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From: legg <legg@nospam.magma.ca>
Newsgroups: sci.electronics.design
Subject: Re: "Barrel" connectors
Date: Mon, 16 Jun 2025 11:59:02 -0400
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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?

They're not infinitely variable.

Some info on the web wikimedia barrel connectors.

Here's a spreadsheet with ID, OD and center pin diameters, 
along with mfr ident and typical use (user beware):

https://ve3ute.ca/query/IEC_EIJ_DIN_Barrel_Connector.zip

Center-pin equipped parts expect resistively programmed 
info for correct function a la USB-C. Some expect to be 
output-voltage-adjusted by the same means.

Note that current ratings assume correct mating and may 
not be guaranteed by various mfrs or vendors.

Labelling the installed connector can be useful if your 
memory doesn't serve you well.

RL