UAV Drone Battery
The eight most prevalent connector types deployed in commercial and industrial drone applications include:
1. XT Series (XT30/60/90)
2. EC Series (EC3/5/8)
3. AS Series (AS150 variants)
4. T/Deans Connectors
5. JST Connectors
6. JR Connectors
7. Molex Connectors
8. ACES Connectors
I. What is a Connector?
The images below may appear familiar—connectors for mobile phones, computers, and power strips. These are common connectors in household or office environments, facilitating electrical connections between devices and circuits for power transmission.
Similarly, drone-specific connectors serve as electronic interface components that connect drone batteries to the drone itself or to chargers. They transmit electrical power and may concurrently support data transfer. Drone battery connectors must meet stringent requirements, including high current-carrying capacity, stable contact, and anti-disengagement mechanisms.
II. The Most Common Commercial Drone Connector Types
Drone connectors vary based on power requirements and application scenarios. Below is a classification based on interface structure and application:
1. XT Series
Developed by Amass, the XT series is among the most widely adopted connectors in the drone industry.
Key features include:
• Yellow nylon housing with robust plug-and-play design resistant to loosening.
• Low contact resistance and high current-carrying capacity.
• Tolerance to high temperatures during soldering processes.
1.1 XT30 Series Comparison Table
Designed for small drones, micro-devices, and low-power scenarios with an emphasis on lightweight design.
| Model | Current Parameters | Core Function | Special Design | Typical Applications | Selection Advice |
|---|---|---|---|---|---|
|
XT30 |
Rated: 15A
Instantaneous: 30A |
Basic power transmission |
Compact rectangular housing, anti-reverse structure |
Micro-drones, FPV racers |
Priority for weight-sensitive racing drones/handheld devices |
|
XT30H |
Rated: 20A Instantaneous: 40A |
Enhanced protection + power transmission |
Nylon sleeve (IP54 dust/water-resistant) |
Industrial sensors, outdoor micro-robots |
Priority for dust/shock-prone industrial devices or humid environments |
|
XT30U |
Rated: 20A Instantaneous: 45A |
High-density soldering + anti-vibration |
Optimized pad structure for high-frequency vibration |
Drone gimbal power, vibrating robotic arms |
Priority for high-vibration scenarios (e.g., direct motor linkage) or space-constrained embedded systems |
|
Common Parameters: Contact resistance ≤0.8mΩ, gold-plated copper contacts, operating temperature -20°C to 120°C. XT30H/XT30U sleeves require “rotational detachment” to prevent damage. |
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1.2 XT60 Series Comparison Table
Mid-power mainstream choice balancing current capacity and size, widely used in consumer drones.
| Model | Current Parameters | Core Function | Special Design | Typical Applications | Selection Advice |
|---|---|---|---|---|---|
|
XT60 |
Rated: 30A
Instantaneous: 60A |
General high-current transmission |
Latch lock anti-disengagement, PA66 flame-retardant housing |
Agricultural drones, power tools |
Priority for medium drones/devices with 30-50A continuous current |
|
XT60H (Sleeved) |
Rated: 35A Instantaneous: 70A |
Enhanced protection + anti-miscontact |
Detachable nylon sleeve (UL94 V0) |
Industrial robots, outdoor power banks |
Priority for shared devices requiring short-circuit prevention or frequent plugging |
|
XT60-F (Signal) |
Power: 30A Signal: 1A |
Power + data dual transmission |
Integrated 2-pin signal contacts (SMBus protocol) |
Smart battery BMS communication, temperature monitoring |
Priority for drones/ESS requiring real-time battery status feedback |
|
Key Differences: XT60H sleeve version supports 1,000 plug cycles (vs. 500 for standard XT60). XT60-F requires protocol-compatible devices. |
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1.3 XT90 Series Comparison Table
High-power professional-grade connectors for heavy-duty equipment and safety-critical scenarios.
| Model | Current Parameters | Core Function | Special Design | Typical Applications | Selection Advice |
|---|---|---|---|---|---|
|
XT90 |
Rated: 45A
Instantaneous: 90A |
Basic high-current transmission |
Dual gold-plated contacts, low-impedance copper alloy terminals |
Agricultural drones, e-scooters |
Priority for conventional high-load equipment (cost-sensitive) |
|
XT90H (Sleeved) |
Rated: 50A Instantaneous: 100A |
Dust/water resistance (IP67 optional) |
Metal spring + silicone seal |
Mining robots, high-pressure cleaning |
Priority for heavy industry in dust/water mist environments |
|
XT90-S (Anti-Spark) |
Rated: 45A Instantaneous: 90A |
Plugging arc suppression |
Two-stage pre-charge resistor design |
Direct-connect LiB systems, ESS |
Priority for frequent plugging or high-value battery protection |
|
XT90S-F (Signal Female) |
Power: 45A Signal: 1A |
Power + bidirectional comms |
4-pin structure (2 power + 2 signal) |
Drone flight control interaction, smart charging piles |
Priority for deep battery management (e.g., SOC calibration) |
|
XT90S-M (Signal Male) |
Power: 45A Signal: 1A |
Active end for XT90S-F |
Asymmetric anti-reverse pins |
Paired with XT90S-F |
Must pair with XT90S-F; no cross-compatibility |
|
Safety Features:
XT90H supports -40°C to 150°C wide temperature range and salt spray corrosion resistance (MIL-STD-810G) |
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2. EC Series
Developed by Amphenol and other global manufacturers, the EC series features:
• Black nylon or PBT housings meeting UL94V-0 flame retardancy.
• Polarity coding markings and anti-misplug design for operational safety.
• Low resistance, high current-carrying capacity, and voltage protection.
• Tolerance to reflow soldering temperatures (peak 260°C).
2.1 EC Series Comparison Table (Aerial Model Battery Plugs)
| Model | Current Parameters | Core Function | Special Design | Typical Applications | Selection Advice |
|---|---|---|---|---|---|
|
EC3 |
Rated: 25A
Instantaneous: 50A |
Compact mid-current transmission |
Latch anti-loosening, diameter ≈3mm |
Small FPV drones, micro quadcopters |
Lightweight requirements, e.g., sub-250g drones |
|
EC5 |
Rated: 40A Instantaneous: 90A |
Balanced current transmission |
Optimized contact area, diameter ≈5mm |
Medium agricultural drones, racing drones |
Balanced performance (40-90A mainstream scenarios) |
|
EC8 |
Continuous ≥60A Peak ≥120A |
High-power stable transmission |
8mm large-diameter terminals, low contact resistance |
Large industrial drones, e-scooters |
Ultra-high-voltage systems (compatible with 6-8AWG wires) |
3. AS Series
Developed by TE Connectivity, the AS series utilizes:
• Aluminum alloy or reinforced nylon (PBT-GF30) housing, silicone seals, and spiral bayonet + lock ring structures.
• High protection and anti-vibration design.
• Tolerance to 260°C peak reflow temperatures.
3.1 AS150 Series Comparison Table (High-Voltage LiB Connectors)
| Model | Current Parameters | Core Function | Special Design | Typical Applications | Selection Advice |
|---|---|---|---|---|---|
|
AS150 |
Rated: 70A
Instantaneous: 150A |
Basic HV power transmission |
PA flame-retardant housing, no sleeve |
Power tool battery packs |
Pure power transmission |
|
AS150-F |
Integrated signal pins |
Supports BMS comms (temp/voltage feedback) |
Smart ESS |
Intelligent management |
|
|
AS150U |
Enhanced protection |
Silicone sleeve (IP54 dust/water-resistant) |
Outdoor industrial robots |
Pure power transmission |
|
|
AS150U-F |
Protection + signal dual-function |
Sleeve + dual-pin signal contacts |
HV drone BMS monitoring |
Intelligent management |
|
|
Common Parameters:
|
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4. T/Deans Type
The T-type connector, designed by Dean, features:
• ABS housing with -20°C to 85°C temperature range.
• Symmetric T-slot design for superior anti-vibration performance.
• Compact size (≈40% smaller than XT30) and light weight (3–5g), ideal for small drones (e.g., ≤250mm wheelbase FPV drones, indoor aerial cameras).
5. JST Connectors
JST connectors are renowned for high reliability and miniaturization, commonly used in micro/small drones:
• Low current-carrying capacity, typically for low-power components (e.g., battery balance charging ports).
• SMT mounting with anti-disengagement "wings."
• Low insertion force and vibration resistance.
6. JR Connectors
Developed by Hirose Electric, JR connectors excel in precision shielding and EMI resistance for high-interference environments:
• Full aluminum alloy housing for EMI/RFI shielding.
• Threaded locking surpasses latch-based designs in vibration resistance.
• Supports 4-21-pin free combinations, 20-16 AWG wires, ≤50N crimping force.
7. Molex Connectors
As a global leader in battery interconnect solutions, Molex serves consumer electronics, automotive, industrial automation, and data centers. In drones, Molex connectors are used in power distribution and signal transmission, notable for:
• High-reliability sealing and wide-temperature adaptability (-40°C to 125°C).
• 10,000 plug cycles, exceeding industry averages.
• Oil/chemical corrosion resistance via dual-ring potting.
• Single-step auto-locking structure; dual-contact anti-vibration design.
• Diverse pin counts and arrangements
8. ACES Connectors
ACES connectors from Taiwan’s Aces Electronics feature high-density SMT and industrial anti-vibration design. The AXT high-current series uses nylon housing with lock ring anti-loosening, 3A continuous current, and 1.2g weight, commonly used for drone flight controller power interfaces.
Ⅲ. Selecting the Appropriate Drone Battery Connector
1. Electrical Requirements
Higher-capacity/higher-voltage batteries require connectors capable of handling maximum continuous current, peak current, and high-voltage testing. Example: XT30 (30A) for small FPV drones; XT90 (90A) for high-power agricultural drones. Low-resistance connectors minimize heat generation.
2. Wire Gauge Matching
Connectors must precisely match wire gauges to prevent mechanical/electrical failures:
- Thin wires + large connectors: Risk of mechanical stress. Insufficient contact area relies on solder/crimping, leading to cracked joints under vibration.
- Thick wires + small connectors: Overheating due to poor contact and exceeding current ratings (e.g., 5A connector with 10A wire causes meltdown/fire).
Technical Note: Wire Gauge
Wire gauge quantifies physical dimensions and electrical properties of wires:
- Inverse logic: Smaller AWG numbers indicate thicker wires (e.g., AWG 10 > AWG 20).
- Dominant standard: AWG (American Wire Gauge) for solid round wires.
- Electrical correlation: Wire diameter determines resistance and ampacity (see table).
| AWG Value | Diameter (mm) | Cross-Section (mm²) | Typical Ampacity (A) |
|---|---|---|---|
|
10 |
2.588 |
5.26 |
20–30 |
|
16 |
1.291 |
1.31 |
5–10 |
|
22 |
0.644 |
0.326 |
1–3 |
|
26 |
0.405 |
0.129 |
<1 |
3. Compatibility
Connectors must match device interfaces in shape, size, plugging method, electrical parameters, and communication protocols.
4. Ease of Use
Prioritize connectors with easy plugging/unplugging and anti-misplug features (e.g., semi-cylindrical plugs, asymmetric layouts to prevent short circuits).
5. Safety and Reliability
For high-vibration/extreme environments, select connectors with spark suppression, anti-disengagement, and shock resistance.
6. Weight Considerations
- Small drones: Prioritize compact, lightweight connectors.
- Large drones: Emphasize current-handling capacity.
7. Durability
High plug cycle counts, high-quality materials (nylon/polyamide), and robust design extend service life.
8. Brand-Specific Designs
Some brands (e.g., DJI) use proprietary connectors (e.g., smart flight battery structures), limiting cross-model compatibility
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