Regarding Card Edge Connectors

TL;DR: I’m looking for beefy, ruggedized card edge connectors to make upgrade slots for a hexapod robot. Know of any good ones or have any better ideas?

So, I've built myself a little hexapod robot. It's pretty nifty so far; I've gotten some walking algorithms down, and most importantly, I’m enjoying the build. I’m thinking about designing a new control board, however. I am hoping to use card edge connectors to make some expansion slots for it, so that I could develop modules that I can drop in for added or upgraded functionality. Conceptually, I want it to feel like the hexapod has a bunch of little Gameboy cartridges on its back, which can be removed and replaced on a lark. It seems like a fun idea, but I’m concerned about the reliability. I’ve heard that they’re only good for about 50 mating cycles. Does anybody know of any ruggedized card edge connectors that can handle a lot of mating cycles?

Some other general notes: I’ve designed a 3d printable housing that allows me to secure the modules with a single M3 screw, so I’m not too worried about vibrations knocking the modules out of place. The housing also should also prevent me from inserting the cards backwards. I’ve also considered using dual rows of headers, like an Arduino with vertical shields. The only issue is that I cannot find right angle headers which mount in such a way that the board is “in between” the headers. The only headers I can find are the style that extends off with a right angle from either the top or bottom of the board. I’m not sure if that makes sense, so I can elaborate, if needed. Does anybody have any other suggestions, feedback, or comments?

Thanks for reading, and thanks for your input!

If you have space for a chunky connector then something like the Amphenol 24 pin connector as used by the IEE488 interface should be pretty durable.

It would be helpful to know how many pins you might need on the connector and if you intend to supply power through the connector as well. It may also help to know the sort of signals you will be sending. Maybe they are PWM signals to drive the hexapod servos?

From what you said, I assume that you want a 2-part connector system, a male and a female, one on each board, rather than a board with copper tracks on the edge that mate up with a connector on the other board?

If it's for a hexapod, then I guess you also want something quite lightweight as well?

You could consider the sort of connectors that are on an Arduino Uno (for the robot) and their corresponding PCB header pins for the card. The header pins come in straight and right angled versions. They are common, pretty robust and cheap.

...R

Possibly some form of a Micro:Bit connector? They come in 40 and 80
pin variations, with straight up and 90 deg versions in both though hole
and smt.

SparkFun micro:bit Edge Connector SMD, Right Angle (40-pin)

AdaFruit micro:bit Edge Connector SMD, Right Angle (80 pin)

In a few weeks Parallax will have 80 pin connectors, straight/90 deg,
though hole for ~$2.

Bill M.

Hi, thanks for the responses!

mikb55:
I like that connector - I'm gonna order a couple of them to play around with. I hadn't considered something like that, and I always love an unexpected option or suggestion. Even if I don't use them, they'd be nice to have around.

markd833:
Good point - more specifics are always great. I need a variety of pin counts for different modules. currently, I need a 24 pin, 12 pin, and 40 pin connector. I could use multiple pins for higher current, though, so those numbers can be higher (I.E. using 6 pins for a power connector.) I plan on using them for both power and signals, and the fastest signal on the board is an I2C bus, so either 100k or 400k b/s. As far as power requirements go, the servos are the MG90S style, so the entire leg draws under 3 amps (2.1 amps + safety margin) during complete stall. I'm doubling up on the pins, however, so each pin only needs to handle 1.5 amps.
Actually, what I want is the copper tracks on the board which go into a female receptacle. I'm looking for something akin to a PCI slot, where I can design cards that simply have the tracks on them. At least that's what I'm currently considering my frontrunner. However, I always like alternatives, so if you've got a cool two part system, I'd love to see it!
For weight, I'm actually still under my max weight by a decent amount, and the hexapod can handle an additional ~.5kg on its back without too many problems. Let me know if there's any other specs you'd like to know, I'd be happy to provide them!

Robin2:
I've definitely considered the headers, as well! I'd be sold if I could find some right angle headers that mount on both sides of the board, so that the board rests in between the rows. I've attached a photo, for reference. This, however, seems a bit prone to wear and tear, and it's definitely a non-standard usage. One other question, what is the mating cycle count on headers? I haven't found any conclusive figures, and the amounts that I've read on forums and reddit range wildly.

wmazz:
I've actually been using the Micro:Bit system as a reference for some of my research! I was thinking that their connectors might be more durable because the cards are designed for kids to use. Those parallax boards look almost exactly like I want the modules to look. Is that set of connectors going to be on parallax.com? I'm assuming that they're going to be releasing them in a few weeks, which is why I can't find any of the connectors on the site currently. That's great to know though, and I'll keep a close eye on them.

SparkSlinger:
One other question, what is the mating cycle count on headers? I haven't found any conclusive figures, and the amounts that I've read on forums and reddit range wildly.

I have no idea but I assume it is a lot greater than for edge connectors formed on a PCB as in the photos in Reply #4 or on an SD Card.

What are you thinking of making that requires a large number of connections?

...R

Your first post makes me think you are planning on removing and inserting cards while the device is powered up. Don't! Unless you have correctly designed the connectors to allow for such use.

Paul

I wonder if one of the DIN41612 series connectors would suit your requirements. They were used a lot for VME card racks/backplanes where I used to work. They come in various combinations. I know you can get shorter ones but the ones I saw most were the 64 pin 2 row (a+c) versions or the 96 pin 3 row (a+b+c) versions. I think some of them were good for 200 insertions. There was a 5 row version that I saw. I think that was for the VME64 bus. They had 2 extra rows of contacts that, from memory, were a bit more substantial than the 64pin or 96pin versions.

There was also a variant of the DIN41612 (or something very similar) that we saw a lot of on plug in modular power supplies on the VME racks. They would easily meet your power carrying requirements but there was only about 32 pins.

Then things started getting fancy with combination connectors that had a few power pins and the rest were data pins.

I'm not sure if they were stackable beyond 2 boards, but they had straight and 90deg variants.

If the slave board includes a microprocessor and if I2C is used to communicate with it then only 4 pins would be needed. Power, GND, SDA and SCL

The soldering of a 64 pin connector would be very very tedious.

...R

Robin2:
If the slave board includes a microprocessor and if I2C is used to communicate with it then only 4 pins would be needed. Power, GND, SDA and SCL

The soldering of a 64 pin connector would be very very tedious.

...R

Those were always soldered using a wave solder machine. It also soldered ALL the components on the board during a single pass through the machine.
Paul

Paul_KD7HB:
Those were always soldered using a wave solder machine. It also soldered ALL the components on the board during a single pass through the machine.

Have I been foolish to assume the OP does not have one of those machines? :slight_smile:

...R

Robin2:
Have I been foolish to assume the OP does not have one of those machines? :slight_smile:

...R

Perhaps he has a solder pot large enough to hold the board. I had a customer that did that. Only one I ever saw.
Paul