This adapter serves as a good option to quickly connect a cble to a battery or power suppply. It is based on an idea by KE5EZZ who describes this in various variants. The base is an adapter from PowerPole to WAGO connectors. These WAGO connectors allow a tool-free connection of conductors between 0.2mm² and 4mm². The connection is established using a clamping mechanism and can be used as adapter or as a repair for a broken cable for popwer supply.
For manufacturing you need the following components:
- 2 PowerPole cases (red/black)
- 2 PowerPole contacts (angled for PCB mounting)
- 2 WAGO 221-2411 connectors
- Some shrink tube
The two WAGO connectors are glued to each other using 2-component glube (apparently there is no variant with two connectors). This just contributes to the overall mechanic stability.
The PowerPole contacts are a little too wide and therefore are grinded after bending them to form them straight.
Additionally the PowerPole contacts are cut to length. The WAGO connectors need about 11mm of length in order to connect properly. The prepared contacts look similar to this:
Then the two contacts can be inserted into the PowerPole connectors. The spacing between the contacts are almost simliar to the spacing of the glued together WAGO connectors.
The slithgly grinded ends of the PowerPole contacts can then be inserted into the WAGO connectors.
This would now be ready to use. For better machanical stability the adapter is wrapped into a few layers of shrink tube. This also secures the “internal” parts of the WAGO connectors against random opening. The finished adapter looks as follows:
