RC13HighStrengthEncoderWires

Overview

In the past, there have been cases of encoder faults being detected due to encoder wires breaking. The terminals in use are the Molex 1.25mm pitch Pico Blade terminals (encoder side) and the Molex 2.00mm pitch Sherlock terminals (board side). Four of these signal wires are bound with heat shrink tubing to create each encoder wire.

Problems and Possible Causation

• The wires tend to break near the encoder side (connector terminal breaks off)
  • Imperfect wire stripping causes poor crimping, making the conenctor very fragile
• Wire tends to break on disconnect
  • The older revision E4P encoder used a through-hole version of the mating connector, which made disconnecting of the wire very difficult
  • High connection resistance and small room for handling the connectors required inevitable improper methods to be taken to disconnect the wire (partial tugging on the wire itself)