Seeking suggestions for terminals for quick-swap battery

Go To Last Post
18 posts / 0 new
Author
Message
#1
  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

I'm working on a project that's going be using one of these 12V batteries (dimensions are 7.07" L x 1.40" W x 2.42" H).  I'm going to keep it in a tray that allows it to be easily removed and swapped with another that will be sitting in a trickle charger.  I'd like the user to be able to slide the tray out, remove the battery, drop in the replacement, and slide the tray back in, without requiring him to make/remove any connections.  I don't mind hooking up wires to the tabs which then terminate in some connector that mates with something in my piece of equipment, though the connector on the battery will need to be fixed to the battery so, again , the user doesn't have to fiddle with anything.

 

I originally thought of using ready-made spring battery contacts like these, placed so that the battery tabs pressed up against them when the battery tray was in place, but now I'm thinking they may be too fiddly to mount in the equipment.  Then I thought of using a couple of banana plugs mating with a pair of banana jacks.  I'm sure I can get either of these approaches to work, but thought I'd check here to see if someone has a better idea.  Thanks for any tips.

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

Molex, and others, have a wide range of Male/female connectors, many of which are polarized.

 

I assume the device is mobile, and at times remote from the charger for the other battery?

 

JC

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

Something like this:

http://uk.rs-online.com/web/p/pc...

Molex and others do something similar.

Be aware that the short circuit current from those lead-acid batteries can be significant and pose a fire threat.

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

I've looked at some Molex connectors, but all the ones I've seen need at least one hand to disengage, or are so small it would be tricky to align them blindly.  A panel mount version of the first one I linked to, like this, might work if I mount each half in a bracket, but it's still a small target.  The "device" is actually a piece of wall-mounted sculpture that I'd like the flexibility of not placing near an outlet; I'd also like to avoid the unsightliness of a cord.

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

Kartman:

 

It's hard for me to tell how those go together.  What's the "male" and what's the "female?"  Of course, any solution will have to be short-proof.

 

 

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

If this is a one off thing, I would say go to a local recycling center(centre) and look for a serious server PC that has redundant power supplies.  Usually the center will either give you the unit or charge you some small fee.  Reason I mention this is that the power supplies on those machines are designed to be hot swapped and have some really great connectors for this purpose...90% of them are not soldered to a PC board, but are direct wired.  Take those for your needs, then bring the PC back to the recycling center(centre)

 

YUP, I have done this before.....several times wink

 

 

 

Jim

If you want a career with a known path - become an undertaker. Dead people don't sue! - Kartman

Please Read: Code-of-Conduct

Atmel Studio6.2/AS7, DipTrace, Quartus, MPLAB user

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

These days it can be hard to tell the difference. I've been told the Adam's apple is the giveaway.
According to the caption, the items are female. The board side is male -either straight or right angle. This challenges one's binary stereotypes.

For inline connection, there's the 'deans' style used in RC models.
http://www.ebay.com.au/itm/like/112450444609?dispItem=1&ul_ref=http%253A%252F%252Frover.ebay.com%252Frover%252F1%252F705-139619-5960-0%252F2%253Fmpre%253Dhttp%25253A%25252F%25252Fwww.ebay.com.au%25252Fitm%25252Flike%25252F112450444609%25253Fchn%25253Dps%252526dispItem%25253D1%2526itemid%253D112450444609%2526targetid%253D91828872577%2526device%253Dm%2526adtype%253Dpla%2526googleloc%253D9071330%2526poi%253D%2526campaignid%253D184043497%2526adgroupid%253D8467825417%2526rlsatarget%253Dpla-91828872577%2526abcId%253D%2526merchantid%253D7364522%2526gclid%253DEAIaIQobChMI4M_Cu6am1gIVShZoCh3cLgndEAQYCCABEgLnYPD_BwE%2526srcrot%253D705-139619-5960-0%2526rvr_id%253D1310496313064&chn=ps&dispItem=1&ul_ref=http%253A%252F%252Frover.ebay.com%252Frover%252F1%252F705-139619-5960-0%252F2%253Fmpre%253Dhttp%25253A%25252F%25252Fwww.ebay.com.au%25252Fitm%25252Flike%25252F112450444609%25253Fchn%25253Dps%252526dispItem%25253D1%2526itemid%253D112450444609%2526targetid%253D91828872577%2526device%253Dm%2526adtype%253Dpla%2526googleloc%253D9071330%2526poi%253D%2526campaignid%253D184043497%2526adgroupid%253D8467825417%2526rlsatarget%253Dpla-91828872577%2526abcId%253D%2526merchantid%253D7364522%2526gclid%253DEAIaIQobChMI4M_Cu6am1gIVShZoCh3cLgndEAQYCCABEgLnYPD_BwE%2526srcrot%253D705-139619-5960-0%2526rvr_id%253D1310496313064&ul_noapp=true

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

I highly recommend "Anderson Powerpole" connectors. Very widely used by hams for exactly the purpose you describe. They are available from Allied Electronics and other sources.

 

Jim

Jim Wagner Oregon Research Electronics, Consulting Div. Tangent, OR, USA http://www.orelectronics.net

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

You mean this:

 

Have you asked the battery manufacturer, and/or your supplier, about mating terminals?

 

They are actually designed for this type of "spade" connector:

http://www.te.com/usa-en/plp/fas...

 

 

I think the "Tamiya" connector (common in RC models) is ideal for this - it's what I use:

https://en.wikipedia.org/wiki/Tamiya_connector

(they are actually made by Molex)

 

EDIT

 

typo

Last Edited: Fri. Sep 15, 2017 - 07:04 AM
  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

You can buy the batteries with the Tamiya connector already attached:

Image result for sla battery tamiya

 

 

and chargers:

Image result for sla battery tamiya

 

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

Notebooks from a decade or more ago used something like pogo pins pressed against flat conducting surfaces, sometimes this was a normal PCB, sometimes it were metal tabs. Today the usually use blade connectors, if you even can remove the battery anymore.
 

Something like that was used:

http://www.ebay.com/itm/18276466...

https://www.aliexpress.com/item/...?

https://www.aliexpress.com/item/...?

 

I didn't find the thing in the picture for "normal" sale but I think that could be suitable:

 

-Patrick

"Some people die at 25 and aren't buried until 75." -Benjamin Franklin

 

What is life's greatest illusion?"  "Innocence, my brother." -Skyrim

 

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

Do NOT use those Tamiya battery connectors. They are HOPELESS. Anyone who's ever been involved on R/C modeling of any sort knows that as soon as you receive anything with Tamiya connectors you chop them off and immediately replace with something more reliable. Personally for small packs and lower currents I use 2mm gold plated connectors or 4mm for larger applications. I then just use heatshrink insulation over them.
.
Other folks replace Tamiya with Sermos or Deans connectors.

Last Edited: Fri. Sep 15, 2017 - 02:33 PM
  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

2mm/4mm connectors :

 

 

Sermos connectors :

 

 

Deans connectors :

 

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

Guys, the OP said NO CABLES that user has to connect. Slide the old battery out and the new one in, that must be all there is to do for the user.
-Patrick

"Some people die at 25 and aren't buried until 75." -Benjamin Franklin

 

What is life's greatest illusion?"  "Innocence, my brother." -Skyrim

 

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

The "sermos"  connectors the Cliff showed are exactly the same as "Anderson Powerpole".

 

Jim

Jim Wagner Oregon Research Electronics, Consulting Div. Tangent, OR, USA http://www.orelectronics.net

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

You can avoid reality, for a while.  But you can't avoid the consequences of reality! - C.W. Livingston

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

I use Anderson Power Pole connectors in my solar generator.  The Forklift industry also uses Anderson Power Pole connectors to connect the 1000Ah batteries to the forklifts and the associated chargers.

 

https://powerwerx.com/anderson-p...

You can avoid reality, for a while.  But you can't avoid the consequences of reality! - C.W. Livingston

  • 1
  • 2
  • 3
  • 4
  • 5
Total votes: 0

pawi777 wrote:
Guys, the OP said NO CABLES that user has to connect. Slide the old battery out and the new one in, that must be all there is to do for the user. -Patrick

 

And you can do that with Anderson Power Pole.

 

https://powerwerx.com/anderson-1...

 

One of these on the chassis and one on the battery tray.  Pull in out! Slide in back in

1

 

 

You can avoid reality, for a while.  But you can't avoid the consequences of reality! - C.W. Livingston