How the 4.0 Robust connections changed the wold of technology?

March 27, 2018 | Author: | Posted in Computer & Technologies

In almost all areas of use of machinery and plant construction and automation, applications are subject to particularly extreme requirements, such as humidity, dust, oil, chemicals, high temperatures and vibrations. At the same time, the safety of the installation must be guaranteed. Many manufacturers have already reacted to these requirements and have developed connectors of different standards, certified according to standard EN 60529 and offering IP67 or IP68 protection.

This is especially true for the M8 and M12 types that are most often installed in industrial applications, but also for modular or USB plugs. In this case, it must be taken into account that the type of protection is only valid for the connected state. As soon as there is one end of the plug open, protection is usually not guaranteed. Molex offers an especially wide range of robust solutions: The “Sealed Connectors” series encompasses standard and customer-specific encapsulated connectors with different types of protection.

In the case of the automation components in switch cabinets, connectors are used mainly for individual wire connections, since with these it is possible to carry out the union of the sensors, the actuators and the power supply in a very flexible way. In power electronics, developers prefer printed circuit board connectors instead of the most common terminal solutions so far. They allow for more compact and flexible device designs and higher conductivity.
In the field of data connections, more and more standardized industrial connectors can be found, e.g. ex. RJ45 and round connectors, since the field bus systems are relieved by industrial Ethernet. The optical connectors allow a fast and interference-free transfer of large amounts of data.


The automotive components have to meet maximum safety requirements, which suits the development of robust models. Another central requirement, in this case, is the reduction of the construction space and the weight. In this way, manufacturers already offer systems with more than 300 contacts. High-performance alloys such as CuNiSi also provide them with greater conductivity, allowing smaller solutions; materials such as aluminum or copper alloys provide a lower weight. JAE, for example, has developed the MX19 series, especially for the automotive sector. The small water-resistant cable-to-cable connectors according to JIS D0203 S1 are connected with just one click. You must also have a digital analyzer to measure the connectors acceptance. They are resistant to temperatures between -40 and 105 ºC, as well as the typical vibrations that form in a car. Thanks to the passage of cables with rear insulation, the MX19 series allows an optimized arrangement of the cable tree and the connection terminals can be inserted better in the housing. The insulation protects against damage, flapping of the cable and against water ingress. The terminals of the connection terminals have a double-plate spring mechanism with a large carrier length to offer a low insertion force and a pressure expansion. There are available 2 and four pole variants designed for the intensity of up to 5A and cables between 20 and 22 AWG.

Electric mobility

Hybrid and electric vehicles bring new kinds of voltage and current, which also means considerably higher temperatures and vibrations. Also, just in electric vehicles, there is a risk that the power will be reduced by environmental influences such as water, dust, dirt, oil, chemicals or electromagnetic fields. As a result, both the design and the base materials and the contact surfaces of the connectors are subject to more demanding requirements. So far no standard has been introduced, original equipment manufacturers mainly use individual solutions. In contrast to the connectors for the load unit: Type 1 standards have been introduced here (especially in the USA and Japan), type 2 (Europe) and GB / T (China). Amphenol has developed its PowerLokTM high-current and high-voltage connection system especially for chargers, charging connections and for making hybrid and electric vehicle cables. It is based on RADSOK® contact technology (RADial SOcKet), which provides a lower voltage drop and temperature rise, and extends the surface thanks to the radial structure. The PowerLok connectors are designed for 750A and 1,000V and are equipped with an HVIL (High Voltage InterLock) protection. It is based on RADSOK® contact technology (RADial SOcKet), which provides a lower voltage drop and temperature rise, and extends the surface thanks to the radial structure. The PowerLok connectors are designed for 750A and 1,000V and are equipped with an HVIL (High Voltage InterLock) protection. It is based on RADSOK® contact technology (RADial SOcKet), which provides a lower voltage drop and temperature rise, and extends the surface thanks to the radial structure. The PowerLok connectors are designed for 750A and 1,000V and are equipped with an HVIL (High Voltage InterLock) protection.

The second automatic locking ensures that the terminals are positioned optimally and offers sufficient clamping force even for arid environments; its different slot options allow a secure connection without damage due to an incorrect connection. In this case, the typical click noise is created, which is so appealing in the automotive sector. The simple connection guarantees maximum protection for the user. If the blockage opens, the high currents are interrupted immediately. The housing meets at least the requirements of the specifications UL94-V-0, RTI130, CTI2 and resists temperatures from -40 to 125 ° C.
The metallic coating of 360º guarantees a complete shielding of the connector for IP6K9K in a connected state and IP2X in a disconnected state (according to DIN 40 050, 9). Amphenol also offers a series of connectors for energy accumulators, which has been developed specifically for high current connections in the battery module and the battery management system (BMS): The economic RADLOK family includes a series of battery designs. Connectors and can be used in the battery as a cell-to-cell connection or externally as a battery-to-battery connection or serial connection to a current accumulator. It offers low insertion and extraction forces, as well as many insertion cycles thanks to the integrated mechanical locking and unlocking. Its maximum current load is 750A; the maximum DC voltage is 1,000V,

Train connections

In the railway field, the demand for connectors is growing due to the growing use of Ethernet networks, p. Ex. for cameras and screens, and for the tendency to build modular vehicles. In this case, the partial systems have to be able to connect with each other without complications, to transmit the power, the damages and the signals by all the units of the vehicle. For external use, these connectors not only have to deal with vibrations and impacts but also with environmental conditions.
Here, models with IP68 or IP69K protection types and with mechanical interlocks are required. In the interior of the vehicle, smaller types of protection are sufficient, but in contrast, the electromagnetic fields are of greater importance. For this purpose, shielded connectors are available. In addition to this, all connectors have to meet the requirements of the specific railway regulations. And these are different in each country. Generally in this case p. Ex. A high resistance capacity against hydraulic oil, aggressive detergents and similar substances.


In the case of LED lighting solutions, the requirements for the connectors are not defined, since they vary depending on the place of use and the application. What is valid is that the more robust the connection solution, the wider the scope of use, as can be seen in the Amphenol SSL-1 series.
With its resistance to impacts and vibrations according to EN61373, it is suitable for indoor and outdoor LED applications, as well as for the transport market. Here it replaces the welding process with the risk of low-value welding points, thus providing shorter SMT production times and lower costs. It requires less space on the printed circuit board, so the density of LEDs can be increased, avoiding the formation of shadows. The SSL-1 series includes connections of 2, 4 and six poles board on board, cable on board and cable to cable.

Medical technology

The applications in the medical technology have to comply first with the norms and specific homologations of the sector, which regulate the requirements of shielding, sealing, the capacity of autoclave and protection to avoid getting in contact and friction. Sometimes high contact security and many insertion cycles are also required, as well as protection against disinfectant products and aggressive cleaning solutions. Connection systems that also meet high requirements often require new production. Also, your development expenses are almost never amortized with mass production.
All this makes them relatively expensive, so they are not suitable for expensive applications or areas of application, where the corresponding protection is not needed. But for everything else they offer many advantages, even becoming a necessary product.

Bases for the type of protection

The type of protection indicates for which environmental conditions the component or the electrical device is suitable. They are indicated in IP codes (international protection); the standards DIN EN 60529 and DIN 40050-9 regulate this coding. In the designation of the type of protection, two characteristic digits are added to the combination of IP letters.
The first indicates the protection against contact or foreign bodies, the second against water or moisture. There are differences between the two standards: In some types of protection, the first digit has an additional “k” according to DIN 40 050, with 6k and 9k specific protection for road vehicles is related. Summary of the most relevant figures (according to DIN EN 60529): First figure: 4. Protection against foreign bodies with a diameter greater than 1mm 5.
Protection against dust in harmful quantities 6. Dust tightness and complete protection against contact Second figure: 6. Protection against strong water jet 7. Protection against temporary submergence 8. Protection against permanent submersion 9. Protection against water in case of cleaning with high pressure/steam jet That is, a connector with IP67 is dust-tight and is protected against contact and momentary submersion.

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I am Shishir Ahmed a content writer on technology. I love to write always about new things which are trendy.


I am a content writer and love to write content

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