Derating factor: 80% of table value for safety margin

Example: 16 AWG rated 10A
Safe continuous: 10A × 0.8 = 8A recommended

V_drop = Current × Resistance × Length

16 AWG (~0.004 Ω/foot):
1 foot @ 5A = 0.02V (acceptable)
10 feet @ 5A = 0.2V (5% of 5V, borderline)

Minimum requirement: < 3% voltage drop
Max length = (3% × Supply V) / (I × wire resistance)

Current rating: 60A continuous, 150A burst
Voltage: 250V max
Uses: Battery to ESC, PDB

Connector structure:
┌─ Positive (large contact)
├─ Negative (large contact)
└─ Shroud (prevents short circuit)

Advantages:
✓ Cheap (~$1 pair)
✓ Common in drones
✓ Built-in shroud prevents shorts
✓ Easy soldering

Disadvantages:
✗ Not suitable for > 60A continuous
✗ Can wear out quickly with frequent plugging

Current rating: 90A continuous, 200A burst
Voltage: 250V max

Advantages:
✓ Higher current than XT60
✓ Spark-prevention circuit (optional)
✓ Robust contacts

Disadvantages:
✗ More expensive ($2-3)
✗ Slightly larger than XT60

PH series: 2.0mm spacing, small robot applications
XH series: 2.54mm spacing, common in hobby

Current: 2-5A typical (small)
Voltage: 250V

Use: Servo connectors, small battery packs
Advantage: Compact
Disadvantage: Low current, easy to disconnect accidentally

Sizes: 2.0mm, 3.5mm, 5.5mm
Current: 5A (2.0mm) to 30A (5.5mm)
Voltage: 250V

Use: Motor to ESC connections
Simple design, cheap, widely available

Old standard (still used in some applications)
Current: 10A typical
Issues: Unreliable, loose connections
Modern: Avoid, use XT60 instead

< 2A: JST PH/XH
2-10A: XT60, 3.5mm bullet
10-30A: XT90, 5.5mm bullet, Anderson PowerPole
> 30A: Custom solution, heavy-duty connector

Good joint:           Bad joint:
┌──────┐              ┌──┐ ← Insufficient solder
│      │              │ │
└──────┘ Smooth       └─┘ Lumpy/cold joint
Shiny, convex        Dull, concave

Red: Positive (+)
Black: Negative/Ground (-)
Yellow: Switched power
Orange: Auxiliary power

White: Signal/Clock
Green: Signal/Data
Blue: Signal ground reference

Main power:
- Red thick wire from battery +
- Black thick wire from battery -

Motor connections:
- Power lines in red/black
- Signal wires in smaller gauge
- Label wires with shrink tube

Good:   Wires bundled together, velcro strap
        ↓
Bad:    Wires scattered all over robot
        ↗ ↙ ↖

Format: [FUNCTION]-[PIN]

Examples:
- MOT_LEFT_PWM-D3
- BATT_POS (marked with red)
- I2C_SDA-A4

Benefits:
✓ Easy troubleshooting
✓ Maintenance simplification
✓ Documentation

Without relief: Wire flexes right at connector → breaks
    [Connector]
         ↓ ← Flexing here

With relief: Strain distributed over longer area
    [Connector]
    [→Strain relief boot→]
              ↓ ← Bending here (better)

Types:
- Male-to-Male (M-M): Breadboard connections
- Male-to-Female (M-F): Arduino to breadboard
- Female-to-Female (F-F): Arduino to sensors

Typical gauge: 24 AWG (signal level only)
Current limit: < 2A
Length: 10cm, 20cm, 30cm standard

Contact cleaner: Use electronics-grade contact spray
Clean annually: Especially if robot not used regularly
Protecting spray: Thin coating prevents oxidation

Problem: Connection feels loose after many cycles

Solutions:
1. Check solder joint (might be cold)
2. Tighten connector screw (if applicable)
3. Use conformal coating (prevents corrosion)
4. Replace connector (if worn out)