The BEST connectors, period

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flat tire
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The BEST connectors, period

Post by flat tire » Apr 03, 2017 1:47 pm

So, people a million different types of connectors for the variety of interconnects found in our ebikes. But not all of these connectors are that great, and for the connectors included with many China sourced generic controllers, they are downright terrible! The goal of this thread is to find the BEST available off the shelf connectors that we can use for any e-biking application. I'm talking high end, money is no object, not "I bought these counterfeit Deans off ebay and they're pretty good for the price".

For everyone's convenience OP will be updated with best connectors in each category. If there's not a clear winner we can list several. Please provide explanations for and against the use of any connectors you bring up. Different power levels mean there will be a variety of "best" connectors under each power category, and all this will be added as it's posted.

Phase Connectors:

Battery Connectors:

Balance Connectors:

Data Connectors (Hall, throttle, CA, etc):
Orange DH w/ Cyclone mid on 6kw
Gary Fisher w/ Leaf hub on 6kw
RC Lipo and domino throttles only!

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teslanv
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Re: The BEST connectors, period

Post by teslanv » Apr 03, 2017 2:01 pm

For 5V-12V signal wires, etc, I followed Justin's lead a while ago and moved to all JST-SM connectors. Once you have the crimping tool, and a well-organized selection of pins and connector housings, this is a great connector type.

The original "SM" is made in Japan by this manufacturer:

http://www.jst-mfg.com/product/detail_e.php?series=238

Knock-offs of the JST-SM connectors are widely available and cheaper than the OEM, and generally work OK, even if those are a bit harder to engage/disengage.

For Battery Connectors, I like the XT90 Connectors for anything under 60A, and XT150 Connectors between 60A and 150A. I have not yet gone over 150A, so I cannot say what connector after that - Perhaps multiple XT150 connectors in parallel?

For Phase Wires:

<80A - 4mm HXT
>80A - XT150
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flat tire
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Re: The BEST connectors, period

Post by flat tire » Apr 03, 2017 8:00 pm

Well, I'm looking for some really high end connectors like you would find on a spacecraft or nuclear bomb. So I googled "mil spec connectors guide" and I'm trying to digest all that...if anyone beats me to it please comment.
Orange DH w/ Cyclone mid on 6kw
Gary Fisher w/ Leaf hub on 6kw
RC Lipo and domino throttles only!

cwah
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Re: The BEST connectors, period

Post by cwah » Apr 04, 2017 2:35 am

Waiting for it. Needs to be waterproof
Help me find my stolen electric brompton: http://bit.ly/1a0vbBC and Bosch Sinus B3 http://bit.ly/1eV0WQz

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