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Connector Tester Hardware / Software Demo

dougw

Intro

This update to the Connector Tester portion of my "Start a Movement" design challenge project covers the completed hardware and software for this machine. Just to recap, the connector tester cycles a connector mating pair open and closed while checking for faults such as open or short circuits on each pin. Such testers are used to determine how many mating cycles any particular connector will typically survive. It can also test cable integrity, but that only needs one mating cycle.

Video - Connector Tester Hardware Demo

I just noticed the video did not show that there is an adjustment for the mating connector to lock down precise alignment.

3D Printed Parts

The connector tester machine has five 3D printed parts held together with at least 55 screws. There are no nuts except the leadscrew Acme nut, so many holes had to be threaded.

Discussion

The connector tester hardware and Mega firmware are working great. The parts fit precisely and the test software works well. Unfortunately I lost the magic of how to set up the motor current and cannot get it set up properly in the TMCL-IDE.

The IDE does a good job of running the repetitive position based cycle I want, but for some reason the full current I set up does not get applied to the motor. Incredibly frustrating after all the meticulous design work that went into the this machine..

This will also be an issue for the thread tapping machine if I can't solve it.

The fixed plastic connector mount is a bit marginal in stiffness - it does flex a bit under the full mating force, but it still works fine. A real production machine would use metal parts for durability and stiffness.

I initially had this problem, but the system suddenly started to supply the proper current. Then the next day when I came back to shoot video, I could no longer get the required current.

Links

  • Progressing nicely.

    Are you mainly interested in repetitive testing of just the one type of connector here ?

    The connector chassis appears to be rather large to have to 3D print out one for every different connector type to be tested. Could perhaps split that chassis into two parts such that the connector holder could become a much smaller component, avoiding having to 3D print the whole chassis each time for each new connector type to be tested.

  • in reply to beacon_dave

    I am making machines to demonstrate possible applications of stepper motors. I am not setting up to test a bunch of different connectors. You are right - to make a system that would be used to test arbitrary bulkhead connectors you would have a generic mount for adapter mounting plates. Since I don't plan on testing a lot of connectors, I am hoping the subsystems such as the linear actuator will be suitable as building blocks for other (future) applications.

    I have some vague idea to use the connector tester circuit as a 16 channel continuity tester, but I am still pondering how to do that in a way that would save time over manual testing. For example, if I made adapters for RJ connectors or usb connectors, I could test ethernet cables or USB cables.