Cable Shielding & connectors

Batteries, Chargers, and Battery Management Systems.
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Kingfish   10 GW

10 GW
Posts: 4064
Joined: Feb 03 2010 11:23am
Location: Redmond, WA-USA, Earth, Sol, Orion–Cygnus Arm, Milky Way. Age: > yesterday < tomorrow
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Cable Shielding & connectors

Post by Kingfish » Jun 13 2010 1:52pm

My APPs are both a blessing and a hateful experience. :?

By far this is my most frequent issue: Disconnects and shorting. ARRRG! :x I end up having to clean the contacts about every couple of weeks. It doesn’t help that I have ump-teen connections in-between the battery and the controller.

The situation: I have two battery packs, a two-way splice to bring them together, a splice for the 12V supply for the dodgy headlamps, and one for the controller. They all lie above my Top Bar and occasionally get disturbed by my legs thrashing about as I pedal like Mad-Max down the road.

The APP crimpers made a huge difference in the quality of the connections, but nothing can stop the vibration and my interference in their function. I was at my wits end with connections intermittently getting worse with each ride, and especially on the long rides where I had felt comfortable and trusting of my equipment.

Then it dawned on me that I needed to provide some support structure or shield, but what to use? My first thought was to clamp the cable to a big tongue depressor: flat, lightweight, firm; I didn’t have one of those. What else could I use…
<rub chin, tap foot> :roll: :?: :?:

Ahh! Epiphany :idea:

I took a sample of some very thin (0.032 inch) black ABS that I had considered using for making my own aeroshell, cut off about a 2-3 inch piece, put it in a vise and applied the heat gun to it, bending it over, shaping it so. Here’s what developed:

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Roughly 9 inches long x 2 or 3 inches wide and folded over.

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On the underside cut out a notch; This is needed for the feral 12V supply tap to pass through.

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The bend is about ½ inch high and tapers towards one side.

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Edge view. Not perfect; closer to anthropomorphic, certainly good enough.

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Mounted, curved-side faces the leg, open-side towards the center.
Sharp edges have been shaved, deburred, or otherwise flamed.

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Add a couple of cheapy Velcro wraps to loosely hold it down and there you have it.

The first ride I took that was used for testing was the first 101 Club entry; end of my problems!
Enjoy! KF
* My 2WD Garden Wall
* Kinaye MotorSports
* Primary ride: 2WD Disc 9C 2806-equiv / Dual Lyen 12FET / 20S7P LiPo.
* Epics: Going to California: 2011 8)
* 50-mph, 101, 10k-Club. 12,527 miles-to-date, 7037 as 2WD.

It is by caffeine alone I set my mind in motion.
It is by the beans of Java that thoughts acquire speed.
The hands acquire shakes, the shakes become a warning.
It is by caffeine alone I set my mind in motion.

Kingfish   10 GW

10 GW
Posts: 4064
Joined: Feb 03 2010 11:23am
Location: Redmond, WA-USA, Earth, Sol, Orion–Cygnus Arm, Milky Way. Age: > yesterday < tomorrow
Contact:

Re: Cable Shielding & connectors

Post by Kingfish » Jun 13 2010 1:53pm

Addendum:
Since perfecting this little cable shield, though it has served me well, I still occasionally have disconnections between the controller and the 12V splice. The next work-item is to integrate the whole works: 2-way splice and 12V supply into one cable.

The alternative is to route the wires differently. I have a triangle bag on P0, so the opportunities are limited. Next bike (P1) however is a different critter all around, and the center of the triangle is where I plan to mount the controllers with all the cabling enclosed. THAT should end of problem.
* My 2WD Garden Wall
* Kinaye MotorSports
* Primary ride: 2WD Disc 9C 2806-equiv / Dual Lyen 12FET / 20S7P LiPo.
* Epics: Going to California: 2011 8)
* 50-mph, 101, 10k-Club. 12,527 miles-to-date, 7037 as 2WD.

It is by caffeine alone I set my mind in motion.
It is by the beans of Java that thoughts acquire speed.
The hands acquire shakes, the shakes become a warning.
It is by caffeine alone I set my mind in motion.

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