thin gauge hall sensor wires

[waynebergman]

I have a mac 10t hub motor with very thin hall sensor wires. I am wanting to solder these thin wires to the leads from a new 5 pin JST connector. I have a new JST connector coming in the mail with 5 wires already crimped in place to the male pin outs. Seems simple enough to just solder my Mac 10t wires to the leads coming out of the new connector but wow these wires are very very thin. I have tried my best to strip the wires to get ready for my up coming solder job but I am noticing there are maybe only 7 tiny strands of wire in each wire lead. Its difficult to strip these wires and still leave all 7 stands in tact. Granted I do not have a pro stripper and I should get one but I have some questions regarding these thin hall sensor wires.

1. Why are they so thin? I realize they only handle low voltage but it just seems crazy thin, is there a reason to go this thin that makes thin better than a bit thicker guage?
2. Just curious, what happens if you strip your wires and shave off 3 of the 7 strands and solder it or crimp it to your conector? I know its a weak link strength wise for the wire to maybe break there easier than it should but would the performance or workings of your hall sensors suffer if you have less than the full 7 strands of wire?
3. What are a good set of wire strippers to get for these thin wires? I have measured them at 1/32" in diameter before the outer plastic insulation.

Thanks Wayne

 

[dnmun]

if your stripper is not adjusted properly you can use a utility knife. run the knife lengthwise and split the insulating sheath, pull the wires out as a bundle and pull the insulation part on the end and the wire in separate directions and the wire peels out of the sheath as the sheath splits, then cut off the insulation far enuff back to solder the wires. they are big enuff for the current they carry.

 

[waynebergman]

Still wondering why so thin when thicker wires would be easier to work with. Why not go with thicker wire? Even a bit thicker. Seems like a job for an eye surgeon fiddling around with these super thin gauge wires.

Also wondering if anyone has any comment on, if the performance of the hall sensors would be effected if you had a sensor wire with some of its strands butchered in the process of stripping the insulation off?

Again, my murderous attempt at this to date is not going to get soldered. I have bought a new wire stripper that should work better but my questions above are more me just trying to learn a bit here.

Thanks Wayne

 

[e-beach]

Still wondering why so thin when thicker wires would be easier to work with. Why not go with thicker wire? Even a bit thicker. Seems like a job for an eye surgeon fiddling around with these super thin gauge wires.

Greed. Less metal and plastic is cheaper ='s more money in the manufactures pocket.

Also wondering if anyone has any comment on, if the performance of the hall sensors would be effected if you had a sensor wire with some of its strands butchered in the process of stripping the insulation off?

Depends on how many. If it is 1 or 2 probably not a problem. 5 or 6, probably a problem because:
A) not enough metal for the electrons to pulse through, and
B) not enough metal the keep the wire from breaking.

Again, my murderous attempt at this to date is not going to get soldered. I have bought a new wire stripper that should work better but my questions above are more me just trying to learn a bit here.

Thanks Wayne

2 ways to strip small wires are:

1) Take a straight razor and lay it almost flat against the wire and gently pull the wire so to shave off enough offending insulation on one side to expose the wires. It is a delicate process so be gentile. you may have to repeat the process a few times. Once you have gently removed enough institution to expose all the wires without cutting them off, peal the rest of the insulation back and cut it off.

If something like this is new to you, get a strand of tiny wire an practice a few times. Just don't cut yourself in the process.

2) The other way is to melt the insulation off with a cigarette lighter. It is stinky and messy and may make it harder to solder the wires together, but if you get all the plastic off the wires, it will leave all the wires intact.

Good Luck!!!