Make sure to place the wire into the proper gauge hole in your wire strippers Squeeze handles until the wire strippers bite through the insulation Slide insulation off the end of the wire, leaving the metal conductor exposed

CRIMPING Step 1 We will now begin making the Vex connector Become familiar with your crimper Make sure you know how to squeeze the handles until the crimper unlocks

CRIMPING Step 1 continued Use the gauge guide (shown at right) to determine which site to use for your gauge of wire In our case, we must use site A (because we have been using 22 AWG wire)

CRIMPING Step 2 The crimper holds the pin in place for you during crimping Locate the spring loaded clamp below the jaw of the crimper Raise the clamp with your finger, as shown

Connects wire to Vex microcontroller CRIMPING Pins Male pins plug into female pins For our example, we want our wire to connect the Vex microcontroller and a motor Male Female Connects wire to Vex microcontroller Connects wire to motor

CRIMPING Step 3 Choose a gender of pin for this connector Place the pin into the open slot on the crimper while the clamp is raised - The male or female end goes in first - The pin cradle should face up or open upward

CRIMPING Step 3 continued The pin should move forward until the front of the pin cradle is against the spring loaded clamp properly loaded pin

CRIMPING Step 4 Release the spring loaded clamp This will lock the pin in position The pin is designed to fit into this crimper - If your pin is crooked, or if the clamp does not clamp down properly, simply lift up the clamp and try again

CRIMPING Step 5 Notice that there are “teeth” on both male and female pins The wire must be positioned using these teeth as guides - Inner set of teeth should be over exposed metal wire - Outer set of teeth should be over insulation Inner teeth: close around bare wire Outer teeth: close around insulation

CRIMPING Step 5 continued Using the guides in the first part of step 5, place the wire in pin cradle, as shown - The bare wire should touch the clamp

CRIMPING Step 6 Squeeze the crimper’s handles to secure the wire into the pin - Make sure to hold the wire steady so that does not move while crimping - Squeeze the handles until you feel them release

CRIMPING Step 7 Remove the wire from the crimper - Push on the bottom of the clamp to release the pin - Once you have reached this state, you cannot separate the wire from the pin without cutting the wire

CRIMPING Step 8 Repeat the steps 1 through 7 for each of the two remaining wires, as shown - Use the same gender pins on all three wires

CRIMPING Housing A crimping housing unit is shown at the right - Once the pins have been inserted into the housing, they cannot be removed - Pins only fit one way into this particular housing unit - Both male and female pins can fit into this particular housing unit Insert pins here

CRIMPING Step 9 Place the wires in the crimping housing - The wires must go in order by color, as shown: black, red, and white - Once you complete this step, you will not be able to remove the wires from the crimping housing without cutting them

CRIMPING Step 10 Line up the wire with the housing - Make sure the locking tab on the pin cradle is facing up, as shown

CRIMPING Step 10 continued Slide the pin into the housing, as shown, until the pin is locked into position - Do not force the wire - The pin might make a clicking sound when it has locked into position

CRIMPING Step 10 continued To test if your pin is locked into the crimp housing, gently tug on the wire, as shown

CRIMPING Step 11 Insert the remaining pins into the housing - Remember the order of colors: black, red, white

CRIMPING Step 12 Repeat steps 1 through 12 for the other side of the wire Check your completed connector against the official Vex connector

CRIMPING Testing Connect the female connector to the motor Connect the male connector to the Vex microcontroller Be sure not to insert these wires backwards; refer to the pictures at the right Turn on your robot and test the motor with your radio control transmitter