What are Flat-Wiping Contacts in Battery Connectors?
Flat-wiping contacts, invented in 1954 by Anderson Power®, offer a number of benefits for equipment battery systems. Flat-wiping contacts are smooth, with a large mating surface that self-cleans as connectors mate and unmate. This self-cleaning capability lowers the risk of connector damage. Their design also improves power transfer, making systems more energy efficient.
Flat-wiping contacts provide key advantages to battery connector systems. Applications that require high power and longevity can benefit from flat wiping, as they can enhance the lifespan of battery connectors. Flat-wiping contacts’ design comes with unique advantages for certain jobs.
- Flat-wiping contacts reduce the potential for arc damage and contact pitting. They have self-cleaning capabilities, which prevents dust buildup on contacts.
- Flat-wiping contacts are genderless, so are used on both plug and receptacle, reducing inventory costs.
- Flat-wiping contacts’ typical copper makeup supports more efficient and higher power transmission, since copper offers excellent conductivity.
- Flat-wiping contacts are usually plated with silver, which prevents the copper from oxidization due to air exposure.
How Flat-Wiping Contacts Extend Battery Systems’ Lifespans
One of the most common impacts on connector lifespan is the dust buildup on charging contacts. While charging in outdoor locations can cover contacts in dirt and grime, even indoor charging can lead to dust buildup over time. Dust buildup on contacts can erode the silver plating of their surface, exposing the copper underneath to oxidization. Oxidized copper creates issues such as electrical arcing and further poor conductivity.
However, flat wiping prevents this buildup from happening. When connectors are mated in this way, the two contacts wipe their silver plating against each other, called over-wiping. When this over-wiping occurs, the mating area is smoothed, and any accumulated grime or dust is removed from the surface. Additionally, since the mating area is smooth with no indented socket, dust has less room to accumulate on the surface. Therefore, flat-wiping contacts extend the lifespan of connectors and further reduce the need for maintenance.
Flat wiping can also help prevent damage from electrical arcing through its sacrificial contact tip. Electrical arcing happens when the connector is frequently disconnected while charging. Electrical arcing can damage the silver plating, which also exposes the copper underneath to outside air.
The front of a flat-wiping contact contains a humped crest called a sacrificial contact tip that constrains any electrical arcs into a small area, so any pits caused by the arcing cannot easily spread further than that area. Therefore, the pitting does not happen where power transfer actually occurs, so charging performance is much less affected and the connectors can stay in service for longer.
How Flat-Wiping Contacts Contribute to Higher Energy Efficiency
Due to the large size and smooth texture of their mating surface, flat-wiping contacts experience less resistance. Therefore, while mated, more power and current can be transferred. This increased power transfer makes the battery system more efficient, since less energy escapes to become wasted heat. For companies that track their cumulative total resistance, adopting flat-wiping contacts can lead to a positive improvement in their energy footprint.
Another way flat-wiping contacts can deliver better power transfer is with their spring. In a pin-and-socket design, the internal spring typically connects directly to the contact surface. This forces the contact to transmit power as well as apply force to the spring, requiring a thinner, more flexible contact. However, limiting the thickness of the contact prevents the contact from transmitting as much energy.
In a flat-wiping connector, the spring is separated from the contact surface. Therefore, the contact does not need flexibility to engage the spring and can transfer power on its own. This separation frees up the contact to be thicker to carry more current. Additionally, the springs are composed of stainless steel, ensuring the security of the mating area by providing constant force to guard against disconnection.
How Anderson Power Flat-Wiping Stands Out
Anderson Power, as the inventor of flat wiping, produces high-quality connectors that improve battery systems. Anderson Power’s flat-wiping contacts are manufactured using high-grade copper and thick silver plating, meaning the quality of their engineering is reliable and long-lasting. They have also undergone rigorous lab testing such as UL 1977 standard tests and life cycle tests, meaning they help keep contacts durable in the long term.
Anderson Power produces several connectors with flat wiping, meeting a diverse array of connector needs.
Powerpole® Connector Series
The Powerpole Connector Series offers four housing sizes that carry a wide range of amperage and accommodate several wire sizes. They also can be stacked together to create a custom multipole connector up to 350 amps.
SB® Connector Series
The SB Connector Series sets the standard for DC power distribution. Ranging in size from SB 50 to the SB 350, they are rugged, reliable, and efficient. These connectors offer color-coded, mechanically keyed housings designed to prevent cross-mating, and they are also UL rated to 600 volts for safety.
SBS®X Connector Series
The SBSX Connector Series is future-ready for electrification in many industries. Featuring options up to 3 power positions, these connectors offer benefits from both pin-and-socket and flat-wiping contacts. They also use IP68 sealing, which is crucial for weatherproofing charging systems.
SBS® Series
With four housing sizes available, the SBS Connector Series provides a versatile solution for high power and signaling up to 110 amps. These connectors feature a genderless design and offer both wire-to-wire and wire-to-board configurations. Both two and three power contact options are available.
SBE®/ SBX®/ SBO® Series
With up to 8 auxiliary power/signal contacts, the SBE, SBX, and SBO Connector Series builds upon the capacity of SB connectors. SBX housings are molded from a PC resin to meet UL/CSA requirements, while SBE housings feature a chemical resistant PBT/PC blend to meet EN1175 standards.
Why You Should Look into Flat-Wiping
High-quality flat wiping in connectors improves energy transference, reducing waste and positively impacting durability, performance, and efficiency in battery systems. Ensuring efficient power transfer and high performance is important for the longevity of battery connectors, and flat wiping can offer these advantages for charging in many situations.
Flat-wiping contacts offer features that are crucial for optimizing charging. Sacrificial contact tips and wide surfaces for self-cleaning reduce the risk of arc damage, and the design of the spring maximizes power transfer. Anderson Power’s flat-wiping connectors can help improve battery systems for all types of electrified equipment, even in harsh environments.