Don't Snip the Red Wire
Need a quick and easy way to connect and disconnect two wires? Use male and female quick disconnects.
Last updated February 2019
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There are tons of ways to connect two wires together, but how do you choose the right one? It depends on your application. To choose the correct one, you have to ask yourself a couple of questions. Do I need to disconnect and reconnect the wires multiple times? Am I following standards that prohibit me from using certain methods? Is this in a high-vibration environment? Do I have the right tool on-hand to crimp the connector? Will these connectors handle the amount of current that is going to pass through them? Okay, that was more than a couple of questions, but I think you get the idea. Not sure how to answer these questions? It can be tough at first, but once you see what’s out there, you’ll know which method to use in any application.
The best way I can answer these questions is to provide scenarios for you. Let’s start with the first question – do I need to disconnect and reconnect the wires multiple times? Let’s say I want to wire two high-powered lights to the 12V battery on my vehicle. Depending on where they’re installed, the wire harness could be long. If the lights break and need to be replaced, I wouldn’t want to rerun a new harness all the way back to the battery, right? I like to think long-term and try to minimize work in the future because nothing lasts forever these days. I’d cut the harness in the most convenient place and install female quick disconnects on one side and male quick disconnects on the other side. This would allow me to easily replace a light if need be.
Am I following standards that prohibit me from using certain methods? Say I was building a rover or a satellite. I would be following NASA standards which would prohibit me from using these types of connectors since they’re not locking. I would need to get a locking connector or solder the two wires together. One of the reasons why you don’t want to use quick disconnects is because it could easily come lose due to the vibration experienced from the rocket it’s being deployed from. Chances are you won’t be getting to the rover or satellite so there is no way to reconnect them.
Is this a high-vibration environment? I briefly touched on this in the previous paragraph with the example about the rover and satellite. Another high-vibration environment would be on the launchpad when the rocket is lifting off. Looking at the thrust of a SpaceX or Blue Origin rocket, it’s highly likely that wires would come undone if they’re not properly secured.
Do I have the right tool on-hand to crimp the connector? This is the easiest question to answer – you either have it or you don’t. If you don’t have it, you might be able to improvise. If you can’t improvise, you’ll need to choose another method.
Will these connectors handle the amount of current that is going to pass through them? In particular, these quick disconnects can handle a relatively large amount of current since you can crimp them up to 10 AWG wire. Looking at a datasheet, it looks like 10 AWG wire can handle up to 55 A which is more than enough for most applications. Furthermore, you do not want to use these quick disconnects for high voltages since the conductor is not recessed or enclosed enough. You could accidentally touch the conductor which could result in injury or death.
What did we learn?
- Choosing how to connect two wires depends on your application.
- Ask yourself the questions mentioned above to narrow down which method you should choose.