Connecting a 4mm^2 cable to a pcb track

[overgeo]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

 

[Ross Herbert]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

Without trying to belittle your efforts, if this design task presents
a problem for you then I would suggest that your inverter isn't going
to work either....

 

[overgeo]

Ross Herbert ha escrito:

Without trying to belittle your efforts, if this design task presents
a problem for you then I would suggest that your inverter isn't going
to work either....

What do you know about me? maybe i'm not going to make the inverter and
is only a prototipe design, or maybe i'm in a team, and my design part
is only make the pcb,and the hard electronic part is done by another
people, or maybe another person give me all the design except the pcb i
have to make the pcb, or maybe..., and if you are so smart that you can
tell the people what they can do and what they can't do, why don't you
answer the question?, if you haven't got any useful to say betther not
say anything,

 

[Frank Bemelman]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

Crimp terminal + bolt + washer + (lock)nut.

 

[[email protected]]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

40A is alot for a pcb track, most people wire the power cables direct
to the power devices.

 

[Fred Bloggs]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

There is quite a lot of physics involved in a proper high current
connection technology- and the real world of applications comes into
play with additional challenges such as oxidation and overcurrrent
conditions. You would be better off using an experienced manufacturer
with a successful track record such as:
http://www.icoregroup.com/hcc_single_pole.html .

 

[John Larkin]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

Either

A nylon-shell (Amp or Molex) connector, using several pins (and wires)
in parallel for current and return

or

2 or better yet 3 (or 4?) faston tabs soldered to the board, multiple
wires again

or, best yet,

leaf through the Mouser and Digikey catalogs, and check out the Amp
(Tyco), Molex, and Methode web sites.


Note that thermal and voltage drop issues get nasty with currents like
this on PC boards. This is not trivial.

John

 

[[email protected]]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

[...]
Note that thermal and voltage drop issues get nasty with currents like
this on PC boards. This is not trivial.

John

Way back in the day, I used to repair 1970s era colour TVs where tracks
had become hot enough to char the PCB material and even burn holes,
destroying the hot track and adjacent ones. (Usually in the line output
stage) It was common practice to cut away the (now much more conductive
than when it was new) charred board material from the edges of the
hole, prepare the ends of the interrupted tracks by scraping and
tinning, and reconnect them with "bridges" of insulated wire soldered
directly to the track. Not pretty but cheaper than a new line output
board, and also often more reliable than the original board.

 

[overgeo]

Thanks for all your answers.

#[email protected]

40A is alot for a pcb track, most people wire the power cables direct
to the power devices.

I'm gonna use a copper bar and I have seen that can carries 40 A or
bigger, but anyway can you tell me some adaptors in wich i can put an
igbt with a to 247 capsule

#John Larkin -

Either

A nylon-shell (Amp or Molex) connector, using several pins (and wires)
in parallel for current and return

or

2 or better yet 3 (or 4?) faston tabs soldered to the board, multiple
wires again

or, best yet,

leaf through the Mouser and Digikey catalogs, and check out the Amp
(Tyco), Molex, and Methode web sites.

Note that thermal and voltage drop issues get nasty with currents like
this on PC boards. This is not trivial.

John

I have already seen that connectors and, it is a possible solution, you
mean connectors like this?
http://www.molex.com/cgi-bin/bv/mol...llink=Introduction&pageTitle=Selection Matrix
I think that is the solution that im gonna use.

#[email protected]
Way back in the day, I used to repair 1970s era colour TVs where tracks
had become hot enough to char the PCB material and even burn holes,
destroying the hot track and adjacent ones. (Usually in the line output
stage) It was common practice to cut away the (now much more conductive
than when it was new) charred board material from the edges of the
hole, prepare the ends of the interrupted tracks by scraping and
tinning, and reconnect them with "bridges" of insulated wire soldered
directly to the track. Not pretty but cheaper than a new line output
board, and also often more reliable than the original board.

It's a good suggestion, i will have in account.

 

[Ross Herbert]

Ross Herbert ha escrito:


What do you know about me? maybe i'm not going to make the inverter and
is only a prototipe design, or maybe i'm in a team, and my design part
is only make the pcb,and the hard electronic part is done by another
people, or maybe another person give me all the design except the pcb i
have to make the pcb, or maybe..., and if you are so smart that you can
tell the people what they can do and what they can't do, why don't you
answer the question?, if you haven't got any useful to say betther not
say anything,

Perhaps my sarcasm was a bit over the top...

You did say "I'm designing an inverter..." so it is logical to assume
that you meant what you said. If you were only responsible for the PCB
design then you would first need to have the schematic and component
makeup fairly well established and that can't be done in isolation
from those responsible for this part of the project.

The problem you have asked about is something which power designers
have had for 60 years since PCB's started to appear and there are
numerous examples of how the problem has been overcome, particularly
in heavy duty bench power supplies, battery chargers, UPS etc., So, if
you had taken the time to look at some of these examples the answer
would have started to become clear.

In the 1960's there weren't forums like newsgroups where lazy people
could just ask and hope to get all the answers on a plate without
doing any research themselves. They had to go out and look at what was
available and even design new and novel solutions if nothing was there
already. It all took time and considerable effort. Nobody minds
helping others to solve a problem where it is evident that they have
at least done some research. However, I have noticed that a number of
queries such as yours emanate from people who have obviously not done
one jot of investigation or research. I don't think those people
really deserve to be simply handed the benefit of hard work done by
others, just because they know the knowledge is out there. Do some
research, look at examples of other equipment, and study connector
catalogues first, like we had to do. If that doesn't produce the
desired result, then you can ask - but when you ask you should explain
how hard you have tried already so we get the right impression.

 

[[email protected]]

#[email protected]
Way back in the day, I used to repair 1970s era colour TVs where tracks
had become hot enough to char the PCB material and even burn holes,
destroying the hot track and adjacent ones. (Usually in the line output
stage) It was common practice to cut away the (now much more conductive
than when it was new) charred board material from the edges of the
hole, prepare the ends of the interrupted tracks by scraping and
tinning, and reconnect them with "bridges" of insulated wire soldered
directly to the track. Not pretty but cheaper than a new line output
board, and also often more reliable than the original board.

It's a good suggestion, i will have in account.

It wasn't a suggestion, you dummy, it was a WARNING! A warning not to
pass heavy currents through PCB tracks.

 

[overgeo]

Ross Herbert ha escrito:

Perhaps my sarcasm was a bit over the top...

You did say "I'm designing an inverter..." so it is logical to assume
that you meant what you said. If you were only responsible for the PCB
design then you would first need to have the schematic and component
makeup fairly well established and that can't be done in isolation
from those responsible for this part of the project.

The problem you have asked about is something which power designers
have had for 60 years since PCB's started to appear and there are
numerous examples of how the problem has been overcome, particularly
in heavy duty bench power supplies, battery chargers, UPS etc., So, if
you had taken the time to look at some of these examples the answer
would have started to become clear.

In the 1960's there weren't forums like newsgroups where lazy people
could just ask and hope to get all the answers on a plate without
doing any research themselves. They had to go out and look at what was
available and even design new and novel solutions if nothing was there
already. It all took time and considerable effort. Nobody minds
helping others to solve a problem where it is evident that they have
at least done some research. However, I have noticed that a number of
queries such as yours emanate from people who have obviously not done
one jot of investigation or research. I don't think those people
really deserve to be simply handed the benefit of hard work done by
others, just because they know the knowledge is out there. Do some
research, look at examples of other equipment, and study connector
catalogues first, like we had to do. If that doesn't produce the
desired result, then you can ask - but when you ask you should explain
how hard you have tried already so we get the right impression.

I don't have to explain what i'm gonna do, i just give you all the
information needed, the pcb is for an inverter you don't need to know
more (and really you don't need to know that is for a inverter). I
still don't understand why ask my messages, do you like to answer
without to say nothing useful?, i repeat you don't know anynthing about
me, and you don't know if a make a research before, if i don't say a
thing, that doesn't mean that i haven't done, i don't have to explain
you everything. And i'm not going to tell you my success or my hard
work just to cause a right impression for you.

And finally if you got a problem with questiones like this, pleas
contact with the moderatos and tell them, and ask them that you want to
be a moderator for ban messages like this, and a little advice, don't
post stupid things like this, teach your "knowledge" to your son (if
you got) or whatever you got (if you really got something). Have a nice
day Ross Herbert.

 

[Michael A. Terrell]

Ross Herbert ha escrito:


I don't have to explain what i'm gonna do, i just give you all the
information needed, the pcb is for an inverter you don't need to know
more (and really you don't need to know that is for a inverter). I
still don't understand why ask my messages, do you like to answer
without to say nothing useful?, i repeat you don't know anynthing about
me, and you don't know if a make a research before, if i don't say a
thing, that doesn't mean that i haven't done, i don't have to explain
you everything. And i'm not going to tell you my success or my hard
work just to cause a right impression for you.

And finally if you got a problem with questiones like this, pleas
contact with the moderatos and tell them, and ask them that you want to
be a moderator for ban messages like this, and a little advice, don't
post stupid things like this, teach your "knowledge" to your son (if
you got) or whatever you got (if you really got something). Have a nice
day Ross Herbert.

This is not a moderated group, whether you like it, or not. You are
accessing a Usenet newsgroup though Google Groups, and they have no
control over this, or any other newsgroup, other than refusing to allow
access to it.

Either learn to run with the big dogs, or go back and hide under the
porch with the other fraidy cats.


--
Service to my country? Been there, Done that, and I've got my DD214 to
prove it.
Member of DAV #85.

Michael A. Terrell
Central Florida

 

[Andrew VK3BFA]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

Dont bother connecting them to the pcb at all - have your power
transformer made with flying leads long enough to terminate on the
output connectors.....

Andrew VK3BFA.

PS - open up a commercial high power ups, see how they do
it.......might save annoyance from group members at your failing to do
basic "screwdriver" reserch"

 

[Chris Quayle]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

Work out the cross sectional area of track needed to carry the current
without overheating. Simple math - track width x copper thickness. Then
use M6 or similar size brass bolts and washers through pth holes in the
board. Use both sides of the board if the copper weight is too low.

That's how many of the 3 phase motor drives and computer power supplies
do it...

Chris

 

[Nico Coesel]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

There are many solutions. The easiest is to use multiple screw
terminals.

 

[Frithiof Andreas Jensen]

I don't have to explain what i'm gonna do, i just give you all the
information needed, the pcb is for an inverter you don't need to know
more (and really you don't need to know that is for a inverter).

It goes like this: *I* and most other people will help even genjuine
*ignorant* folks; but *I* will not help people who are obviously too lazy,
stupid and too full of themselves to make an effort. Like

still don't understand why ask my messages, do you like to answer
without to say nothing useful?, i repeat you don't know anynthing about
me, and you don't know if a make a research before, if i don't say a
thing, that doesn't mean that i haven't done, i don't have to explain
you everything. And i'm not going to tell you my success or my hard
work just to cause a right impression for you.

Correct - We got all the information to make a judgement whether we should
bother with you or not right here ... sadly for you.

And finally if you got a problem with questiones like this, pleas
contact with the moderatos and tell them, and ask them that you want to
be a moderator for ban messages like this, and a little advice, don't
post stupid things like this, teach your "knowledge" to your son (if
you got) or whatever you got (if you really got something). Have a nice
day Ross Herbert.

Only a fool takes a fools advice!

 

[overgeo]

Michael A. Terrell ha escrito:

This is not a moderated group, whether you like it, or not. You are
accessing a Usenet newsgroup though Google Groups, and they have no
control over this, or any other newsgroup, other than refusing to allow
access to it.

Either learn to run with the big dogs, or go back and hide under the
porch with the other fraidy cats.


--
Service to my country? Been there, Done that, and I've got my DD214 to
prove it.
Member of DAV #85.

Michael A. Terrell
Central Florida

Hi, thanks for your answer, i didn't know that it was a moderated
groups, i think that was like the forums that you find in the web,
don't worry, i'm new in the usenet but not new in the internet i'm
customary to see people who likes to flame.


Andrew VK3BFA ha escrito:

Dont bother connecting them to the pcb at all - have your power
transformer made with flying leads long enough to terminate on the
output connectors.....

Andrew VK3BFA.

PS - open up a commercial high power ups, see how they do
it.......might save annoyance from group members at your failing to do
basic "screwdriver" reserch"

Thanks for your answer, mmm it's another solution but i will like to
use a pcb because i have to do a pcb for the driver (ir2113) and i have
seen in the international rectifier documentation that it's possible to
carry the 40 A in a pcb, but if i find problems i will make that.


Chris Quayle ha escrito:

Work out the cross sectional area of track needed to carry the current
without overheating. Simple math - track width x copper thickness. Then
use M6 or similar size brass bolts and washers through pth holes in the
board. Use both sides of the board if the copper weight is too low.

That's how many of the 3 phase motor drives and computer power supplies
do it...

Chris

Chris thanks for your answer, I have already the width track with a
temperature rise of 10ºC, i made some calculus and i used a calculator
that somebody says in this groups. It's another good solution use the
M6 and a through hole.


Nico Coesel ha escrito:

There are many solutions. The easiest is to use multiple screw
terminals.

Thanks for your answer, yes the easiest solution is that, and is the
solution that i'm gonna try.

Thanks for all your answers, i got enough information to make the
connection, and also i get many bonus information, thanks for the help.

 

[Rich Grise]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.

Frankly, I'd be MUCH more worried about how a PCB is going to handle
40A.

If you've got that solved, then figure out whether it's easier to
build/repair with Fastons, screws, or solder holes.

Good Luck!
Rich

 

[Phat Bytestard]

Hi, i'm designing an inverter, and i'm having problems connecting the
pcb tracks to the output cables, the current is 40 A. I have thought to
solder the cable to the track but i think this solution is a little
shoddy work, so some suggestions to make this?, thanks in advance.