Headphone Jack Connector Alternatives

[m3g4by73]

Hi, I'm working on a project in an enclosure that will need an external probe with a temperature sensor and light sensor. 4 conductors total.

In the past I've used 3.5mm stereo headphone jacks that offered 3 conductors (see attached photo showing PCB and what it looks like when it's mounted in a CNC'd enclosure), and I know that you can get 4 conductor versions as well that would theoretically do the trick.

I've also tried using a PG-7 cable entry gland in some products, but it's just way too big and clunky for my purposes and necessitates a lot of final assembly which ultimately adds cost.

I was wondering if you guys can suggest any better alternatives (smaller, cheaper, more reliable etc.) than using ugly cable glands or bastardising these headphone connectors that were mainly designed for audio?

[Vgkid]

What about a mini 4 pin xlr connector.Not sure about it being cheap though.

[f5r5e5d]

cheaper is very unlikely considering the volume/competition of TRS

kobiconn makes a pretty small camera iris motor control 4 pin connector pair

there is a "tiny XLR" series from Rean - smaller than mini XLR

plenty of other circular format multipin connectors, some small - none cheap as TRS - by orders of magnitude in common industrial types

[m3g4by73]

Thanks for the advice. Cost is an important factor so it sounds like the TRS connectors are the way to go then.

Cheers!

[f5r5e5d]

TRS jack/plug combos have, in many realizations, the possibility of temporary shorts between T,R when being plugged/unplugged - design your circuits accordingly

[m3g4by73]

Thanks, that was one of the troubles I learned about since my initial designs. Thankfully it was never a problem but it remains something to be mindful of in the future and part of the reason I was hoping to learn about a viable alternative 

[Marco]

Micro-USB?

[m3g4by73]

Good on the price front, but even more hacky than the TRS jacks wouldn't you agree?

[newbrain]

8P8C or 4P4C connectors?
Not much bulkier, and cheap.
Cannot say about reliability, but if they are good enough for our networks...

[Ian.M]

Never use a common consumer entertainment or IT external connector for a different purpose unless your gadget can tolerate whatever commonly has the same connector being plugged in without any damage, or your gadget will only be used by qualified technicians.  This would specifically rule out any flavour of USB, 'RJ45' 8P8C, or RJ11 6P4C and RJ12 6P6C  connectors unless you want to cope with idiots plugging in USB chargers, Ethernet with POE or phone lines!

For a permanent or semi-permanent installation, if you can stand the size, a 0.1" pitch 6 way female right angle header may be the way to go.  Use one way for a polarising plug (insert) and omit one pin from the mating connector.  That gives you two non-reversible, non-interchangeable plug/socket combos (1x3456 and 12x456) and if you use a dual row one on the PCB, is more compact than your existing jacks.

[Stwspoon]

Also look at microphone connectors (not XLR). The CB/ ham ones have 4-8 pins and are locking. Old style PS2 keyboard/ mouse connectors may work as well.

[bicc1306]

1st thing came in my mind is XLR connector.

[Tomorokoshi]

What is your budget?

Do you need a coaxial shield or can you route the cable shield to a pin?

How about Conxall?

[rx8pilot]

What is your budget?

Yes, the budget stated can eliminate a mountain of guessing. I would use Lemo for performance/reliability, but they are major budget destroyers.

Do you have $1 per connection? $10/connection?

[MosherIV]

How about mini circular connecters, like the one used for ps2 mouse/keyboards?
They can come with upto 12 connection.

[Ian.M]

Yes, you'll find mini-DIN connectors on a lot of stuff.  Probably best to avoid the 4 pin (S-Video) and 6 pin (PS2 Kbd/Mouse) variants.   

[Pack34]

I agree with Ian, it's bad form to use a common connector for a different purpose.

How about some of the smaller switchcraft connectors? The assembly is only $5 and it's a unique connector.
http://www.alliedelec.com/switchcraft-en3c5mx/70214353/