Electrical connectors on control system items

[Greg Needel]

Hey All,
We have been working on a bunch of new products for upcoming seasons and wanted to get the community's opinion on an internal debate we have been having at REV.

In the current control system there are numerous styles of electrical connectors, each one has it's own advantages and disadvantages (cost, size, current carrying ability, easy of installation, robustness, etc) and there have been a few "standards" that have appeared over the years. While we are still in the phases of working on new projects I always think it is a good idea to question previous assumptions rather than just assume they are correct.

Here are all of the connectors that are commonly used

• .1inch headers (PWM) - used for all signals to the roboRIO & motor controllers - minimal retention but cheap
  
• Weidmuller wire-to-board - Used for CAN connections & module connections - expensive, good retention, requires precise wire striping
  
• Wago - Used for the Power distribution board - Expensive, good for high current, very reliable
  
• Screw terminals - Used on SPARK motor controllers & others - low cost, good retention, small, screws can strip/get lost
  
• Spade terminals - Used on the Spike relay and wire to wire connections - cheap
  
• Anderson Powerpole - main battery connector & commonly wire to wire connections - medium price, good quick release, hard to crimp without special tool
  
• IDC connectors - used for MXP, SPI, & talon motor controllers
  
• USB - Used on the roboRIO & other places
  
• Barrel jack - used on the radio
  
• RJ45 (ethernet) - Used on the radio & roboRIO
  
• RJ11 - used on Jaguar motor controller

Here are some new connectors I would like opinions on.

JST connectors (PH series for example ) http://www.jst-mfg.com/product/detail_e.php?series=199 - As a replacement for PWM cables
XT Connectors (30 or 45) https://www.amazon.com/OOOUSE-XT60-C.../dp/B005FAPYXS instead of power poles or wagos
Deans connectors - https://www.amazon.com/dp/B00S7G4A14/ instead of power poles or wagos



So you tell us, What frustrates you or makes you happy about the existing connectors? What connectors do you hate and which ones do you like.

We are also open to other suggestions let your opinions fly.