High-current (>100A) crimped bullet connectors - Page 1
Forum section: electronics / projects

author: kubark42
author_rank: Contributor
timestamp: March 28, 2022, 10:36:48 pm
content: It's easy to find inexpensive solder-on bullet connectors for >100A (or even >200A), but I can't find any equivalent crimped connectors. I've seen crimped lug connectors, but I was hoping to avoid the weight, volume, and hassle of having to add a block to hold the connectors, nuts, and bolts.Are there any crimped bullet connectors out there for these currents?

author: thm_w
author_rank: Super Contributor
timestamp: March 28, 2022, 10:56:31 pm
content: Why does it have to be bullet?Whats wrong with the common anderson powerpole style, etc.https://www.andersonpower.com/us/en/resources/PowerPoleResourcesPage.htmlOr are you using this to connect to existing battery packs.edit: I don't see any existing 200A bullet connectors, the most I see is AS150 and XT150.

author: kubark42
author_rank: Contributor
timestamp: March 28, 2022, 11:15:00 pm
content: I've got some Anderson PP connectors, and I love/hate them. Their small stuff is awesome, without reservation, but their big stuff is bulky and heavy, they weigh much more for the same power load, and they're nigh impossible for my hands to connect/disconnect. All that structural plastic insulates the connectors and makes it hard for them to shed heat, plus when the connectors get too hot they soften and can lead to shorts (ask me how I know!)In contrast, a bullet connector has just a thin coating of heat shrink which, if appropriately chosen, is much better for dissipating heat and can withstand a higher temperature.I'm connecting the three-phase motor cables to the motor controller cables, and I hope that connection will last twenty years. My understanding is that soldered joints of that nature wick up too much solder to be stable, so I'm hunting for crimps.Quote from: thm_w on March 28, 2022, 10:56:31 pm8mm bullet connectors are pretty good for those current levels:https://www.progressiverc.com/products/8mm-bullet-connectors

author: thm_w
author_rank: Super Contributor
timestamp: March 28, 2022, 11:58:55 pm
content: Quote from: kubark42 on March 28, 2022, 11:15:00 pmThey weigh more because they are actually rated for 200A continuous.If the connector softened to the point of shorting, you might have been using a counterfeit part.If you really want something to last 20 years then use quality branded connectors. These RC bullets are fine for hobby use, but, we have no idea about the reliability or if they even meet the given specifications.QuoteThese similar plugs are rated for 80A continuous 170A peak:https://www.tme.eu/Document/58871157ae0a09146c79dab4399bd814/amass8.pdf

author: kubark42
author_rank: Contributor
timestamp: March 29, 2022, 12:29:36 am
content: The connector softened because I was running waaay too much current through it. They were quite tiny and I was running >100A. I'm fairly sure they were real, Anderson is located just up the street from me. They just can't shed heat as quickly as an equivalently-sized bullet connector, and they don't have as much surface area for mating. (No idea how they compare w.r.t. contact pressure, though).Quote from: thm_w on March 28, 2022, 11:58:55 pmI can't find the link, but someone did some load tests a while back and different brands performed radically differently for the same size connector. So for instance Lehner (which is about the best in the industry), gets <40uOhm for their 8mm connectors.https://www.lehner-shop.com/en/accessories/high-current-connection-400-a.html. So it's definitely a YMMV situation.And thus everything you say about unknown reliability is spot on. That's why I'm hoping there for some other proven options better than APP or battery lugs.

author: fchk
author_rank: Frequent Contributor
timestamp: March 29, 2022, 10:51:35 am
content: You can use these power poles for your PCB. Rated up to 500A.https://www.we-online.com/catalog/en/WP-SHFU_FULL_PLAINFinding crimp-on ring terminators for your cable should be not that difficult.fchk