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):

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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.

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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
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Re: The BEST connectors, period

Post by spinningmagnets » Jan 10, 2018 10:05 am

Jonescg has used amphenol mil-spec connectors for all-weather E-motorcycles, they have recently been added to the connectors reference thread.

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Re: The BEST connectors, period

Post by ThierryGTLTS » Jan 10, 2018 11:44 am

Fischer, ODU, and Lemo do very good waterproof connectors, even IP67 :!:

Thierry

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Re: The BEST connectors, period

Post by electricwheels.de » Jan 30, 2018 1:28 pm

For general use there is JST-SM on the signal side, Anderson for Power up to 25A, and AMASS XT-90S for battery or MT-60 for phase wire connectors.

If you take your e-bike into the dirt, you need at least an IP65, ideally an IP66 rating. No dust ingress, and they can hold against a strong water spray nozzle. Here the HIGO Mini-B series connector* is first choice, they are only 9 mm in diameter and used by many OEMs. They are also available as panelmount connectors*, which lets you build clean looking wiring containers.
HIGO also supplies motor cables for currents up to 40A like the HIGO L-1019* with 3 phase and 7 signal wires.

I used to work with Amphenol connectors a lot, they are good but I find them too big and too expensive.

* From moderator: deleted electricwheel's links to products on his own website. Not allowed in a technical forum by Endless Sphere rules. Anyone interested in his products can PM or find his sales topic in Resources & EV Related Parts and Services.
Custom made cables and wiring harnesses for e-bikes. HIGO connectors and extension cables. XT90-S antispark battery connectors. MT60 phase wire connectors.
>>> World wide mail order <<<
https://www.e-bike-technologies.de/index.php/en/

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Re: The BEST connectors, period

Post by Rube » Jan 31, 2018 5:21 am

Nice IP rated JST connector available with multiple pin configurations.
6 pin male manufacturer part number JSTJWPF MFR PT 06R JWPF VSLE.
jwpf2.jpg
jwpf2.jpg (35.08 KiB) Viewed 369 times

John in CR
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Re: The BEST connectors, period

Post by John in CR » Feb 10, 2018 8:01 am

flat tire wrote:
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.
If you're building something that well, why do you need connectors? Just hard wire everything. In the amount of time it takes to install connectors you can hardwire 2 or 3 times. Connectors are useful for charge plugs but not much else on my builds.

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Re: The BEST connectors, period

Post by okashira » Feb 14, 2018 1:40 pm

cwah wrote:
Apr 04, 2017 2:35 am
Waiting for it. Needs to be waterproof
MX150's are nice. Tesla uses them extensively.
The hand crimper is reasonably priced and there are a massive selection of contacts and housings.
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Re: The BEST connectors, period

Post by zzoing » Feb 18, 2018 12:23 pm

The best possible plugs for the battery connection are not XT150/XT80/Anderson, the reason is that the slow time necessary to align the plugs plastics and slowly slot them in, giving plenty of time for an ark to corrode the edges, gold plating just melts straight away, I have XT80 on a 50A battery and they are corroded after a week... just trying them out for battery.

They are fine for phase.

For battery wires +/- which can ark at 60V, you can have a plug that has a plastic dustcap which requires you to force the plug in and when you have 3-4 pounds force on the plug it CLACKS and latches into place, without much arking, they last 5 times longer.

For cars I don't know what would suit. For an Ebike, I can walk to the french shop and get the smallest 2 pin 240V plugs, which have integrated dustcap-spring mechanism and which cost 2-3 dollars. Size wise they are a bit bigger, the 2 pin M/F all in is about the size of a small matchbox.

For a car you'd be best off having a heavy and clunky lever-switch out of an old factory, no live plugging the battery terminals, which then last forever. In this french town I'm living in there's factories from 1920 with sawmills, high pressure steam tanks all riveted and with 1920's electric control panels and pressure gauges, and some 1970's switches in another factory. damn cool.

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