Heavy Duty Connector

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Heavy Duty Connectors Protect the Flow of Power and Data in Robots in Harsh Environments

The definition of "harsh" varies significantly across the many operating environments that require automated processes. Some robots may be working in a highly controlled clean room or surgical suite, while others operate on a grimy, dusty, or contaminated factory floor. In both instances, they will face aggressive cleaning or sterilization agents, vibrations, extreme temperatures, welding sparks, gaseous environments, or electromagnetic interference.
For a robot to perform within its specified parameters, the controllers need accurate, real-time information on its position. If the position data flow is interrupted, the computer cannot accurately measure the position of the robot. Its assumptions may be inaccurate, and it may issue commands that lead to overreaching or overcompensating movements. Rugged interconnects that can protect the flow of power and data even under less-than-ideal conditions are essential to safe and reliable robot operation, and overall productivity.
Sensitive robotics and automated systems used in industrial environments face several types of challenges. High temperatures, for example, can gradually degrade component materials, which increases the potential for interruptions to the flow of power and data. Yet concentrated high temperatures are common in many environments where robotics are used. Injection molding machines, commonly experience temperatures up to 220° C.
The compatibility of electronic components with various cleansing agents and procedures should be considered when designing systems. Cleaning agents are frequently present in production or processing areas, usually under high pressure and temperature. These chemicals can be extremely harsh and corrosive to sensitive electronics. They are also application-specific.
Heavy-duty connectors (HDC) can help engineers meet both the requirements and the challenges of building robots for harsh industrial environments. Built in a rugged housing and designed to transmit power, data, and signal, HDCs help guarantee safe, reliable, and productive operation of robots in the toughest conditions. Modular HDCs are an ideal complement to hybrid cable systems, as they provide the ability to create a component that matches the exact needs of a unique or flexible design.

How to Specify Heavy-Duty Connectors and Cable Assemblies for Harsh Industrial Applications

Designing and specifying cable assemblies for use in harsh environments presents a number of challenges. Industrial equipment can be subjected to harsh conditions, such as high temperatures, water, high humidity, particulate ingress, electromagnetic interference (EMI), vibration, and impact from close proximity to moving factory components. Over time, exposure to these conditions begins to impede assembly conductivity and can require the replacement of cabling or, worse, the expensive equipment.
Heavy-duty connectors (HDCs) are a good choice for harsh-environment industrial applications such as food and beverage or oil and gas processing. HDC systems provide almost unlimited connection options inside a heavy-duty industrial housing. These versatile housings are designed to industrial standards, ranging from IP to NEMA ratings, that quantify the degree to which an assembly can withstand harsh conditions. Housing material flexibility is another benefit to choosing an HDC assembly. For instance, the best housing material for reducing or eliminating the impact of a wet environment on a connector is plastic. Additionally, if there are shielding concerns, designers can select a housing with an integrated filter that can reduce or eliminate electromechanical interference (EMI) from surrounding equipment.
Once the protective housing type has been selected for the application, the housing size will be determined by a hybrid combination of pluggable inserts that are required to carry power, signal, or data to or from factory equipment. This is where HDC systems are uniquely positioned to meet the demands of the hybridization trend in pluggable cabling for industrial manufacturing, which is a result of increased consumer demand for customized products that require more flexible, decentralized manufacturing processes. This increased flexibility requires more functionality at device or factory equipment connection points rather than at a central control cabinet. As such, hybrid HDC solutions that offer a combination of power, data, and signal in one connector are in high demand.Modular HDC inserts provide an integrated hybrid assembly that creates new considerations for power and signal wiring beyond the fundamentals of approval ratings, wire gauge, and clamping type. Options for insert type can include, but are not limited to, RJ45, M12, USB, D-Sub, fiber optic, pneumatic (with or without a stop valve), high-density signal, and high-current power connections. Cable length has always been a factor for power transmission, but it can also determine the use of Ethernet-compatible cabling systems like Cat. 5, Cat. 6, or for very long cables, fiber optics. With the use of diverse contact types, it is also important to consider the assembly build process.
Ingress protection (IP) ratings are another key concern for hybrid assemblies in harsh-environment applications. In hybrid systems, cables that provide air, signals, power, or data are threaded through a single cable gland. Multiple cables fed through one circular gland can leave a gap at the gland entry point and this gap can allow dust or moisture to enter the housing and make it challenging to maintain the hybrid assembly's IP rating, but there are several available solutions. One solution is to submit every assembly to an environmental test prior to use in order to ensure that its IP rating is maintained. This testing should be conducted in addition to the typical testing performed on the data, signal, and power connections.
The available options for maintaining ingress protection via a single cable entry point into a protected housing include the use of cable gland grommets or conduit. A grommet or insert fitted inside a cable gland will seal the opening around each individual cable to maintain the assembly's IP rating. However, it is important to note that options may be limited based on the number of cables and the size of the housing opening. If cable gland grommets are not an option, many types of plastic or metal conduit can be attached to an HDC cable gland via an adapter. When cables are run through conduit, it is important to adhere to the National Electrical Code (NEC) maximum fill percentages for the application to prevent overfilling the conduit.

Requirements for HDCs: Robustness, Stability, and Flexibility

HDCs have outstanding and reliable performance in harsh environments. They are mainly used for the data, signal, or electrical connection between different equipment and functional units. Apart from enabling extremely convenient installation and maintenance for complex control equipment, their modular and standard interface design can maximize application efficiency.
With the rise of Industry 4.0, the demand for customization, stability, and integration of equipment increases in industry production
HDCs consist of three key elements: inserts, contacts and hoods, and housings. The inserts and the contacts together form an electrical module for equipment electrical connection. The housing is made of either metal or thermoplastic with a robust structure to provide reliable mechanical and environmental protection for electrical connection. The water and corrosion resistance of the metal housing ensures that HDCs can work in any harsh environments and fulfill the outdoor connection demand of customers. Also offers a complete product range with current from 5A to 350A. The module range makes connection with custom interfaces a reality.
There are different kinds of connectors for different applications and different environments. As all these applications require electrical and signal connection in environments challenged by temperature, humidity, and long-term vibration that leads to connection loosening, HDCs are designed for use in harsh and complex environments to ensure the stable operation of the entire system.