For a number of years I've been trying
to come up with a low cost plug for the BA-5590/U family of batteries
and now have a working prototype.
The top photo is larger than the planned size because it's has a lot of jumper
options to allow making about any type of cable you can think of, for
- 12 Volt output (shown)
- 24 Volt output
- 24 Volt Charging
- 12 Volt Charging
- 4 wire output (two wires for each battery side)
- Dual voltage split output. Three wires, +12, gnd, -12
The next version will have a dedicated PCB for "12 Volt Output" and another for "24 Volt Output". (17 July 2009 see above).
Next is to come up with some packaging options such as: potting, Aluminum can, bail to pull plug, etc.
It's a very easy thing to add electronic circuitry to a PCB.
These solutions would have a selling price far below what is now on the
- Switching mode power supply for a Toughbook computer
- Switching mode power supply to drive a high brightness LED
The cost of this plug after it's in the final cable should be lower than the alternatives because of the ease of assembly.