Power and Control Connector-- All-in-one?

I'm tired of googling... and I haven't found what I need. Here's the end goal: one plug that connects power and control wiring. The thing is, the power cables are thick and running at 40amps, and the control wiring are teeny-tiny running low loads. I want to be able to connect ONE connection and have everything connected. Any ideas?

How many wires do you have in total.

I can think of two right off the bat:

Anderson Multipole, which can come in several varieties, including small plus large contacts. Not sure if they have an existing one that has all the pins you need; you'd have to check with them.

I'm not sure of it's common/correct name, but at Honeywell we called them the "Canon" connector, which is round, keyed for insertion only one way, and locks together, and can be weatherproof. It's commonly used in aircraft, military applications, test equipment, etc. Multiple pin sizes can be used in a single connector: I have a harness from some equipment that has a few pins much larger than the rest within it, which I have considered using for a hubmotor-to-controller connector, if the attached wires were longer. (the pins are crimp-on, and I dont' have new pins for them, though I think I have a tool that fits them).

Within the connector/plug, I would need three main power connections (capable of 40ams) and 14 small control connections. After some looking, I found that they're called hybrid power data connectors. I haven't been able to find one to suit my purposes... yet.

If we take this in steps, first find a suitable connector; then figure out how to buy small quantities.

Here is a catalog of mixed power and signal connectors. Connector 21WA4 on page 6 might do the job for you.

http://www.connectpositronic.com/downloads/pdf/c040revb_pwrcnctrslctngd_web.pdf

Also 21WA4 on page 24 of this catalog
http://portal.fciconnect.com/Comergent//fci/documentation/webdsub_catalogue.pdf

A quick google of that number finds this:
http://parts.digikey.com/1/parts/1159548-dsub-power-stb-21wa4-pin-dcl21wa4p500g40lf.html
which they don't stock but maybe they can order a "sample" quantity for you.

RS Components UK has them for pretty cheap, at £2.42 for 1:
http://uk.rs-online.com/web/search/searchBrowseAction.html?method=searchProducts&searchTerm=693-1042P&x=7&y=22
Their USA site doesn't list that p/n.

Cannon also makes a similar type of connector, in a few versions:
http://www.ittcannon.com/product.aspx?id=2278
and the power contacts are made for up to 40A.

An interesting type of connector designed for servo motors, that also handles up to 40A on the power contacts, is the CMx series:
http://www.ittcannon.com/product.aspx?id=1482

I tried to see if anyone had them in stock anywhere, but I seem unable to properly figure out their p/n schema. For instance, Page 7 of the ComboD style (the first one) specs has a chart for figuring out what options create what p/n, but regardless of how I pick the options and search for a p/n, I get no finds even on Cannon's site, which has to be wrong, so I must not be using the right method of p/n creation. I *think* that you would want this one: DBM-E-17H5-P for the male side and DBM-E-17H5-S for the female side, to get solder cup versions you can bolt to a shell, but whether I use dashes or not, it doens't pull up anywhere.

These are some of the round Cannon connectors I was talking about:
http://www.ittcannon.com/MetaSearch.aspx?bq=Cannon&mq=&pq=Circular

These
http://www.ittcannon.com/product.aspx?id=1380
are the larger rectangular versions used as the interconnects for all power and data for the MD-80 flight computers, which are rather power-hungry things.

THey make a lot of connector types:
http://www.ittcannon.com/content.aspx?id=42

It might also be worth searching for "mixed signal" connectors.

As amberwolf says, its not a requirement confined to bikes or EVs. It happens all the time in electronic assemblies and sub assemblies.

But with EV's, the requirements are made harder because the power is much larger and usually at a higher voltage. The power lines are also likely to be a lot "dirtier" on EV's - ie. have more electrical noise on them. This takes you straight into all the EMC and interference problems, and its easier to solve these if the power and the data are on separate cables and connectors.

Nick

Awesome, thanks for all the useful info I saw several that should suit my purpose.

Joined just resurrect this thread-- anyone have any success with an all-in one?

Or maybe this setup?