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Connectors - Learn

Ebike Connectors

Electric bicycle systems have used various types of connectors without any real standardization on connector type or pinout. In 2008, we decided to standardize our systems to use Anderson Powerpoles for high current connections and JST-SM connectors for small signal wires.

Both these connectors can be easily crimped and installed. Their pins can be removed from the housing, enabling voltage signal measurement on the plugs even when connected for diagnostics. They are available in various pin counts, but neither is intrinsically waterproof. They don't look as polished as many of the overmolded plugs used on modern e-bikes, leading us to explore other options.

Anderson Powerpoles, PP15/30/45 series

This connector, invented by Anderson Power Products in the 1960s, is popular for several reasons: genderless design, stackable dovetail joints, and separate making and connection contacts.

1) Genderless: The connectors on an Anderson mate with each other, simplifying usage without confusing male or female plugs.

2) Stackable: Anderson plugs can stack side by side, allowing multipin connectors suitable for different configurations.

3) Separate Contacts: The connectors engage with clean metal contacts, preventing spark damage from affecting the electrical connection.

Current Rating: Despite different versions (15A, 30A, 45A), they are all interchangeable, with their current handling depending on wire gauge. Anderson connectors with 12g wire can handle up to 60A of continuous current.

Crimping vs Soldering: Anderson pins can be crimped for a reliable connection or soldered if preferred.

Pin Detent: Available in standard and high detent versions, the latter offers greater retention force against small tugs and vibration.

Retention Pins: Anderson offers retention pins to prevent connectors from being pulled apart accidentally.

Knock-offs: Authentic Anderson plugs can be identified by a capital 'A' on the end and sharp corners. Be wary of cheap imitations that melt at lower currents.

Signal Connectors

JST-SM

The JST-SM series is a compact (0.1" pitch) connector with a latch, suitable for small signals and accessory power up to about 2 amps. It's versatile, allowing ease in troubleshooting and pin extraction. However, it isn't waterproof, leading to possible corrosion after prolonged water exposure.

Pinouts: The pinout configurations can vary; we have adopted a specific standard for our components.

HiGo Mini-B

The Higo Mini-B series is widely adopted for various e-bike connections. It has the advantage of being waterproof but isn't widely available as solderable inline plugs, limiting their DIY usability.

HiGo Main Signal

Factory e-bikes often use a single connector from the motor branching into multiple plugs for accessories. We have adopted a similar standard for our CA3-WP devices, making them compatible with generic bike setups.

Tajima

A decade ago, Crystalyte switched to a metallic round 5-pin plug resembling the Tajima connector, though it wasn't significantly advantageous over JST connectors.

Hirose DF62

Although not yet widely used in commercial e-bikes, we prefer the Hirose DF62 series for its compact design and advantageous features, such as crimpability and gold-plated pins.

BMS Header

Lithium pack management circuits often use single-row header connectors varying in pitch for connecting to individual cell tap points.

Molex / Spade

Common in Chinese e-bikes, these large white connectors aren't high-quality but generally function well if kept out of sight.

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Motor Specific Connectors

HiGo Z910

The HiGo Z910 plug is popular in lower power hub motors systems and includes phase wire and hall sensor terminals. We adopted it for all our low power kits.

HiGo L10

For mid to high power e-bike kits, we transitioned to the 10 pin locking L1019 HiGo connector, capable of handling higher currents and offering better connectivity for sensors.

Julet Z916

The Julet Z916 connector is commonly found in medium power e-bikes. Although not in our motors, we plan to make adapter cables for compatibility with these systems.

MT60

The MT60 is a high-current connector suitable for powerful e-bike motors. It's compact and reliable but requires soldering.

Battery Connectors

Anderson SB50

Popular in larger electric vehicles, Anderson SB connectors are somewhat bulky for e-bikes but often used in battery packs.

XT60

The XT60 connector, designed for the RC market, is compact and handles high currents. It's used predominantly as a battery plug despite the need for soldering.

XT90

Similar to the XT60, the XT90 handles even higher currents and has a version with a precharge resistor to prevent sparks.

Charger Connectors

Rosenberger

The Rosenberger connector, intended for universal battery and charger compatibility, hasn't gained much traction due to its high cost and lack of inter-product compatibility.

XLR

Widely used in audio equipment, the XLR plug has been adopted for e-bike battery chargers. It varies in quality, with higher quality brands offering better current handling.

DC Jack

Commonly used for charging ports, DC jack plugs aren't ideal due to low current ratings and short circuit vulnerability.

ST3

Developed to support higher currents and avoid exposed contacts, the ST3 charger plug is adopted in our battery packs.

RCA

Another example of repurposing audio industry connectors, RCA plugs are inexpensive but susceptible to short circuits.

Others:

Numerous other connectors from various industries find applications in e-bikes and conversion kits. Identifying specific models can be challenging, and proprietary connectors ensure exclusivity.

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