Connectors deliver cost-effective and simple installation solution for Ethernet and military applications

Connectors deliver cost-effective and simple installation solution for Ethernet and military applications

Multiple types are available, designated for use by their characteristics, which can range from their physical construction and size to their ruggedness and resistance to vibration

BY LANCE BREDESON, Director
and
ABDI AYANLE, Product Manager
TURCK
www.turck.com

Today’s fast-paced industrial applications require connector solutions to increase productivity and accommodate diverse performance requirements. Designed to connect components, including sensors and actuators to the main bus line or system, connectors can simplify wiring and expedite automated processes. Delivering flexible operation for diverse applications, connectors provide enhanced communication capabilities within Ethernet applications or ensure safety and mobility in military applications. With such versatility, there are multiple types of connectors available, designated for use by their characteristics, which can range from their physical construction and size to their ruggedness and resistance to vibration.

The IP 67 Bayonet RJ45/Ethernet field-wireable connector

Traditional hardwiring procedures are prone to failure from corroded contacts or mechanical loosening of the connections. Further, hardwiring can be expensive and time consuming for operators, due to the amount of equipment needed for diverse applications and maintenance for mis-wiring or faulty connections. Alternatively, today’s connectors provide a durable, reliable solution, ensuring quick installation and continued performance.

With diverse connectivity requirements and performance standards, it is important to select a connector with suitable components, design features and intended uses. The appropriate connector helps to create a better overall automated system by saving costs and improving machine efficiency. Additionally, knowing the connectivity requirements needed for an application’s specifications ensures minimal wiring errors and connection issues.

A closer look

A connector is composed of a contact carrier or contact holder and pins or pushing, depending on if it’s a male or a female connector. Each half of a pair of mating connectors is designated as male or female. The female connector is generally a receptacle that receives and holds the male connector. For Ethernet applications, the pins and pushing are generally gold plated. The contact/carrier holder is often either made from a nylon or thermoplastic polyurethanes (TPU) material. For military applications, the contact carriers/holders are made from neoprene.

In addition to male/female designation, connectors are characterized by many other features, including physical construction, size, contact resistance, insulation between pins, resistance to entry of water or other contaminants, resistance to pressure, reliability, longevity and ease of connecting and disconnecting. Additionally, some connectors are “keyed,” which means certain mechanical components on the connector prevent mating, except with a correctly-oriented matching connector—avoiding incorrect or damaging interconnections. Furthermore, some connectors feature housing designs with locking mechanisms, such as a Bayonet-style housing. These designs prevent inadvertent disconnection or poor environmental sealing, including the resistance to water and dust and protection in areas of high impact. These are especially useful for military applications using off-road equipment, such as fire trucks or heavy road equipment, as these applications are prone to such conditions.

Most connectors are developed to satisfy certain industry standards, including those set by the International Electrotechnical Commission (IEC) which standardizes the dimensions of a connector. Specific design factors are important due to the high volume of connectors made. Interoperability/inter-mating between connectors is important as many manufacturers develop various products that all use the same connector style. The design features of a certain connector have an impact on whether it is selected for an application. For example, an A-Coded connector type would be used with sensor and actuators, a B-Coded connector with field buses and a D-Coded connector with Industrial Ethernet.

Along with adhering to industry standards, the environment where a connector will be used generally determines the type of connector to use. In most industrial applications, a connector with an Ingress Protection Rating of IP65 or IP67 is desired to protect against contaminants entering the connector and degrading performance. For example, industrial applications with wide, spacious areas may use a larger connector with a locking mechanism featuring an IP67 sealing gasket system to guard against water and vibration. Alternatively, a more compact IP20 connector may be used for clean areas or inside control cabinets. For even smaller applications, there are extremely compact connectors—with some as little as 12 millimeters—that offer the same quality performance and robustness.

Factors to consider when selecting cables and connectors

In determining which type of cables and connectors to use for any specific application, there are several important considerations to take into account, including connector evaluation and location and environment evaluation.

Connector evaluation

The connector evaluation includes analyzing the following:

• Connection components : These factors include determining whether the application requires straight or right angle connectors, nickel-plated brass or stainless steel connectors, armored or flexible cables, cable connection, thread and pin size and terminator use.

• Diagnostics : Operators should determine if the application requires the transfer of data and power, and then, select the best suited cables and cordsets rated for the amount of voltage and current needed.

• Esthetics : LEDs can aid in error identification and lessen the time it takes to fix problems. Additionally, color coding wires and special labeling can assist in simplifying installation and reducing errors.

Location and environment evaluation

In addition to connector evaluation, operators should also analyze the environment in which the components will be used and the approvals needed before operating. These include:

• Environment: Factors to consider include determining if the environment requires welding, high-flex robotics, cut/abrasion immunity, RFI/EMI shielding, washdowns or sanitary/hygienic conditions.

• Potential conditions : Operators should also consider whether or not the cables and connectors will be subjected to shock and vibration, crushing and pulling, bending or twisting, dust and dirt, water, oils, chemicals, corrosive gasses or temperature extremes

• Approvals : Numerous industrial and process environments require approvals from various agencies like the NEC, UL or CSA.

If the connector is being used in Ethernet applications, additional factors need to be considered. Each Ethernet protocol, such as Modbus TCP/IP and Ethernet/IP, presents multiple differences, requiring connectors with diverse performance standards and components. Operators should analyze network categories, including CAT 5, 5e, 6, 6A and 7, two pair or 4 pair cabling, D-code or X-code connectors, solid or stranded cabling and shielded or unshielded cabling.

Alternatively, if a military specified connector is being used, operators have the option of selecting between multiple shell sizes, mounting and pin configurations to meet their application requirements. Further, these connectors generally offer an IP sealing, overmolded design for optimal use in harsh environments.

In the field

Connectors that meet military specifications are often used in off-road equipment, such as fire trucks and heavy road equipment. Military specified connectors are also found in the following applications: power generators, engines, sensors, motion control, earth moving equipment, ships, oil and gas, mobile equipment, industrial machinery, telecommunications, railroad equipment and mass transit.

Alternatively, connectors used in Ethernet applications are common as Ethernet-based networks are the most dominant form of networks used in today’s world. A significant portion of the Internet infrastructure is built on Ethernet based, switches, hubs, bridges and routers. Ethernet is emerging as the protocol of choice for incorporating video cameras at factory floors where cameras use high-resolution images to send frames back to the controller for inspection and analyzing. Ethernet is also used at traffic intersections and for connecting to cameras monitoring interstate highway traffic. ■

About the authors

Lance Bredeson is the Director of TURCK’s Connectivity Division, where he is responsible for the Product Management group and the Project/Sales Engineering group.

Abdi Ayanle is a Product Manager for TURCK’s Connectivity Division.

In this group, both authors are responsible for developing and promoting new products as well as provide custom solutions for our customers.