Skip to content

Commit 28afd18

Browse files
jasondamingclaude
andcommitted
Address PR 3142 review comments from sciencewhiz
- Remove redundant "Reliability" bullet point (covered by other bullets) - Add "Connector Types Used in FRC" section before tools/crimping instructions - Fix formatting for recommended tools list and other sections - Replace "brownouts" with "momentary disconnections" (accuracy fix) - Reorganize "Other Connector Types" to focus on crimping best practices 🤖 Generated with [Claude Code](https://claude.com/claude-code) Co-Authored-By: Claude <noreply@anthropic.com>
1 parent 97fc4da commit 28afd18

1 file changed

Lines changed: 43 additions & 22 deletions

File tree

source/docs/hardware/hardware-basics/crimping-best-practices.rst

Lines changed: 43 additions & 22 deletions
Original file line numberDiff line numberDiff line change
@@ -1,32 +1,56 @@
11
# Wire Crimping Best Practices
22

3-
Proper wire crimping is essential for creating reliable electrical connections on your FRC robot. Poor crimps can lead to intermittent brownouts, voltage drops, and connection failures that are difficult to diagnose. This guide covers best practices for crimping Anderson Powerpole connectors and other common FRC connectors.
3+
Proper wire crimping is essential for creating reliable electrical connections on your FRC robot. Poor crimps can lead to voltage drops, momentary disconnections, and connection failures that are difficult to diagnose. This guide covers best practices for crimping Anderson Powerpole connectors and other common FRC connectors.
44

55
## Why Proper Crimping Matters
66

77
A properly crimped connection provides:
88

99
- **Low electrical resistance** - Minimizes voltage drop and heat generation
1010
- **Mechanical strength** - Prevents wires from pulling out under vibration
11-
- **Reliability** - Eliminates intermittent connections that cause brownouts
1211
- **Safety** - Reduces risk of shorts and electrical fires
1312

1413
Poor crimps are a common source of mysterious electrical problems. A connection that works on the bench may fail under the vibration and stress of competition.
1514

15+
## Connector Types Used in FRC
16+
17+
Before learning how to crimp, it's important to understand the different connector types commonly used on FRC robots:
18+
19+
### Anderson Powerpole Connectors
20+
21+
Anderson Powerpole connectors are the primary power connectors used in FRC. They feature a genderless design that allows any connector to mate with any other connector of the same size. They come in three amperage ratings:
22+
23+
- **15 amp (PP15-45)** - Used for smaller loads, typically signal wiring or low-current devices
24+
- **30 amp (PP15-45)** - Common for motor controllers and moderate current loads, uses the same housing as 15 amp
25+
- **45 amp (PP15-45)** - Used for higher current applications, uses the same housing as 15 and 30 amp
26+
27+
All three contact sizes fit in the same PP15-45 housing. The contacts are what differ - they accept different wire gauges and have different current ratings.
28+
29+
### Ferrules
30+
31+
Wire ferrules are crimped metal sleeves placed on the end of stranded wire. They provide a solid, uniform tip that works well with screw terminals found on motor controllers (like the Spark MAX), the PDH, and other FRC electronics. Ferrules prevent strand fraying and ensure all wire strands make good contact.
32+
33+
### Ring and Spade Terminals
34+
35+
Ring terminals (closed loop) and spade terminals (open fork) are used for bolt-on connections such as battery terminals and chassis ground points. These terminals are crimped onto wire and then secured with a bolt or screw.
36+
37+
### Wire-to-Board Connectors
38+
39+
Many FRC components use small-pitch connectors like JST, Molex, or Dupont-style for signal wiring. These require specialized crimp contacts and precise wire stripping.
40+
1641
## Required Tools
1742

1843
### Crimping Tools
1944

2045
**Ratcheting Crimpers** (Highly Recommended)
2146

22-
Ratcheting crimpers provide consistent, high-quality crimps by ensuring proper compression force every time. They prevent under-crimping or over-crimping by not releasing until the crimp cycle is complete.
47+
Ratcheting crimpers provide consistent, high-quality crimps by ensuring proper compression force every time. They prevent under-crimping or over-crimping by not releasing until the crimp cycle is complete. Recommended tools include:
2348

24-
Recommended tools:
2549
- **TRIcrimp** - Designed specifically for Anderson Powerpole connectors (15, 30, and 45 amp)
2650
- **IWISS Powerpole Crimper** - Ratcheting tool for Anderson Powerpole connectors
2751
- **Anderson 1309G3** - Official Anderson Power Products crimping tool
2852

29-
.. important:: Invest in a quality ratcheting crimper. While they cost more initially ($40-100), they produce vastly superior crimps compared to generic wire strippers with crimping dies. The FRC Tool Recommendations document lists approved options.
53+
.. important:: Invest in a quality ratcheting crimper. While they cost more initially ($40-100), they produce vastly superior crimps compared to generic wire strippers with crimping dies.
3054

3155
**Manual Crimpers** (Budget Option)
3256

@@ -93,7 +117,7 @@ After crimping, the contact must be properly seated in the plastic housing:
93117
3. **Push firmly** - Insert the contact and crimped wire until you hear/feel a click
94118
4. **Pull test** - Gently tug the wire to verify the contact is locked in place
95119

96-
.. important:: Contacts that are not fully inserted can cause intermittent connections, brownouts, or complete disconnection. Always perform a pull test!
120+
.. important:: Contacts that are not fully inserted can cause intermittent connections or complete disconnection. Always perform a pull test!
97121

98122
### Common Powerpole Crimping Problems
99123

@@ -176,36 +200,33 @@ Higher resistance indicates a poor crimp that should be redone.
176200
- Reusing contacts after a bad crimp (throw it away and start over)
177201
- Not doing pull tests or visual inspection
178202

179-
## Other Connector Types
203+
## Crimping Other Connector Types
180204

181-
While Anderson Powerpole connectors are the primary FRC power connectors, other connectors are also used:
205+
### Ferrule Crimping
182206

183-
### Ferrules
184-
185-
Wire ferrules are crimped metal sleeves used on stranded wire ends for screw terminal connections (like motor controllers, PDH channels, etc.)
207+
When crimping ferrules for screw terminal connections:
186208

187-
**Best Practices:**
188209
- Use properly sized ferrules for your wire gauge
189-
- Ferrule crimpers provide better results than generic tools
210+
- Ferrule crimpers (square or hexagonal) provide better results than generic tools
190211
- Strip wire to match ferrule depth (usually 8-10mm)
212+
- Insert all wire strands into the ferrule before crimping
191213
- Crimp should compress ferrule evenly without deforming it
192-
- Check that no strands are outside the ferrule
214+
- Verify no strands are outside the ferrule after crimping
193215

194-
### Ring and Spade Terminals
216+
### Ring and Spade Terminal Crimping
195217

196-
Used for battery terminals and some ground connections.
218+
When crimping ring or spade terminals:
197219

198-
**Best Practices:**
199220
- Use heat-shrink or insulated terminals to prevent shorts
200-
- Crimp both the conductor barrel and insulation support
201-
- Verify terminal size matches stud size (battery terminals are typically 1/4" or M6)
221+
- Crimp both the conductor barrel and insulation support wings
222+
- Verify terminal hole size matches the stud size (battery terminals are typically 1/4" or M6)
202223
- Apply anti-oxidant compound to copper-aluminum connections
224+
- See :doc:`robot-battery` for detailed battery terminal information
203225

204-
### Wire-to-Board Connectors
226+
### Wire-to-Board Connector Crimping
205227

206-
Many FRC components use JST, Molex, or Dupont-style connectors for signal wiring.
228+
When crimping small signal connectors (JST, Molex, Dupont-style):
207229

208-
**Best Practices:**
209230
- Use the manufacturer's specified crimping tool when possible
210231
- Strip very precise lengths (typically 2-3mm for these small connectors)
211232
- Ensure contacts click fully into the housing

0 commit comments

Comments
 (0)