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From: john larkin <jl@glen--canyon.com>
Newsgroups: sci.electronics.design
Subject: Re: "Barrel" connectors
Date: Mon, 16 Jun 2025 06:32:12 -0700
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On Sun, 15 Jun 2025 13:50:46 -0700, Don Y
<blockedofcourse@foo.invalid> wrote:

>We have frequent need (many times each week) to match devices to
>"suitable" wall-warts/bricks.  *I* do this with a dial caliber
>and drill bits -- and a bit of math.
>
>I need a scheme where "less skilled" (e.g., developmentally disabled)
>folks can do this *reliably*.  Even if I have to spot-check their results.
>
>I'm thinking of just buying one of every connector and mate, labeling
>them, putting them on a "key ring" and then just having folks fumble
>around until they think they've found suitable mates.
>
>The downside is that there are cases where a connection may *appear*
>to "fit" but isn't truly appropriate.  E.g., ID is a bit oversized
>(or undersized, depending on your point of view).
>
>Is there a better way?
>
>Are there any other *mechanical fitting* issues that I may have
>overlooked (obviously, there are electrical issues)?
>
>Does such a prebuilt "kit" exist (nicely packaged, etc.) so I
>can just buy a couple and save myself the hassle of making them?

The barrel connector situation is a nightmare. It doesn't help that
products come with unmarked warts with random voltages and powers and
connectors.

There should be two power sources, USBc and PoE.

We need more cheap surface-mount modules that pick off and isolate
power for us. We use a Silvertel module in our PoE gadgets. It's not
cheap.

People are starting to put magnetic isolators on monolithic ICs, which
is progress in the right direction, even if most are not very good
yet.