I’ve been working on tidying up my recently-built machine (https://www.v1engineering.com/forum/topic/new-canadian-robot/), notably the wiring (and adding an air blast system), and decided that I wanted a really clean way to do the stepper wiring. To that end, I designed and printed some components.
The wiring harness bits are designed to fit inside my tubing, with just a tiny lip to stop it from going fully into the tube. They have slots that securely hold female JST SM connectors. One side has 2 connectors (one for a motor, and the other is the output to the controller) and all the wiring for the serial harness is done internally on this side. The other side is just a single connector for the other motor. The wiring slots fit 18ga wires, which is overkill but will significantly reduce voltage drop (I’ll be running 18ga back to the controller as well). The “top” and “bottom” of the design are flattened so they can be printed without supports.
In order for this design to work, I had to redesign the roller plates – the stock design blocks access to the end of the tubing, and I needed full access both to install the system at all and to be able to plug in the male connectors later.
I’m really happy with this solution. I like that it turns all the wiring into a clean, modular system. If I ever need to partially disassemble this thing for maintenance, dealing with the wiring is now super easy since it’s all just easily-accessible plugs.
My design is hard-coded for my tubing size right now (1.00" OD / 0.75" ID) but if there is enough interest I’d be willing to go back and parameterize the design and share files.