can you give me direct links to the product pages of the solution you suggest: Anderson SBS75X — best feature overlap (finger-proof, power + signal, flat-wipe self-cleaning contacts), widely available including from RS in Norway, but mates horizontally and isn't sealed CHOGORI FC09 Pro — closest application match (e-scooter battery swap, blind mate, IPX7, 40A+5A), but uses conventional pin/socket rather than interleaving fins Amphenol BSC — most configurable (modular power + signal inserts, IP2X finger-proof, optional IP67 shroud), but oversized for a 10A ebike-scale application
Created
March 13, 2026 23:41
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battery contector
Author
Author
Let’s pick a concrete 6‑pin pogo block geometry and then size the pad island around it.
Reasonable 6‑pin pogo block assumptions
Since Accio is an aggregator, we’ll assume a standard 6‑pin block like the common 2.54 mm pitch strips (or equivalent): aliexpress
- Pin pitch: 2.54 mm (center‑to‑center). [ccpcontactprobes](https://www.ccpcontactprobes.com/sites/default/files/2020-01/CCP-Standard-Pogo-Pin-Connector.pdf)
- Pins in a single row (simplest layout).
- Pin count: 6 → total length between outer pins ≈ (5 × 2.54 = 12.7) mm.
- Contact diameter: ≈ 1.3–1.5 mm barrels. [ccpcontactprobes](https://www.ccpcontactprobes.com/sites/default/files/2020-01/CCP-Standard-Pogo-Pin-Connector.pdf)
- Block body length: ≈ 15–18 mm, width ≈ 3–4 mm, height ≈ 6–9 mm typical. johotypro
- Current: 1–3 A per pin, 5 A for some heavy‑duty types. connectors-cables
We can refine once you choose an exact part, but this is good enough to size the island and keep clearances realistic.
Pad island dimensions (frame side)
Assume inner down‑tube width at the bottom is at least 30 mm (you can adjust later). Frame‑side island is a small “speed bump” PCB glued or molded onto a plastic pedestal on the DT floor.
Proposed island:
- Island PCB footprint: 24 mm (L) × 10 mm (W).
- Top surface: gently domed or chamfered edges so water sheds.
- Copper pads area: centered strip about 16 mm (L) × 5 mm (W).
Pad pattern (to match 1×6 pogo row):
- Row along length, pitch 2.54 mm, 6 pads → ~12.7 mm active length.
- Each pad: about 1.5–2.0 mm wide by 2.0–2.5 mm long, with rounded ends.
- Outer keep‑out margin: at least 2–3 mm from island edges so water has “gutters” to flow around the pad zone, not over the pad edges.
Height:
- Island pedestal height above DT floor: 3–4 mm.
- PCB thickness: 1.0–1.6 mm → total ~4–5 mm above the lowest drain point.
- DT floor around the island slopes or is cut away so water naturally bypasses the island and runs along the sides.
Clearances:
- Shortest distance from live pad edge to DT metal: ≥ 3 mm creepage in air (36–48 V is forgiving, but this leaves margin).
- If you pot/overmold the island’s base, you effectively increase creepage along plastic.
Battery dock (pogo side) to match island
Given a 6‑pin row ~12.7 mm long and block ~15–18 mm long:
Dock cavity:
- Internal length: 26–28 mm (island length 24 mm + 1–2 mm margin front/back).
- Internal width: 12–14 mm (island width 10 mm + 1–2 mm margin).
- Depth (from battery bottom opening to pogo contact tips at mid‑stroke): 6–8 mm.
- Enough that fingers cannot reach pins.
- Pogo stroke: design contact at ~1/2–2/3 stroke height; e.g. pins 8.8 mm total, 1–2 mm effective stroke. aliexpress
Guides:
- Entry chamfer: dock opening chamfered 30–45° around all edges.
- Side clearance: 0.5–0.75 mm per side between island and dock walls → self‑centering funnel but not too tight for tolerances.
Mounting pogo block:
- Pogo block soldered to a small internal PCB fixed at the top of the dock cavity.
- Vertical offset so at nominal dock engagement, pins compress ~1 mm from free height.
Simple OpenSCAD‑friendly parameters
You can start with something like:
island_len = 24;island_w = 10;island_h = 4.5;// pedestal + PCBpad_pitch = 2.54;pad_n = 6;dock_inner_len = island_len + 2;dock_inner_w = island_w + 2;dock_inner_depth = 7;side_clearance = 1;
Then:
- Frame: model a cylinder or oval for DT, subtract a channel at the bottom, then add a rectangular “island” solid with filleted/chamfered edges.
- Battery: a rectangular cavity with those
dock_inner_*dimensions, plus chamfers.
Once you pick a specific Accio 6‑pin module with exact pitch and body size, we can tighten these numbers. Do you know your approximate down‑tube inner width at the bottom (e.g. 28, 30, 32 mm), so we can check that the 24×10 mm island still leaves enough drainage on both sides?
Author
I mean to make a dock design you have to understand basics of docking. the battery part is reseeded. the down tube part is elevated. it's not that hard. the bat part has pogo pins. the downntube elevated part has pads.
Author
You’re right: I inverted the roles and made everything confusing.
For a proper dock:
-
Battery part is recessed
- On the battery scaffold bottom you have a shallow cavity.
- Inside that cavity sit the pogo pins, pointing upward.
- The cavity walls protect the pins and give lead‑in for docking.
-
Downtube part is elevated
- At the downtube floor you have a raised boss (a small platform) that sticks up into the battery cavity.
- On top of that boss you have flat pads (no springs).
- When you drop the battery in, the boss enters the battery cavity, and the pads meet the pogo pins.
Mechanically:
- Gravity pulls the battery down; the recess makes sure the pins are never exposed when the pack is out.
- The elevated boss keeps the frame pads out of any water at the absolute bottom and makes cleaning easy.
- Alignment is trivial: cavity walls guide the boss; the last few mm compress the pogo pins and give the wipe.
I flipped that in the SCAD (pins on the block in the pocket, plug above), so the picture you see is wrong from a docking‑mechanics standpoint.
Author
Here’s a very small, self‑contained OpenSCAD snippet that models:
- A cylindrical down tube section.
- The raised pad island on the inside bottom.
- The matching battery dock cavity with pogo block above.
You can paste this into a new .scad file and tweak dimensions.
// Simple demo of pad island + recessed pogo dock
// Units: mm
$fn = 64;
// ---------- Parameters ----------
dt_inner_d = 30; // down tube inner diameter
wall_thick = 2; // tube wall
section_len = 60; // length of shown tube section
island_len = 24;
island_w = 10;
island_h = 4.5; // pedestal + PCB
dock_depth = 7;
dock_clear = 1; // clearance around island inside dock
pogo_block_h = 3; // pogo plastic height
// ---------- Main ----------
module down_tube_section() {
difference() {
// outer tube
cylinder(h = section_len, r = dt_inner_d/2 + wall_thick, center = false);
// inner bore
translate([0,0,0])
cylinder(h = section_len, r = dt_inner_d/2, center = false);
}
}
module pad_island() {
// Island at bottom inside tube (z = 0 plane is bottom)
translate([0, 0, 0]) {
// Use a rounded box as pedestal+PCB
translate([0, 0, island_h/2])
rounded_box([island_len, island_w, island_h], r = 1.5);
}
}
module rounded_box(size = [10,10,5], r = 1) {
// quick-and-dirty rounded rectangle prism
hull() {
for (sx = [-1, 1])
for (sy = [-1, 1])
translate([sx*(size[0]/2 - r), sy*(size [reddit](https://www.reddit.com/r/openscad/comments/1lowpyi/designing_connecting_cubes/)/2 - r), 0])
cylinder(h = size [hackster](https://www.hackster.io/chloe-hor/building-a-reliable-magnetic-pogo-pin-usb-charging-interface-2efafd), r = r, center = true);
}
}
// Battery dock cavity that drops over the island
module battery_dock() {
// We show only the dock “block” here, not the whole battery.
dock_len = island_len + 2*dock_clear;
dock_w = island_w + 2*dock_clear;
// Position the dock above the island, leaving some air gap.
translate([0, 0, island_h + 2]) {
// Outer block (for visualisation)
color("lightgray")
difference() {
// Solid block representing the battery bottom
cube([dock_len+6, dock_w+6, dock_depth+5], center = true);
// Hollow cavity that fits around the island
translate([0, 0, -1]) // cavity starts a bit above bottom
cube([dock_len, dock_w, dock_depth], center = true);
// Simple chamfer / funnel: subtract a slightly rotated hull
// (kept crude for simplicity)
}
// Pogo block “inside” roof of cavity
pogo_len = island_len - 4;
pogo_w = 4;
translate([0, 0, dock_depth/2 - pogo_block_h/2])
color("silver")
cube([pogo_len, pogo_w, pogo_block_h], center = true);
}
}
// ---------- Assembly views ----------
// Uncomment ONE of these at a time:
// 1) Frame only with island
//rotate([90,0,0]) {
// translate([0,0,-section_len/2])
// down_tube_section();
// pad_island();
//}
// 2) Frame + dock in position
rotate([90,0,0]) {
translate([0,0,-section_len/2])
down_tube_section();
pad_island();
battery_dock();
}This is intentionally simple and blocky: it just shows the relationships and clearances. You can now:
- Adjust diameters/lengths to match your actual DT and battery scaffold.
- Replace the
battery_dock()solid with your real battery bottom geometry and fuse this dock into it.
Want me to add a second module that shows just the pad island and its PCB as a 2D projection you can export as DXF for the copper pattern?
Author
that's cool 2 things. 1. only 1 dock and one island. dont make double sets. 2. the island must be square. dont chafer it. and recede the pins way more into the dock. human fingers cant reach it. also make the island smaller. so the dock is narrower. safetysafetysafetysafetysafety
Author
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That's a really clean inversion. Let me confirm the logic because it's elegant:
The architecture
Why this works so well
Water: the elevated pad island has no cavities for water to pool in — it's just a smooth bump with gold traces. Rain, splash, condensation all slide off and drain down.sameskydevices+1
Safety: pogo pins are buried inside the battery dock. Even if a child sticks a finger into the battery's bottom, the recess depth + narrow pin wells make it nearly impossible to touch live contacts.[johotypro]
Alignment: the dock cavity on the battery slides over the pad island on the frame. The walls of the dock are the guide — no separate fins or funnels needed. Last few mm of travel compresses the springs onto the pads.[sunkye]
Cost: high‑current pogo pins (10A each, gold‑plated) run about $0.18–1.40 per pin depending on quantity. A 6‑pin set on a small PCB inside the battery dock = a few dollars total.[alibaba]
Durability: gold‑plated pogo pins handle 10k–100k cycles easily, and the flat pads on the frame side have no wear mechanism at all.attend+1
Pin layout suggestion
For a 36V system at ~10A continuous:
2 power pins (paralleled, 10A‑rated each = 20A headroom)
1 ground pin
1 thermistor / NTC
1 communication (UART TX or one‑wire)
1 spare / ID
The pad island on the frame side is just a small PCB (~20×15 mm) potted onto a raised plastic pedestal. The battery dock is a matching rectangular cavity with a 6‑pin pogo block soldered to its internal PCB.
This is arguably the simplest, cheapest, and most weather‑resilient swappable battery contact system you could build. Want to start dimensioning the pad island and dock cavity for your DT inner diameter?
The architecture
Why this works so well
Pin layout suggestion
For a 36V system at ~10A continuous:
The pad island on the frame side is just a small PCB (~20×15 mm) potted onto a raised plastic pedestal. The battery dock is a matching rectangular cavity with a 6‑pin pogo block soldered to its internal PCB.
This is arguably the simplest, cheapest, and most weather‑resilient swappable battery contact system you could build. Want to start dimensioning the pad island and dock cavity for your DT inner diameter?