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e-Minicopter Joker > Battery connectors for the Joker 2
 
 
UAVdesign
New Heliman
Location: Arlington, Texas

I have a Joker 2 helicopter with a Plettenberg motor, Schulze Future 40.160H Motor Controller and ThunderPower Prolite TP8000-5S4PL batteries. It will carry an additional load of 1.5 kg.

I would like to know what connectors are recommended for the batteries. I would use 6mm bullet connectors, but I can't find any plastic cases for them and they are difficult to disconnect. The other option is to use Deans Ultra connectors, but I don't think they can reliably handle the high current required. What do you use and what problems (if any) did you have with them?

_______________________________
UAV Helicopter Project
http://arri.uta.edu/acs/pestingu/UAV/
05-02-2008 07:39 AM
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Gerd
Senior Heliman
Location: Vellmar/Germany

When you have an older 40.160 with 2x3 PP35 connectors you should design three Y bridges from short cable rests. When you have a newer one with three 6 mm plugs you must use them of course but currently you will not find any plastic grips for them, so isolate the open ends with good shrink tube. This is easy and works as well as plastic grips. For helicopter use (average current is less than 80 amps) you can also use round 4mm Gold contacts. About the quality of Deans an american should answer.
When you have batttery packs with very thick cables that do not allow plastic grips you should instead use shrink tube on the Goldcontacts. But use good polyolefine tube and not this cheap (glossy) PVC material.
When you use shrink tube then you have a free contact on one side as shown on the pic. To protect this contact from mechanical damage and to avoid a short circuit I always make a blind connector with plastic grip (without any cable) that I always plug on the open pole after charging and after flight. If you like that then prepare two or three of these Dummys, I donīt know why, but they disappear frequently
05-02-2008 10:04 AM
 
 
UAVdesign
New Heliman
Location: Arlington, Texas

Gerd, thank you. I already have some 6mm bullet connectors and I might just use them together with some good quality shrink tube.

During my searches for suitable connectors I have seen these Sermos/Anderson PowerPole connectors. I'm thinking about the 75 A version: http://www.robotmarketplace.com/products/0C-PP75.html

They seemed too big at that time and I gave up the idea of using them.
Their advantage is that there are no exposed metal parts, the plastic cases have a locking mechanism so they don't separate during flight and are also polarized.

Still, I have seen somewhere that they might have a tendency to spark during flight. Is that true? Is anyone using the 75A version?

_______________________________
UAV Helicopter Project
http://arri.uta.edu/acs/pestingu/UAV/
05-04-2008 07:23 PM
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e-Minicopter Joker > Battery connectors for the Joker 2
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