So far I have been using RCY connectors to connect some low power fans for a custom thingy (fursuit head, this will be relevant later (space limitations)). They have a fairly low power draw, so around 5v 0.1A.
This has worked for around a year, but as there is a lot of movement where I use it, the power leads have ripped right at the connector. It looks like this is caused by the lack of any strain relief as the connector is crimped and does not have the usual stress relief thingies, which are often seen at other stuff like psu cables, usb etc.
So I’m looking to upgrade / replace that with a different connector. I’m looking for one which has:
- stress relief against bending
- is twistable / unidirectional (so something more like a barrel jack / headphone jack)
- is small / slim (I have very limited room that’s why I initially used RCY). The size is mostly limited in thickness, not length.
- is able to carry the very low voltage and current of 5v 0.1-0.2A (so basically anything will do that)
- available in germany (most likely most things should be)
Things I have already considered:
- 5.5mm 2.5mm (/2.1mm) barrel type connector --> too thick sadly
- trying to protect the RCY plug with stuff like shrink tubes --> doesn’t work, just slips off
- thinner barrel type connectors --> can’t find a matching set of cable with plug and cable with receptacle
Rn my best bet seems to be 2.5mm headphone jacks. I do have the feeling that there might be something better out there, so that’s why I’m asking here.
Any help would be very appreciated. Thanks in advance!
ragebutt@lemmy.dbzer0.com 6 months ago
jst sm for wire to wire like this, keyed, latching, rated to 3A. Should be easily available worldwide
www.digikey.com/en/products/detail/…/8543394
You can get them pre crimped like this if you don’t have a quality crimp tool. If you don’t go with this route. If you need to make like 200+ connections consider getting a quality crimp tool and then the crimp ends and housings, bonus there is no potential failure from solder joints (just from bad crimps since you will most likely not buy the 450€ JST WC-240 that is the official crimp tool. Tbf the engineer PA-09, which is what I use, is pretty solid once you get the hang of it and much more reasonable at ~ 30€. They don’t ratchet and they’re slower because they don’t have the wide dies but the crimp shape is very high quality, which matters. Just don’t get the ultra cheap unbranded or noname ratcheting crimpers with shit dies that cost like 10-15€ and give you bad crimps that fail 40+% of the time)
lennyaa@pawb.social 6 months ago
That connector does look robust, the only issue with that are the hard edges. I see now that I should’ve added that to the list of requirements (my bad). The thing with hard edges is that they can get caught in the fabric which then not only damages the fabric but also pulls on the cable / plug damaging them as well.
About getting quality gear, I fully agree with that, I’d rather spend a bit more if it means it won’t break later. If you can find / help me find some kind of round connector that would help me a lot.
ragebutt@lemmy.dbzer0.com 6 months ago
Wrap with 3m friction tape? Depends on how often you need to plug unplug I guess
This was an interesting dilemma so I researched it a bit:
Apparently some people use brass/tin plated snaps. Conductive and good for low voltage. Sew in and when the suit is put on just snap them together: www.adafruit.com/product/1126
Some of these are used in a medical context and actually officially rated for voltage/current if you’re worried about that: romed.com/medical-electrical-snap-fasteners.aspx
Alternatively rosenberger makes a series of magnetic snap connectors with softer edges. Pricey though www.rosenberger.com/…/magnetic-connectors/
morbidcactus@lemmy.ca 6 months ago
Second recommendation of the engineer PA-09, handled everything from molex microfits to tiny jst gh happily. I’ve used crappy ratcheting ones due to the volume I had to do on one project and ended up redoing half of them anyhow.
Dont cheap out on tools.