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So far, we have identified the following use cases for connectors in MSXII:
| Type | Scenario | Expected Voltage | Expected Current | Number of Circuits |
|---|---|---|---|---|
| Wire-to-board | Connecting signal wires between boards or panel mounts within an enclosure (ex. CAN, BMS) | 3.3v | <1A | 2~16+ |
| Wire-to-board | Supplying power to boards or relays | 12v | <1A (3.2A peak) | 2 |
| Wire-to-board | Supplying power from Chaos to other systems | 12v | 2A (6A bursts if for horn) | 2 |
| Wire-to-board | Supplying power from the DC-DC or aux battery to Chaos | 12v | 10A? | 2 |
| Wire-to-board | HV measurement for precharge | 150v | <1A | 2 |
| Panel-to-panel | CAN, power, and auxiliary signal (ex. killswitch or MPPT enable) between enclosures | 12v | 2A (6A bursts if for horn) | 6+ |
| Panel-to-panel | HV power | 150v | 150A | 2 |
Currently, we have identified the following connectors as possible candidates:
| Connector | Purpose | Max. Rated Voltage | Max. Rated Current |
|---|---|---|---|
| Molex Clik-Mate | Wire-to-board: 1.25mm for signal and 1.50mm for power | 1.25mm: 50V 1.50mm: 100V | 1.25mm: 1A 1.50mm: 2A (3A with 2 circuits) |
| Anderson SB120 | HV power - note that this does not follow any of the rules | high | 240A |
| Hirose DF3 | Alternative to Clik-Mate (2mm pitch 2 circuit variant available) | 250V AC? | 3A |
| M12-5 (DeviceNet) | CAN and power | 300V? | 4A (power) |
| TE Deutsch | CAN, power, aux signal |
After testing, the Clik-Mates 1.5mm will be a good choice for any signal wire-to-board connections required. The 1.25mm versions extremely difficult to crimp and have a maximum wire size of 26 awg.
We plan on powering all boards through the carrier board, so we want to find a high-current (10A) 2-pin connector for all LV power usage.