Picking up where Gray left off, we are trying to find an effective, easy way to fit all of the electronics (mote and battery charging circuit) into the supplied UIHC pagers. Gray’s design connected the boards with a Hirose 8-pin IDC connector. The connector is mounted to the battery charging board, and the leads of the ribbon wire are directly soldered to the mote at the other end.

Both boards in the pager enclosure
You can see the connector in this picture, and where the battery rests below it. In this design, there is almost zero clearance between the inside of the pager and the battery, and zero clearance between the inside of the pager and the ribbon cable (in fact, the crimp terminal of the IDC connector was partially disassembled and replaced with superglue in order to fit the cable in the enclosure).
The two main issues in this design is the minimal amount of lateral clearance between the inside of the enclosure and the battery/connector; and the connector surgery required to make the ribbon cable fit inside the enclosure (which is a direct cause of the first issue). Thus the goal is to provide more clearance where the battery sits, and the most direct way to achieve this is to replace the connector.
To find a particular connector for this application, we apply the following criteria:
- at least 7 pins (2 for battery, 2 for USB I/o, 3 for mote ground, power, and analog input 0)
- wire-to-board type
- less than 10mm height (vertical displacement from board)
- a footprint of less than 10.5mm in either direction.
The size constraints lead us to connectors of the miniature or subminiature type, and the height constraint suggests we will be using a connector with a right angle header. In order to get something into our hands, Geb ordered a few Molex connector kits. The connectors of interest in this kit are branded Microlatch and Sherlock. These connectors seemed right-on in terms of our selection criteria, but there are still other options, and they will be considered later in this post.
The main difference between the Sherlock and Microlatch connectors is that Microlatch using a latching friction fit while Sherlock uses a pretty slick lever latch. The vertical Microlatch connectors are slightly (~2mm) shorter than their Sherlock counterparts; Microlatch is vertical orientation only.
Finally, it’s determined that for the pager board, the Sherlocks are the best fit of what is available. In order to be systematic and space-effecient, the board will use (2) 2-pin connectors (for the battery and USB I/O), and (1) 3-pin connector (for the mote terminals). Using these connectors should satisfy the space requirements for the pager board and allow the battery charging board to sit in the bottom of the enclosure, eliminating fit problems that Gray had experienced.
In the next revision of the battery charging board, I have replaced the connectors and enlarged the peg holes that provide a fit into the bottom of the pager enclosure.
Other Connectors
The Sherlock connectors will work quite well for the pager as it is, but it is useful to consider other options and future options for connectors. Both the Microlatch and Sherlock connectors use a 2mm pin pitch, which (at least looking at the Molex catalog) is just a bit oddball. The I/O 10-pin pinout on the mote, for example, uses 0.1″ (2.54mm) pin pitch, which seems to be far more common. This is an important consideration. It isn’t terribly relevant now because we are only using 3 pins on the mote interface, but if we plan on using more in the future, it will be far easier and more reliable to use a mounted header. Which means a different connector system. We could find a wire-based crimp connector system that will simply crimp in to other types or pitches of connectors; however, it may be easier in the long run to standardize and use 0.1″ pitch connectors in all of our designs in the future. I will later update this post with relevant model numbers of connectors that are in this pitch and meet our size requirements for other boards. For now, we will continue to use wire-to-board connectors on the battery charging board, and directly solder the other end of the wires into the mote (using a header on the mote board is impossible due to geometry).
Other Considerations
There current design of the pager board hides all of the circuit LEDs (4 on the mote, one on the battery charging circuit). This problem may be circumvented by redirecting the light using fiber optic cable, acrylic light pipe, or simple reflectors. It may be more efficient to solve this problem in the next design revision (which will be outlined in an upcoming post), but I will first work on solutions using reflectors (light pipe and fiber optics can become quickly very expensive and complicated). I don’t know how important they are to the rest of the folks for diagnostics. Also to-do is to find a nice solution to cover what used to be the face plate of the pager. In Ted’s boards, it is covered by a rectangle of laminate cut out to accommodate the USB male mate, this seems to work nice, but there might be an easy, prettier solution.