With the application of the Internet of Things, will connectors become more and more important in harsh environments?

Last Update Time: 2021-08-05 10:48:58

As the Internet of Things is widely used, the application environment is sometimes very harsh. Connectors that meet all performance requirements may not yet exist. This is why customization is required. Rugged connectors, including power, signal, fiber and hybrid connectors. Need to be able to withstand extreme environments. In this diverse market, there is no one connector that can meet the performance requirements of all applications. Most applications of connectors in equipment have very high specific requirements, which makes connector decision-making a key part to ensure the success of electronic systems. If standard connectors are not available, custom connectors may be the best option.

David Cianciolo, Fischer Connector Engineering Director, said: "For most commercial applications, connector manufacturers can customize solutions. Customization allows designers to understand whether the connectors used in the new environment meet the requirements. Such a design is more economical and more Easy to manufacture. "The Fischer MiniMax series connectors are designed to handle signals and power. In this configuration, there are 24 contacts, 4 of which can carry 5 amps each. Other configurations can meet the fast data transmission speed, or transmit data and power at the same time.

Design engineers need to ensure that connectors can withstand high vibration and harsh environments without reducing power, signal, or data transmission performance. Michael Comer, director of business development and product marketing at Amphenol RF, said: "As the Internet of Things provides expanding market opportunities, we are designing new products for unexpected environments every day."

Cianciolo said that if the application environment involves water, dirt or dust, chemicals, temperature extremes, shock or vibration, radiation or microorganisms, then a strong connector is required. These connectors are also the right choice for "major critical applications", such as aerospace, defense, medical equipment and equipment, railways, heavy equipment, electric vehicles, wireless sensing, and industrial connections. Choosing a sturdy connector can ensure that the product remains durable and running under pressure, and the choice of connector is particularly important to reduce the risk of failure.

The main driving factors for designing rugged connectors are the need to connect and transmit high-speed data signals, smaller size, and lighter weight. Wes Morgan, Director of Project Management at ITT Cannon, said: "These challenges can be addressed with new electroplating technology and improved coupling options to ensure a safe connection between the two connectors, a smaller compact design and seal level, etc. "


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Rugged connectors are usually made of nickel-plated brass. However, many applications require aluminum and stainless steel, or even composite plastics. Nickel / chrome plated brass connectors are highly wear-resistant and provide a longer life cycle than many other materials. If weight is an issue, aluminum is usually a good material choice. Zinc-nickel-based coating can provide high conductivity and signal stability. In RF products, brass, stainless steel and beryllium copper are common materials for many products. For low-use or one-time applications, plastics may be a good choice, but full testing may be required to confirm durability.

The optimized ITT Cannon MDM and MDV mini series connectors are used for data and signal transmission, saving space and weight, in demanding applications such as space vehicles, defense systems and oil exploration equipment. This series of connectors is durable, sealed and moisture-proof. Sealing is probably one of the most critical parts in making a robust connector. When the seal is used to prevent environmental pollution, the interface seal can protect the connection between the two connectors and keep harmful particles away from the connection area. Cianciolo said: "Installation panel sealing, protection contact area sealing, and cable sealing etc. are used to protect the connector connection performance."

Sealing materials include Viton, a fluoropolymer with low permeability and excellent chemical resistance. To prevent gas leakage, common connector sealing materials are glass, ceramic, or epoxy resin. The market needs smaller, rugged connectors to provide wireless connectivity for small portable devices. The durability of the connector is also improving, and can achieve 10,000 or more life cycles.

Comer said, "With the start of 5G connections, more devices will be connected to the cloud. Many of them will need to be applied in harsh environments, and some application environments may not have been encountered so far. Therefore, key signals need more powerful EMI protection. Morgan said: "As the signal transmission rate and frequency continue to increase, the possibility of interference or crosstalk also increases, resulting in data leakage, inaccurate intelligence, and possible loss of life."

Miniaturization is perhaps one of the most powerful design trends. Designing a single connector today may require two to three connectors a year ago to provide the same functionality. Although miniature connectors are a good form of packaging, Cianciolo warns that only a few designs can transmit power and signals simultaneously. He believes: "If the pin size is too small, it cannot meet the required power, or the signal is more susceptible to interference. As the connector package becomes smaller and smaller, the voltage it bears is also smaller.

When considering the impact of cable assemblies and data speed and miniaturization requirements, the choice of connectors may become more complicated. Related factors and strength requirements that support the full functionality of the connector are important, and custom connectors can meet these requirements. Cianciolo pointed out that although customization is possible, new connectors or adjustments to existing products usually extend preparation time. However, on the bright side, you may get more engineering expertise from an experienced connector company, which will shorten your study time.

 

If you want to know more, our website has product specifications for connectors, you can go to ALLICDATA ELECTRONICS LIMITED to get more information