Electronics > Projects, Designs, and Technical Stuff

Decent DC power connectors that aren't barrel or powerpoles?

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bd139:
Ok so I'm thoroughly done with both powerpoles and DC barrel jacks now. Powerpoles because I've got dicky contacts already on a connector pair plus a number of other issues. Barrel jacks because they're either ridiculously expensive or utter total crap quality and nothing in between.

So what can I use for this?

1. Needs to withstand regular use (5000 cycle lifetime min)
2. 5A current max (normally ~3A)
3. 12V
4. Cheap
5. Reliable
6. Available from legitimate non grey market suppliers.
7. Casual misuse doesn't result in short across pins (one end will be permanently connected to li-ion pack)
8. Doesn't matter if it's gendered or hermaphroditic.
9. Relatively small (smaller than powerpole)
10. Available in cable or panel mount with strain relief.
11. Latched if possible.

XT30 is a good starting point apart from points 7, 11

MarkF:

bd139:
Have discounted these as they're not latching. Currently looking at Molex mini-fit...

Tomorokoshi:
Lots of options in the Phoenix COMBICON series, although I'm not sure what your definition of "cheap" is:

https://www.digikey.com/products/en?keywords=277-5816-ND
https://www.digikey.com/products/en?keywords=277-5710-ND
https://www.digikey.com/products/en?keywords=277-5928-ND

David Hess:
The Molex 1625 series work for this type of application and I have seen them used this way before in commercial equipment.

https://www.mouser.com/Search/Refine?FS=TRUE&N=4292887429+4292906361

The crimping tool and pin extractor are reasonably priced:

https://www.amazon.com/Waldom-Electronics-W-HT-1921-CRIMPING-ELECTRONICS/dp/B0195UWT9U
https://www.amazon.com/Extractor-Diameter-Standard-Terminals-11-03-0002/dp/B00IZOD3NE/ref=sr_1_2

However they are only rated at 5 amps per pin maximum.  There is similar but larger 15 amp version which uses the same crimper above and a larger .093" pin extractor.  Besides industrial stuff, I have seen them sometimes used on commercial armature radio equipment:

https://www.molex.com/molex/products/family?key=standard_093&channel=products&chanName=family&pageTitle=Introduction&parentKey=power_connectors

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