Mini electrical connectors?

[T i m]

Hi all,

Does anyone know where / if you can get the little in-line elctrical connectors like seem to be on our PowaCycle please (I did ask in another reply but thought it might be best asked on it's own).

They need to be little, locking (or at least firmly connecting) and polarised.

Waterproof isn't essential as they will be suitably protected.

They need to 3 pole (although a range choice would be nice).

Fairly low voltage (50V DC?) and low current (1A rating but will typically carry much less)?

Cheers, T i m

 

[Straylight]

could this be what you're after?

The connectors commonly used in e-bikes seem to be made by a Chinese compant called Wuxing, but I've not found a source for them in the UK, so somewhere like Farnell is the UK alternative.

 

[T i m]

could this be what you're after?

The connectors commonly used in e-bikes seem to be made by a Chinese compant called Wuxing, but I've not found a source for them in the UK, so somewhere like Farnell is the UK alternative.

Hi and thanks for the reply.

Whilst that wasn't the level of connector I was thinking of it's interesting non the less. ;-)

I was thinking more of the signal cable connectors I currently have on there, like where the throttle cable connects to the controller (so very low power).

On your replacment for the motor bullet connectors I note that it wouldn't be waterproof (whereas the bullets would have been or should have been <g>). Has that been a problem? If not I might be tempted to use three of the 'Powerpole' connectors as they are quite substantial and have self cleaning contacts (and I already have some). ;-)

The plugs / sockets I'm looking for are similar to computer CPU fan connectors although that may not help much. ;-)

Cheers, T i m

 

[Alex728]

I've heard of them being called "PCB header connectors", but not sure how you get them in small quantity. They get used on lots of cheap Chinese made AV equipment.

Collect a broken discarded hi fi system or "ghetto blaster" or DVD player dumped in the street and gut it and you might strike lucky...

 

[flecc]

I know the kind you mean Tom, but they come in a bewildering variety of sizes, types and connector numbers and are mainly used in manufacturing. They're not to easy to source a specific type, but you might find what you want through RS Components or Farnell. However, it's much easier to just change to a known and trusted type like the Powerpoles as many members have done.
.

 

[NRG]

T I M, those bullet connectors are not waterproof all the other connectors on the controller are not waterproof either, so Its best to house the controller in a bag that is and protect the connectors with a contact spray or similar.

Flecc is right they come in such a large array of shapes and sizes it's difficult to find the part you need...I'll have a look though....

 

[Tiberius]

I was thinking more of the signal cable connectors I currently have on there, like where the throttle cable connects to the controller (so very low power).

Tim,

It will vary, but a common type used here is JST-SM. JST is the manufacturer and SM is the type.

Nick

 

[NRG]

Well done Nick!

Industrial | Farnell United Kingdom

 

[Haku]

Connectors for RC-car battery packs are lockable & (fairly cheap from eBay).

Battery Connectors : Battery Connectors : Maplin
Tamiya Connectors x2 Pair - Male/Female on eBay (end time 20-Dec-09 20:26:29 GMT)

Or the 4-way Molex connectors used to power (pre-SATA) harddrives:

Hard Disk Drive Power Connectors : Disk Drive Power Connectors : Maplin



I've been using JST connectors at work and am getting quite fed up with them - massive range of them meaning I've been having to sift through several bags just to find the right one and unless you get pre-crimped leads they're a complete pain to crimp properly.

 

[T i m]

It will vary, but a common type used here is JST-SM. JST is the manufacturer and SM is the type.

Hi Nick and thanks VERY much for that, spot on. ;-)

http://www.jst-mfg.com/product/pdf/eng/eSM.pdf

I would love to have a selection of 2, 3 and 5 way SM's in my connector box as I think they fit the niche of small / locking / polarised / signal / low power connections perfectly (and can probably be made water resistant with the use of a bit of silicone / silicone grease).

It looks like Farnell do them:

http://uk.farnell.com/jsp/level5/module.jsp?moduleId=en/209317.xml

I've not ordered from Farnell before but a quick look suggests they don't have a minimum order but I don't know what the postage would be?

Once that bit is sorted I just need to find a suitable length of 5 core flex in black to go from the handlebars to controller and we are in business. ;-)

Thanks to all who have offered help so far (it's good here innit?) ;-)

T i m

 

[T i m]

I've been using JST connectors at work and am getting quite fed up with them - massive range of them meaning I've been having to sift through several bags just to find the right one and unless you get pre-crimped leads they're a complete pain to crimp properly.

Thanks for the connector links Haku. I think I have used nearly all of them at some time or another (RC modeller / PC builder / Electronics eng etc).

Re the JST-SM's if I may. Is there any reason you couldn't crimp them up gently with decent needle nosed pliers then back that up with a quick touch of solder (that proper leaded mans stuff)? ;-)

FWIW, PowerPoles I generally only solder, the Tamiya style I tend to crimp then solder and it's usually the actual connector that fails in use rather than my terminations (The Post Office trained solderer you see). ;-)

So, this bucket of JST connectors you are fed up with and about to throw out at work ... ? <whistles>

Cheers, T i m

 

[T i m]

Well done Nick!

Industrial | Farnell United Kingdom

Sorry NRG, missed your link (doh). ;-(

Cheers, T i m

 

[RobinC]

I've not ordered from Farnell before but a quick look suggests they don't have a minimum order but I don't know what the postage would be?

I was told over the phone a few months ago that web orders get free delivery irrespective of size but didn't test that as I was above the threshold (£45 I think) for free delivery for any order.

Robin

 

[T i m]

Collect a broken discarded hi fi system or "ghetto blaster" or DVD player dumped in the street and gut it and you might strike lucky...

Hmm, you are right, they do appear inside such things (and I don't need any excuses to collect junk <g>) but there's nothing like using a nice fresh plug on summat (if you can get them etc).

I have been given a 3 way SM plug with some very short tails that would be ok to hook up the throtle cable at the controller end but there is nothing neater than seeing a cable with the plugs sitting directly on the ends. ;-)

I think I'm going to need a short length of 5 (at least) core flex, 3 cores for the throttle and two for the brake interlock (do we call it .. on Bk/Gy) but what's supposed to be on Bk/Bn please (currently n/c)?

Cheers, T i m

 

[T i m]

T I M, those bullet connectors are not waterproof all the other connectors on the controller are not waterproof either, so Its best to house the controller in a bag that is and protect the connectors with a contact spray or similar.

Hmm, I assume that the controllers don't produce a lot of heat then?

On my controller it says:

HL2413LDL2, 24V / 21.5V / 13A / 2008-11-10. I think I know what the 2413 means but what of the bits before and after? Is this a 'pretty standard' controller?

Flecc is right they come in such a large array of shapes and sizes it's difficult to find the part you need...I'll have a look though....

Cheers. ;-)

T i m

 

[Tiberius]

Hi Nick and thanks VERY much for that, spot on. ;-)

http://www.jst-mfg.com/product/pdf/eng/eSM.pdf

I would love to have a selection of 2, 3 and 5 way SM's in my connector box as I think they fit the niche of small / locking / polarised / signal / low power connections perfectly (and can probably be made water resistant with the use of a bit of silicone / silicone grease).

It looks like Farnell do them:

http://uk.farnell.com/jsp/level5/module.jsp?moduleId=en/209317.xml

I've not ordered from Farnell before but a quick look suggests they don't have a minimum order but I don't know what the postage would be?

I have an account with Farnell and delivery is free; don't know what they charge for non account holders. They seem to only do them in white and not carry the 5 way shells, so if you find another UK source please let us know.

The terminals can be crimped up with a standard tool. The technical term is a "half-barrel" crimp. Molex do a general purpose tool that will work with these SM terminals. Otherwise you can fold them over with small pliers and solder them.

Nick

 

[T i m]

I have an account with Farnell and delivery is free; don't know what they charge for non account holders.

Cheers. I'll check it out later (thanks).

They seem to only do them in white and not carry the 5 way shells, so if you find another UK source please let us know.

Will do. I don't need a 5w atm but I guess you could either use a 2 and a 3 or a 6 (if they carry them). Do you know if the 5 signal wires coming out of the motor (Rd/Y/Gn/Bl/Bk) follow any std colour pattern and what they generally carry please? I'm assuming a pair would be some sort of speed / rev counter?

The terminals can be crimped up with a standard tool. The technical term is a "half-barrel" crimp. Molex do a general purpose tool that will work with these SM terminals. Otherwise you can fold them over with small pliers and solder them.

I have several crimp tools (RJ11/45, Coax etc) but not sure if I have anything specifically for the Molex connectors.

Thanks Nick,

T i m

 

[Tiberius]

Do you know if the 5 signal wires coming out of the motor (Rd/Y/Gn/Bl/Bk) follow any std colour pattern and what they generally carry please?

Sounds like a set of Hall sensors. Green, Yellow, Blue will be the Hall signals to the controller. Black ground, Red the supply from the controller to the sensors, usually 5 V.

Nick

 

[Andrew harvey]

If you want some neat in line 3 pin plugs try mini head phone plugs. I've used these a lot. They are ideal for throttles, brakes and are dead easy to waterproof with silicon and heatshrink, they are also very neat. . Fitted at the handlebar end means you only have to run one multicore to the controller and if anything needs changing peel of the heat shrink and unplug.

 

[T i m]

Sounds like a set of Hall sensors. Green, Yellow, Blue will be the Hall signals to the controller. Black ground, Red the supply from the controller to the sensors, usually 5 V.

Nick

Ah, Gn/Y/Bl match the phase feed wires, Rd/Bk std power colours <slaps head> thanks. ;-)

I asked in case knowing might help me fault find in the future.

Cheers, T i m