Electronics > Projects, Designs, and Technical Stuff
Connector sparking and damage due to inrush at "mating" time?
Nusa:
Any connector rated for 10K or more connections will have it in the datasheet, as well as prominently in their description, since it will be a strong selling point.
Ditto if it's designed for hot-plugging. Also a selling point.
Datasheets that don't mention it at all are probably rated in the 10s or 100s, depending on the material used for contacts and style of connector. If you are set on XH connectors, contact JST and ask them flat out. Whatever the numbers, special-ordering gold-plated contacts will get you the highest number on the list.
Tomorokoshi:
As a comparison look at a mid-range connector from Phoenix:
https://www.digikey.com/products/en?keywords=277-16346-ND
It's rated to 25 cycles. Now, that doesn't mean it disintegrates on cycle 26. It means that the datasheet values should be applicable if the connector was used within the ratings of the datasheet. Note that with these connectors the stress is applied to the wire, not the connector housing.
As others pointed out various standards may apply. A quick look at 61010 finds some areas of concern. There isn't enough information about the design, product, and application to really dig into it here. Commercial? Industrial? Internal test fixture?
Topics to ignore your boss about who is trying to make it faster and cheaper:
- Batteries. Lots of safety issues regarding batteries, particularly high-current lithium types.
- Environment. 48V lands right in the middle of dry compared to wet location concerns in 61010. Could this be a wet location?
- Access. User access to conductive terminals and wires with thin insulation.
- Connectors. Terminal spacing, wire size, etc.
- Misuse. Foreseeable issues.
- Faults. Single and multiple faults. Wire breakage.
mikeselectricstuff:
Measure the peak current on connection - likely tens of amps, way over the connector's rating
tggzzz:
--- Quote from: zenerbjt on August 31, 2020, 11:43:46 am ---Thanks but relays have switching operation data (eg "10,000 operations") , so i am surprised that connectors dont have it.
--- End quote ---
Some do. Others don't.
In a similar vein, some aircraft specify that spin recovery will take up to X rotations when loaded within the limits. All the aircraft I've piloted do have such a specification, but Boeing 7x7 and Airbus 3xx don't.
Now why do you think that might be?
bdunham7:
Treez, is that you? :-DD
JST connector and 10K mating cycles? The same JST connectors that I carefully pry out with two plastic picks when I have to repair something and hope I don't hurt them? Yes, they are commonly used for battery packs and the like, but the housings just aren't going to hold up to your long-term expectations.
The amount of energy that it takes to charge up an 82uF cap is pretty small, even at 48VDC. I doubt your JST life is going to be determined by how long it takes to arc the contacts down to a nub. Just make sure that either the connector is accessible and repairable or that your product is disposable. Or, you can just blame the inevitable problems on user abuse.
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