Connection system targets the most rugged environments

Connection system targets the most rugged environments

A connector meets the requirements of the new SAE J 2839 standard

BY ANDY SLEEMAN
Business Development Director of Heavy Equipment Hybrid and Energy Storage
Amphenol
www.amphenol.com

Digital data communications in such industrial applications as factory automation, machine data transmission, and other communication between sensors and computers, require a high-speed connector that can withstand harsh industrial environments and the interference of electrical noise. For years, the industry-accepted the M12 form factor as the connection system of choice to meet the needs of harsh industrial environments and exposure to heat, oil, and moisture.

Compact and reliable, the M12-style circular connector is in compliance with IP67 and is based on the IEC 61076-2-101 specification. It is available in 4-, 5-, or 8-pin count with voltage ratings varying from 1.5 to 4.0 A.

With the many advances in technology, however, high-speed digital transmission has now found its way into heavy equipment, rail and mass transit and open environment process control. Data link connectors are required to shift out of the “safe” environment of industrial applications and move into the realm of even more harsh surroundings.

In response to this changing landscape, the Society of Automotive Engineers developed a new specification, SAE J 2839, for the use of interconnection devices in these extremely rugged, more rigorous environments.

Upon learning about the latest SAE specification, design engineers at Amphenol were quick to react, heading to the drawing board and the factories to work on the development of the Max-M12, a first-to-market SAE J 2839-compliant version of the M12 connector.

Fig. 1: The Max-M12

Providing high-speed transmissions in harsh environments

The new connection system is backward compatible with the IEC 61076-2-101 specification and is housed in a ruggedized metal body. The Max-M12 is targeted toward applications requiring high-speed data transmission in harsh environments with the potential for rough handling of cables.

Available in two basic physical configurations, a 90° right angle connector and a straight version, the Max-M12 provides a customized solution that includes just the connector mating pair, or the complete cable assembly and options to overmold the cable assembly. Both configurations are available in 4- and 5-pin configurations with B, D, and P polarity codes in line with the IEC 61076-2-101 specification and are capable of being terminated into 0.8-mm2 (18-AWG) or 0.5-mm2 (20-AWG) wires defined by SAE J1128 and 0.75- or 0.50-mm2 conductors as defined by ISO 6722.

In compliance with the SAE J 2839 specification, Max-M12 (EX version) has been tested to withstand 400 Newton (100 LBF) of pull force on the cable and has passed extreme high-pressure wash down environmental testing based on SAE J 2030 requirements. The Max-M12 can withstand temperatures ranging from -40°C up to 125°C, while maintaining its current rating of 4 A at 250 V (for 4 pin) and 60 V (for 5 pin). All versions of Max-M12 are IP67 and IP69K compliant, making them dust- and water-proof, resistant to high-pressure and high-temperature washdowns.

Max-M12 is housed in a HDM 12 EX version impact resistant metal shell ensuring its performance in extremely rugged environments and harsh conditions as well as meeting the requirements of the SAE J 2839. The housing of the Max-M12 is retained using a M12 thread that has an optimum tightening torque of 0.8 to 1.0 N-m.

Max-M12 has undergone intensive vibration testing with forces up to 20 times gravity oscillating at a frequency of 10 Hz to 2,000 Hz, and shock testing of forces jerking the connector at 50 times gravity, 10 times at a go. Max-M12 is the most durable data link connector in its class with connector retention forces of 444 N and contact retention forces of 110 N tested 50 cycles per minute.

Fig. 2: The Max-M12 is ideal for use in rugged terrain and harsh environments.

Max-M12 is as electrically robust as it is physically strong. The dielectric withstanding of the connector is 1,000 V, while the connection is rated for impulse voltage of 1,500 V. The electrical insulation provides an insulation resistance of over 20 MΩ, while providing a high-temperature life of 1,000 hours at 125°C. Max-M12 for both cable-to-cable and cable-to-device is backward compatible with the original M12 connector and the IEC 61076-2-101 specification with higher environmental rating. The contacts are rated at less than 10 milliohms each with a maximum millivolt drop of 50 mV.

Table 1: The differences between the M12 and the Max-M12.

Following standards, paving a way for the future

As technology continues to evolve, designers and engineers will continue to work hard to meet the standards set forth by the SAE. These standards play a key role in improving safety, reducing costs, increasing productivity, providing market access, and advancing new technologies. By working together and following the standards created, designers and engineers are able to pave the way to a promising future.

Beginning in the fourth quarter of 2011, Amphenol’s Max-M12 will be in mass production. If you are designing a system that requires customization, will be used in an extremely rugged and harsh environment and requires up to 10 Mbits/s of high-speed data transmission, the Max-M12 is the ideal solution for your application. ■

About the author

Andy Sleeman is the Business Development Director of Heavy Equipment Hybrid and Energy Storage at Amphenol Industrial Operations located in Sidney, NY. He has been in the industry for 16 years and with Amphenol for four. Sleeman has a B.A. in Marketing from Cleary University, Ann Arbor, MI, and an MBA in Global Leadership from Lawrence Technological University, Southfield, MI. He is an SAE committee member.