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How to connect wires of different gauges togather?

Former Member

Hi, i need to connect wires of different gauges togather . The connection should be secured (cannot be pulled apart easily) and yet must be easily disconnectable by means of using a screwdriver etc. The wires thickness are from 3mm to 10mm. an anyone recommend a element14 product for this? Thanks!

  • 0

    Hi,

     

    Are we talking about square mm or diameter?

     

  • 0

    Hi,

     

    is 3mm - 10mm the wire gauge range?

     

    What will you be connecting this to? 

  • 0

    Hi Kee,

     

    Wire size is usually based upon the current load each is expected to use.  As long as you do not draw too much current through the smaller wires you are usually OK.  If your connections are signal and not power connections, then you need to look at the frequency of the signals.  You usually need to go to stranded wire verses solid wire for high frequency signals.

     

    So if you are just working with signals, you are probably ok to connect, but if there are high current on any of the wires, then you probably do not want to do it.  The smaller the wire, the higher the resistance per foot.  That affects how long your wire runs can be before you get serious signal degradation.

     

    Hopefully this helps.

     

    DAB

  • 0

    Changing wire sizes for sending a signal is not advisable, you will experience interference due to signal reflection at the junctions.

    Thinner wire also introduces a higher resistance to the system. Due to this, the smaller gauge wire will get hotter than the larger. Be sure to address that in your design.

     

    If you must do that, solder the wires into screw down terminal ends, spade terminalsspade terminals.

    - Pull the plastic cover off the end

    - Place the wire in and scrip one side

    - Crimp the other side on top of the first

    - Solder the wire to the terminal

    - Use heat shrink tube heat shrink tube to cover your solder work. This also acts as a strain relief.

     

    Hope this helps.

     

    Cabe

  • 0 in reply to MDeGrauw

    Same gauge but they are red and black. The larger cable is already connected

  • 0

    Hi Kee,

     

    I don't think there is an off the shelf solution for what you are looking.

    A connector for gauge 4/0 to 11. I don't know what use-case need such a connector.

    Like DAB was saying gauge of a wire is decided based on the current that wire should handle. Gauge 4/0 is quite uncommon in electronics.

    Generally they carry heavy load in electrical systems and battery connections. Even gauge 11(3mm) is used in high current applications.

     

    One solution I can think of is get two ring terminals and make a custom nut and bolt attachment for those.

    Take a look at these two products. The stud size is different in both cases. So you need to use some kinda washers to adjust the bolt.

    https://in.element14.com/amp-te-connectivity/0-0035108-0/crimp-terminal-ring-pidg-m4-yellow/dp/4217469

    https://in.element14.com/amp-te-connectivity/321878/terminal-ring-tongue-3-8-4-0awg/dp/2774898#anchorTechnicalDOCS

     

    Note : Please check the load current passing through each of these wires in your application. Low gauge to high gauge electricity transfer can heat-up the high gauge wire and sometimes melt the entire wire depending on how much current the source/load is driving. So be careful.

     

    Regards,

    Aswin