BA-5590 Style Plug

© Brooke Clarke 2008 - 2009

17 July 2009 2nd prototype "12 V" only
5590Plug BA-5590 battery Plug
I have a small number of these available for sale.  Contact me for details.
5590Plug for BA-5590 battery
1st Prototype "Universal" in application
BA-5590 Style Plug Prototype 0.0
BA-5590 Plug Prototype Pins side
11 July 2009 - Have some prototpe locating pins machined and attached with nuts.  Solders are to hold a bail to make removing plug easy.
BA-5590 Plug with Locating Pins


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 example:
  • 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 market.
  • 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.


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