battery contector

battery contector.md

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

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.

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?

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