The design challenges of connector miniaturisation
Figure 1: The ix Industrial connector provides the next generation of miniaturised products with perfect high data transmission rates
The miniaturisation trend in the connector market is a direct response to consumer demands for smaller, more compact electronic and industrial equipment.
Devices such as sensors, cameras and automation equipment are rapidly decreasing in size, while displays and screens are becoming thinner and flatter.
Yet, as these components get smaller, they simultaneously need to become more powerful to meet the increased data, signal and power requirements of consumers.
As a result, device connectors must decrease in size to ensure they do not take up too much of the limited installation space available on this new format, miniaturised, equipment.
Device manufacturers are redesigning products in ever shorter cycles to ensure they are both future‑proof and tough enough to cope with demanding environments.
RJ45 replacement
For example, Harting has introduced the ix Industrial interface.
Figure 2: Offering an alternative to the RJ45 socket, the ix Industrial PCB jack is 70% smaller
This robust and compact Ethernet interface is designed to provide the next generation of miniaturised products with high data transmission rates.
The ix is designed to replace the traditional RJ45, which is deemed too large to use in the latest generation of micro products.
In order to resolve the sizing issue, the ix Industrial PCB jack is 70% smaller than the RJ45 socket, which has been established for decades and is used extensively.
Not only does it mean the ix can be easily incorporated into smaller device designs, it also allows a significantly higher packing density, as the spacing between the sockets is just 10mm.
Transport
The ix interface combines both data transmission and power supply into a single interface, which further reduces the area required for connectors.
Its use has applications in the transport sector, for example, as flat screen displays and passenger information systems on public transport can be supplied with both power and data via the interface.
Although reduced in size, the ix Industrial produces Cat. 6A performance for 1/10Gbit/s Ethernet at a control level.
Manufacturing
The company has also designed a push‑pull connector technology specifically to meet the demands of new, high-tech manufacturing environments.
With the advent of the smart, or connected factory, and increased automation for more flexible production processes, the ability to quickly and efficiently disconnect and reconnect data, signal and power is vital to avoid production downtime which can prove costly.
Its PushPull series incorporates an uncomplicated connection and termination technique.
It is a tool-free method of connection. The two sections click into place for an error-free, secure connection.
This means that interfaces can be changed quickly and easily without the need for specialist training.
Tool-free applications
Figure 3: PushPull connector technology is specifically designed to meet the demands of high‑tech manufacturing environments
Colour‑coding is allocated to each PushPull plug and socket in an installation, to help reduce cabling errors. For example, data, signal and power lines can be colour-coded to ensure that each line is easily identifiable.
As well as ensuring performance levels and innovative designs are able to meet consumer requirements, the reliability of new products is equally important.
By undertaking rigorous testing of IPx protection, mating reliability, robustness, vibration resistance and EMC safety, developers can be assured that all critical factors have been assessed and production completed to the highest standards.
Users are able to rely on powerful and proven systems that are designed precisely for their applications.
Construction
The PushPull V4 Industrial range comprises a resilient, one-piece housing material which protects the connection from aggressive chemicals such as cutting oils.
This allows it to be used in both harsh industrial environments and outdoor applications.
The V4 Industrial also comes with additional IP65/67 protection covers on both ends, to safeguard against total dust ingress and water.
Similarly, the ix Industrial has been specifically designed and built for the rigours of industrial environments. It resolves issues associated with the RJ45, whose plastic locking tabs can be broken easily.
By securely locking the socket and connector together with two metal snap-in hooks, the connection is robust and vibration‑proof from the cable to the circuit board for up to 5,000 mating cycles.
Industry standards are also an important facet of new connector technology. They ensure the reliability and compatibility of new products whilst speeding up the time it takes to get a new development to market.
Both the ix Industrial and PushPull V4 Industrial have been tested to ensure they meet the required standards.
The housing of the V4 has been tested according to railway standards for shock, vibration and temperature, meeting EN 45545-2, while the ix complies with IEC 61076-3-124 and conforms to the shock and vibration resistance levels set out in EN 50155 railway specifications.
