The rise of battery-powered, tech-savvy outdoor power equipment is creating new demand for advanced power and signaling in high power density connectors. Anderson Power™ is leading the charge with new, innovative sealed connector solutions.
Outdoor power equipment (OPE) is going “smart”. The newest snowmobiles, lawnmowers, snowblowers, hedge trimmers, and leaf blowers are incorporating innovative smart technologies and the Internet of Things (IoT) to improve their functioning and efficiency.
Zero-turn electric lawnmowers packed with features like Bluetooth connectivity, expanded user interfaces, and LED lights are becoming common. The latest battery-powered snowblowers include programming designed to match the user’s natural walking pace. Autonomous equipment like self-driving tractors and robotic lawnmowers are using advanced GPS tracking and smartphone apps to control their operation.
The popularity of this smart equipment is expected to grow as customers embrace enhanced convenience, efficiency, and user control. However, these high-tech, battery-powered designs require more power and data transmission capabilities from their connectors than ever before. New Anderson Power connectors like the SBS®XPRO and SBS®X-75A feature the power and signaling capabilities that electrical design engineers and quality engineers require to power their latest innovations.
What Are Auxiliary Signals in Battery Connectors?
Before exploring these connector solutions, the role of power and signaling in high-tech OPE designs is important to consider. Auxiliary signals are the physical, auxiliary pins within a battery connector. Signals are used to transfer data and keep tabs on the batteries and electrical loads like motors. Engineers can use signals to monitor battery lifespan, mating cycles, internal temperature, control brushless motor sequencing, communicate with the battery monitoring system (BMS), and more. This intelligent data is useful to maintain peak battery and motor performance. The data flags any potential battery maintenance issues, permitting the user to respond proactively to issues.
The need for signaling in OPE designs is growing. Large electric equipment that used to require four signals might require six or even eight signals today to support all their technological features. Standard battery connectors only provide four or six signals, so those that offer eight provide design and quality engineers with an advantage
The SBSX-75A Connector from Anderson Power is an example of a sealed connector with up to six signals and two power contacts.
More auxiliary signals are also particularly useful to monitor the growing number of lithium-ion (Li-ion) powered equipment. Li-ion technology enables fast charging, but excessive or improper charging can lead to overheating and, in rare cases, thermal runaway. This phenomenon involves a chain reaction in which the battery heats rapidly and releases toxic gases, including hydrogen fluoride, carbon monoxide, and hydrogen cyanide.
Newer connectors with six or eight auxiliary contacts can be used to provide extra Li-ion temperature monitoring capabilities. The real-time battery data from the auxiliary pins provides an additional layer of safety by enabling a proactive response to any overheating issues. This also helps to extend the lifespan of lithium-ion powered equipment.
This advantage is particularly important as the switch to battery powered equipment from internal combustion engine (ICE) equipment continues. 44% of OPE customers expect to purchase battery-powered equipment in the future, compared to only 35% for gas-powered models.
A detailed illustration of the SBSXPRO Connector from Anderson Power that shows the power contacts and signal pins.
What Are Power Contacts in a Battery Connector?
The other important consideration for battery connectors involves their power contacts. Power contacts are the conductive elements, typically metal pins or blades, that establish a secure and efficient electrical connection to the battery. These contacts facilitate the flow of electrical current through the connector, enabling equipment to draw power from the battery.
Power contacts are often the point of failure on a connector, but flat-wiping contacts help ensure a durable and reliable connection. Invented by Anderson Power in 1954, flat-wiping contacts over-wipe to self-clean the mating surface when engaged or disengaged. The universal, genderless design includes a sacrificial tip which confines damage to a non-conducting area when mating or breaking under load. Using these features, flat-wiping contacts deliver long-lasting performance in demanding industrial environments. They help reduce inventory costs, expand storage battery life, and simplify assembly. The power contacts on the SBSX Sealed Connector Series from Anderson Power are flat-wiping.
Most battery connectors provide two power contacts in total. However, three power contacts can come in handy for certain OPE designs with brushless DC motors. Using the extra power contact, design engineers can replace the traditionally hardwired internal connection between an equipment’s power source and its motors and controllers with a connector. This allows users to disconnect the battery by simply unplugging the connector rather than necessitating specialized tools, significantly speeding up equipment assembly and repairs. Battery connectors that offer three power contacts thus provide an effective and convenient maintenance interconnect solution for brushless motor designs.
Some connectors that deliver three power contacts lack robust signaling capabilities, requiring OEMs to purchase separate signaling connectors. To avoid this inconvenience, the best approach involves obtaining a connector that combines high power and advanced signaling into an all-in-one solution. For example, the SBSXPRO from Anderson Power provides up to eight signals and three power contacts in one powerful connector.
What Should Design Engineers Look for in Battery Connectors?
To support the needs of tomorrow’s outdoor power equipment, battery connectors must deliver the required levels of power and signaling while remaining tightly sealed against water/dust intrusion. Larger applications and more technologically-advanced applications will usually require more auxiliary signals than smaller applications. Regardless of size, electrical design and quality engineers should look for options that combine their required power and signaling into one connector for maximum convenience.
The benefits of combining power and signaling include:
- With increased signaling capabilities, customers retain better control over their systems.
- Powering up and down becomes a unified, more efficient process, as signaling provides crucial data on system status in real time.
- By reducing the size of the connector’s outer housing, the streamlined design saves space and enhances the aesthetics of the power application.
Battery connectors used for outdoor applications should also be IP-rated against moisture and dust ingress. This ensures the connector will continue to perform regardless of rain, snow, humidity, and dust exposure. IP68 is one of the highest IP ratings and indicates the connector is fully dust-tight and can withstand complete water submersion while mated for up to 30 minutes at a depth of six feet.
What Sealed Connectors Exist That Offer Advanced Power and Signaling?
Anderson Power recognizes the need for advanced connector solutions that deliver enhanced power, signaling, and sealing. The SBS® Connector Series accommodates power and signaling into one convenient package, supporting up to 110A and four signals. For even more capability, the IP68-rated SBS®X Series provides up to three power contacts and eight signals to support the industry’s most advanced sealed charging applications. Both SBSX Series connectors are UL-rated to support up to 140A and 600V, meaning they can handle substantial current without overheating.
- The SBS®X-75A Sealed Connector features two power contacts and up to six auxiliary signal pins or ground to deliver enhanced signaling capabilities. Designed for applications such as commercial and riding lawnmowers as well as other electrified lawn and garden equipment, the SBSX-75A is durable for 5,000 mating cycles. The SBSX-75A is well-suited to rugged, outdoor applications with an IP68 weatherproof rating while mated and consistent performance from -20° to 105°C.
- The SBS®XPRO Sealed Connector provides a powerful connector solution for larger electric applications that utilize DC brushless motors such as riding lawnmowers. With up to eight auxiliary signals constructed of a gold-plated copper alloy, the SBSXPRO delivers industry-leading signaling capabilities to support the most technologically advanced designs. Its three power contacts can be used to provide a maintenance interconnect solution that makes equipment assembly, servicing, and troubleshooting easier than ever. With a rugged IP68 rating, the connector is protected against moisture, rain, dust, and debris intrusion. It also operates effectively in temperatures from -20°C to 105°C and is durable for 5,000 mating cycles.
The two connectors provide the perfect solution for large outdoor power equipment. Beyond OPE, these sealed connectors can also be used for a variety of industrial and marine electric applications up to 140A.
The Future of Electric Outdoor Power Equipment
As technology advances, the market for smart, battery-powered outdoor power equipment will only continue to surge. Anderson Power is committed to supporting the latest high-tech designs by ensuring the highest levels of performance and reliability in its connectors.
The SBSX-75A and SBSXPRO connector combine standout power and signaling capabilities into one convenient unit. Both connectors are IP68-rated for ultimate protection from moisture and dust ingress while mated. Additionally, with support for up to eight signals and three power contacts, the SBSXPRO provides industry-leading capabilities for Li-ion equipment, brushless motor designs, smart technology, and more. Customization of Anderson Power connectors is also available to fit specific customer needs.
As design engineers craft the next generation of smart outdoor power equipment, Anderson Power has the rugged, high-power connectors they need. Contact us and take the first step toward Your Best Connection™.
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