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Submitted URL: http://app.connected.arrow.com/e/er?s=600830862&lid=149295&elqTrackId=545ca3984a85485280ea69c4ff5e5757&mi_u=CARRE000004290142&e...
Effective URL: https://www.arrow.com/en/research-and-events/articles/bulgin-essential-connector-features?utm_source=eloqua&utm_medium...
Submission: On December 17 via api from US — Scanned from DE
Effective URL: https://www.arrow.com/en/research-and-events/articles/bulgin-essential-connector-features?utm_source=eloqua&utm_medium...
Submission: On December 17 via api from US — Scanned from DE
Form analysis 5 forms found in the DOM
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* Essential connector features for surviving the most extreme environments
ESSENTIAL CONNECTOR FEATURES FOR SURVIVING THE MOST EXTREME ENVIRONMENTS
25 Oct 2021
While most of us live and work in relatively protected and safe indoor
environments, much of the world’s most critical electronic systems and equipment
operate in harsh conditions. Whether it’s water, dust, extreme weather,
explosive atmospheres or pressure, a range of harsh environments can create
challenging conditions for these systems and their connectors to operate in.
One of the most common points of damage in any electrical system is where cables
are plugged in - the connector. Connectors are at the junction of system and
cable. They need to have the flexibility to mate and disconnect easily and
securely, all while keeping the elements out. As the guardians of the entry
points to both system and cabling, their integrity in harsh environments is
critical.
Since they’re at the entry point to the system, connectors face the same hazards
as any electronic system, including water, dust/dirt, extreme temperatures,
potentially explosive “ATEX” environments, pressure/weight, and salinity.
WHAT DEFINES A HARSH ENVIRONMENT?
Wet or dirty environments with water, high humidity/water vapor, dust or dirt
can wreak havoc on electrical equipment, causing short circuits or
malfunctioning equipment. If salinity is a factor, such as in a seaside
environment, corrosion can also be a serious issue.
Electrical systems are also often sensitive to temperature extremes, which can
cause components to fail or malfunction. For data connections, Electro-Magnetic
Interference (EMI) can be an issue as it can disrupt wired communication.
Physical force is another hazard which can come in the form of mechanical shock
and vibration or pressure. To withstand shock and vibration, a robust mating
method needs to be in place.
Connectors in undersea, aerospace or pressurized environments also need
additional ruggedization.
For connectors used in explosive environments, an additional requirement is that
they do not have any way to set off a spark, either mechanically or
electrically, and cause a hazardous explosion.
RUGGED APPLICATIONS
The range of rugged applications is extremely varied and crosses many industry
lines. Ruggedized systems and connectors are used in industrial, marine, oil and
gas, transportation and infrastructure, telecom, and more.
INDUSTRIAL
In industrial environments, automation, machinery and measurement come together
to create today’s hyper-efficient manufacturing systems. Industrial environments
are often exposed to a variety of harsh elements including water, vibration,
chemicals and temperature extremes. The move to greater automation and
“Lights-out” manufacturing means environmental challenges will only increase as
equipment now increasingly has the freedom to operate in inhospitable
conditions.
Industrial equipment such as food slicers, saws, sandblasters, food processors,
coating machines can generate significant shock and vibration, as well as create
dust or airborne contaminants. Sealed, rugged metal or plastic housing
connectors with IP66, IP67, IP68 and IP69K ratings can withstand these harsh
conditions and keep power, signal and data connections secure.
Because of the noisy EMI conditions in industrial environments and the
dependence on sensors and communication, EMI is also a concern for data
connections. In these cases electrically shielded connectors are ideal.
MARINE
Marine applications include surface and undersea environments. Surface marine
applications such as boating equipment, ship deck systems, or marina facilities
face threats from corrosion due to high salinity, as well water ingress, making
robust, sealed components essential.
IP rated components should be chosen depending on the level of water and dust
protection needed, with IP66 and IP67 sufficient for many surface applications
while IP68 or IP69K will be necessary when connectors may be submerged. For
undersea applications such as diving electronics, depth loggers or undersea
remotely operated vehicles, IP69K or other pressure-resistant designs are
important.
OIL & GAS
The Oil & Gas industry faces many of the same environmental hazards of
industrial and marine environments, but also must deal with explosive
atmospheres which require the use of ATEX / IEC Ex rated equipment. For offshore
platforms, both marine hazards and explosive atmospheres exist. In addition, the
oil and gas industry makes extensive use of underwater ROVs for drilling and
construction support as well as exploration.
These underwater remotely operated vehicles are essentially remote-controlled
robots. They require power, data, and often fiber optic lines, have to operate
in rough undersea conditions, and are often asked to go to depths beyond what’s
possible by a human diver. Bulgin’s ROV tether connector is designed to keep
these robotic helpers working reliably in uncertain waters. Made of 316
marine-grade Stainless steel, it is a Pressure Balanced Oil Filled (PBOF)
cabling solution that uses oil as a compensating fluid for water pressure,
allowing ROVs to go to depths of 7000m.
OTHER APPLICATIONS
From transportation and infrastructure to automotive and agriculture, a wide
variety of applications operate in the outdoors. These use cases require
connectors that can weather extreme temperature changes, water and dust ingress,
physical duress, and more.
KEY FEATURES
IP rating – IP ratings define the level of protection from dust and water
ingress of the component. The first digit indicates the level of dust protection
and goes from 0 to 6, while the second digit indicates liquid ingress
protection. For harsh environments, sealed connectors should always be
dust-tight, with water ingress protection depending on the application.
IP66 - protection against powerful water jets, and IP67 - immersion up to 1m, is
suitable for many above water applications where systems may be rained on, or
otherwise repeatedly exposed to water. Connectors which may be continuously
submerged should be at least IP68 (immersion to 1m or more) or greater, and for
undersea applications, IP69K (close-range high pressure and high-temperature
spray downs) provides protection even under pressure.
Besides undersea and immersion applications, IP68 and IP69K also have medical
and food processing use cases as these ratings allow the equipment to be
regularly washed and sanitized without harm to electrical components.
LOCKING/COUPLING MECHANISMS
With many connectors being exposed to environments with shock and vibration
present, a robust coupling mechanism is a must. There are many different types
of connector couplings, including ring, twist locking, threaded, bayonet,
push-pull and quick disconnect couplings, all with different attributes for
various types of applications. Some, like the bayonet connector, provide better
security against shock and vibration, while others like push-pull and quick
disconnect provide greater ease of use when connectors may need to be
disconnected often.
HOUSING AND INSULATION
The material the connector is made of helps it resist the challenges of its
environment. For applications with temperature extremes as well as plenty of
moisture and dust, a corrosion resistant metal housing may be appropriate. If
lightweight and flexibility are key, temperature-resistant plastic composites
will be more attractive.
CONNECTOR DESIGN
The connector’s shape, mating mechanism and pin positioning also play a part in
its ruggedness. Circular connectors have the benefit of easy
engagement/disengagement, as well as the capacity to fit a wide variety of
contacts. Circular connectors also are easy to seal and less likely to wear out.
An intelligent “scoop proof” design can be used to avoid pin damage while trying
to mate the connector.
MAKING THE RIGHT CONNECTIONS
Our world is becoming increasingly connected. From outdoor cellular base
stations to connected factories, to IoT sensors on oil and gas platforms,
electronics are being placed in every environment imaginable. The electronic
systems must be guarded against all the forces of nature.
As the point of entry to the system, connectors must be robustly designed to
seal off and protect against all environmental challenges present - from shock
and vibration to dust and water, or EMI. Thankfully today’s connectors from
companies like Bulgin provide strong ruggedization for just about every
application on the market. Through choosing the right IP rating, locking
mechanism, housing material, and connector design, almost every rugged use case
today can be made to work reliably with the right connector.
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