Power & Data Connectivity

Expand Electronic
Capabilities eBook
NOVEMBER 2021
2
 Power & Data Connectivity Expand
— —
Electronic Capabilities eBook

Our latest eBook, 2021 Power & Data Connectivity Expand Electronic Capabilities, highlights
the many ways today’s connectivity solutions optimize the delivery of power and data while meeting
increasingly demanding application requirements. Experts from 14 leading connectivity companies
address the unique challenges electronics face in various environments (space, autonomous vehicles,
data centers), for popular applications (military vehicles, IoT and machine learning, rail systems,
warehouse automation, 5G devices), or with specific connector types (M16, RAST, Micro D).

This eBook also features a Product Briefs selection of more than forty innovative connectivity
products designed to support connected systems across a range of application environments and
markets.

Please enjoy this edition, the final of three 2021 eBooks. Our first 2022 eBook, Rugged
Interconnects for Harsh Environments, will be available in Spring 2022. This collection will look
at the ways connectivity solutions are pushing the limits to serve challenging applications and
technologies in harsh environments. Connectivity solutions are subjected to extreme temperatures,
shock and vibration, dust and water, chemicals and radiation, but constant advancements allow
them to keep electronic systems running smoothly and efficiently.

Please subscribe to our weekly e-newsletters, follow us on LinkedIn, Twitter, and Facebook, and
check out our eBook archives for more, expert-informed connectivity content.

John Bishop Amy Goetzman AJ Born

Managing Director Managing Editor Associate Managing Editor
CONTRIBUTORS
 TABLE OF CONTENTS

CONNECTIVITY FOR UNIQUE ENVIRONMENTS

Speed Up Your Data: How to Design High-Speed Digital Signals for an Onboard Network in Spacecraft

Axon’ Cable 7
Important Factors to Consider When Selecting High-Power Connectors for Data Centers
BizLink 12
Innovative Connector Solutions from Industrial to UxV
LEMO 15
Work Harder and Smarter: Four Electric Powertrain Considerations for Warehouse
Automation Applications
TE Connectivity 17

SUPPLYING POWER & DATA FOR TRANSPORTATION

Solutions for In-Vehicle Tactical Communications and Power Interconnectivity
CDM Electronics 23
IDT Meets SKEDD: Superior Benefits for Automobiles and More
Lumberg 27
Keeping Rail Passengers Informed
Smiths Interconnect 31
Four Connectivity Solutions to Optimize Cost and Design Flexibility for Automotive On-board
Power and Data Electronics
Greenconn 33

INNOVATIVE CONNECTIVITY FOR INNOVATIVE TECHNOLOGY

M16 8-Pin Connectors: The right solution for 5G applications
Binder 40
Configurable, Modular Connectors Provide Design Expedience
Weidmüller 46
5G Small Cell Deployments are Booming — and Redefining the Requirements for
Coaxial Cables and Connectors
Times Microwave 48
A New Breed of Hybrid Connectors for IoT and Machine Learning Systems
Omnetics Connector Corporation 51
Rise of the Connector as Modern Day Digital Influencer
Amphenol ICC 55
Conforming to IEC Standards: Next-Generation Ethernet Connectors
Hirose Electric 60

POWER & DATA CONNECTIVITY PRODUCTS 65

Power and data connectivity solutions, from connectors and cable assemblies to components and
accessories.
 Connectivity for
Unique Environments
 7

Speed Up Your Data: How to Design

High-Speed Digital Signals for an Onboard
Network in Spacecraft
Stéphane Hermant, R&D Project Manager, and Kévin Provost,
R&D Project Engineer - Axon’ Cable

The quantity of data transmitted between devices on board spacecraft can reach up to several tens of Gb/s, and
that volume is constantly increasing. Data transmission is much more than transmitting 0s and 1s. The type of
information, the speed, and the signal integrity are key issues which also must be considered. The high-speed links
have to be adapted to the environment. When designing the links for spacecraft, engineers must take into account
parameters for outgassing, resistance to radiation, and weight-saving.

More and more data

The increasing number of devices on spacecraft, as well as the quantity of data to be transmitted, make the use of
more adapted networks necessary. In some cases, the bus network topology to the MIL-STD-1553-B with a data rate
close to 1 Mb/s needs to be replaced by point-to-point links with faster data transmission including high-speed data
links up to several tens of Gb/s. These networks may be made with several physical links to allow redundancy or to
share the bandwidth. As an example, SpaceWire according to ECSS-E-ST-50-12 (ESA standard) is a data-handling
network for use on spacecraft. It connects instruments, mass memory, processors, downlink telemetry, and other
onboard sub-systems. SpaceWire provides high-speed (up to 400 Mb/s), bi-directional, full-duplex data-links, which
connect SpaceWire enabled devices. Data-handling networks can be built to suit particular applications using point-
to-point data-links and routing switches.

Data rates must be compatible with current and future needs

Today, onboard digital signals require more and more dedicated media with specific features. Low-speed data bus
use multi-purpose cables and connectors including D-sub and Micro-D types but as data rates rise, it is necessary
to have more technical media. The SpaceWire network designed to connect high data rate sensors, processing
units, memory devices, and telemetry/telecommand sub-systems on spacecraft provides speeds from 2 to 200 Mb/s.
Now, however, data rates are starting to reach 400 Mbit/s when a matched impedance connector is used. Multi-Gb/s
networks like SpaceFibre accommodate faster communication and improve the data rate by a factor of more than 10
with up to 10,000 Mb/s.

To be compatible with these standards, engineers have to take into account several parameters: impedance
connection, signal losses, skew, and crosstalk.
8

Matched impedance connection

Characteristic impedance is one of the most important features for good signal integrity (low signal distortion). As
100 Ohm differential characteristic impedance is very often used for transmission lines, the whole electrical chain —
the cable, the cable connector, as well as the equipment connector — must be adapted to this value. If one of the
components doesn’t fit this requirement, it causes reflections, which degrade the signal, especially at high frequency.
This is particularly true with multi-pin rectangular and circular connectors like D-sub, Micro-D, or MIL-DTL-38999.

The characteristic impedance depends on the cable architecture. The conductor diameter, the dielectric material,
and the dielectric thickness are among the most important properties of an impedance-controlled cable. The same
properties are just as important for the connector to avoid impedance jumps.

» Impedance measurements in time domain reflectometry: important mismatching on the micro-D connector (on the left)
compared to MicroMach matched connector (on the right).

Low signal losses or attenuation

Attenuation in an electrical system is the loss in the
amplitude or strength of a signal as it passes along its
length. As the signal passes through the conductor, part of
the signal is absorbed. Attenuation is the result of resistance
in the conductor and associated dielectric losses that are
proportional to the length and frequency. Attenuation can
be reduced by improving the dielectric properties of the
insulation and the conductor resistance. The easiest way
to reduce attenuation is to decrease conductor resistance
by increasing the size of the conductor. The size of the
contacts is also important even if the contact connection
does not represent a long length. To reduce the conductor
resistance, high conductivity copper can be used, but in
» Example of SpaceWire cable with four shielded pairs,
high frequencies the plating plays a key role because of
manufactured by Axon’ Cable
the skin effect (the higher the frequency, the more the
signal migrates to the periphery of the conductor). Another
relevant parameter to consider is the structure of the conductor. A single or multi-stranded conductor will not behave
in the same way in terms of attenuation, and flexibility of the cable will also be impacted.

A good cable for high data rate applications can be produced only if these parameters are controlled. SpaceWire and
Low Mass SpaceWire have been developed to meet these goals and their performance is continuously improving to
serve evolving application needs.
 9

Low skew
Electricity flows through a wire at a finite speed, defined as the propagation velocity of the signal. If a signal is flowing
at the same speed through different wire lengths, the signal will not take the same time to pass through each wire.
This results in skew. The wires’ insulation materials also impact the propagation velocity. If a cable is designed
with wires made with different insulating materials, a skew can appear regardless of the different lengths of wire.
The skew is a key parameter because high speed networking technologies use several wires/pairs in the cable. If
the skew is significant between each wire/pair, signals sent at the same time from one end of the cable may arrive
at a different time to the receiver. In this case, the receiver does not correctly interpret the original signal. Several
solutions exist to minimize skew in a cable:

• Use two coaxial cables

• Use parallel pair (with no twist, skew is limited)
• Change the configuration and the geometry of the cable

•
•
•
•
•
•
•
•
•

» Comparison of two eye patterns (same media, same data rate): good skew on the left hand side, bad skew on the right hand
side

Low crosstalk between ways

Crosstalk occurs in any system with two or more conductors. Each wire segment acts individually as an inductor and
a capacitor. Consequently, a signal transmitted through one circuit or transmission line creates an undesired effect in
another circuit or transmission line. Crosstalk must be reduced to guarantee good signal integrity.

Non-optimized connector

Optimized connector

» Crosstalk measurements for optimized Axon’ MicroMach » Axon’ male MicroMach made with four differential contact
connector and a non-optimized connector. The lower the pairs
crosstalk, the better the link.
10

Crosstalk reduction can be obtained with good segregation between each way. However, this is not completely possible
with commercial connectors such as D-sub, Micro-D, and D-38999 connectors. Adapted cable and connectors are
required to guarantee segregation for the whole link.

Eyes wide open!

Matched impedance, skew, and losses all contribute to signal integrity. By providing better signal integrity, the cable
assembly terminated with adapted connectors can reach far higher data rates. Cable length also plays a role on the
signal quality — the longer the cable, the worse the signal.

The Eye Diagram (or Eye Pattern) is used to visualize signal quality. The name of this measurement comes from the
fact that the signals are displayed in the shape of a human eye. It is created by superimposing successive waveforms
to create a composite image. The eye pattern shows, on a bit time only, the filtering effects of the electrical signal
through the cable such as distortion, reflections, and losses. The wider the eye, the better the signal integrity.

» 3D printing is becoming the dominant manufacturing process to fabricate low-volume specialty shells, including those
which specify alternative materials.

How to reduce EMI in high data rate links

» A comparison of shielding effectiveness between an optimized MicroMach
connector and a non-optimized connector.
Cable screen is the best way to minimize
electromagnetic interference on a signal
line and guarantee good signal integrity
for high data rate links. Screening is a
conductive layer on wire/cable insulation.
The conductive layer can be made with
a stranded silver copper braid only or
reinforced with a conductive foil. Cable
screen termination to connector plays a
major role in reducing EMI in a harness. If
the termination is not correctly achieved,
the whole shielding is jeopardized. The
technical challenge is to guarantee the best
possible junction between cable screen
and connector shell. Backshells, which are
usually used to fulfill this function, must be
properly connected to the connector shell.
Simulation tools are useful to optimize the
EMC performance by taking into account
parameters including weight and shield
coverage.
 11

Saving weight is a key isue for spacerft

Space ompnetsc must be as light as posible to reduc launchig ost.c The weight can be reduc by using
lightwe materils such as alumin for the conetr . body The heavist part of het asembly is the cable, so
construi of the cable must be optimzed to reduc the weight. Alternaiv solutin ot the standr SpaceWir
cable can creat 50% weight saving.

» The Axon’ MicroMach cable assembly made with low mass SpaceWire cable to ESCC 3902/004

The ualityq of the design, manufctre, and contrl of the complet transmio line — consitg fo het cable,
the cable , conetr the equipmnt , conetr and the bondig to the PCB — are esntial to safely ransmit het
informat contaied in the elctria signal with a safety margin. This safety margin is esntial for plicatons
requing hig . reliabty The shieldng is not only a scren aginst elctromagni interfcs but also protecs the
sytem from digtal dat spying for defns or senitv aplictons.

istV Axon’ Cable to learn more.

12

Important Factors to Consider When Selecting

High-Power Connectors for Data Centers
Terry Wu, Product Manager, BizConn International Corp. (A BizLink Group Company)

High-power connectors play a significant role in the delivery of high-reliability performance and connectivity across
an extensive range of applications. Among those are data centers, which are responsible for managing and storing
a wealth of information and data that help drive operations globally each day. Because these types of connectors
are designed to meet specific application needs, multiple factors must be considered when selecting high-power
connectors for data centers. Here are the most important.

Electrical requirements
When choosing a high-power connector, carefully review whether its electrical and technical specifications meet
the requirements necessary for the data center to perform optimally. One crucial specification to pay close attention
to is the connector’s power rating, including the maximum voltage and amperage that it is designed to handle.
Another critical factor is the connector’s maximum operating temperature since an increase in temperature above
the maximum will reduce the rated power for the connector. This derating factor will help determine how to specify
the proper power rating for a given application in the data center.

In general, connectors should be specified so that their maximum power rating is higher than the environmental and
electrical characteristics they are likely to be subjected to when installed in the data center equipment. This is known
as the design margin or the safety margin. In effect, reliability and performance will increase if the connector is not
subjected to electrical overstress. For example, if an engineer needs to select a connector for an application rated
at 380Vac/25A – peak rating of 380Vrms is about 538Vpeak and at least 125% of 25A according to NEC (National
Electrical Code) – the recommended connector specification would be greater than 600V and 32A (125% of the peak
power rating).

» The BzKlip300 Series High-Power DC Busbar Connector is designed for power distribution in data center servers, hyperscale
computing architectures, modular power supplies, rack-mounted high-power systems, and industrial applications.
 13

Mechanical requirements
Equally as important as the electrical specifications of any high-power connector are its mechanical characteristics.
This includes the device’s dimensions, measurements, and design features – all of which impose certain limitations
that can affect installation of the connector and its performance within the data center application. For this reason,
consideration of the connector’s form factor and profile to determine whether it is compatible with the data center’s
configuration is imperative. High-power connectors are required to handle high voltage and high current electrical
loads, which in turn require that the connections have adequate separation from each other and from other devices
in the system to prevent unwanted electrical contact or interference. Furthermore, the connected cables should be
properly specified to handle the maximum rated voltage and current of the connector, using a similar design margin,
or derating factor, to specify the cables. For example, a 50A connector would require a minimum cable size of 8AWG,
whereas for a 32A connector the minimum requirement is a 10AWG cable. In addition, the connector’s contacts
on the printed circuit board (PCB) need to be specified for the maximum power load, with adequate derating. It is
also important to consider how the connector will be attached to the cable and the PCB – whether it be via screw,
soldering, or the use of a lock function.

Quality assurance
After the mechanical requirements of a potential high-power connector are assessed, the next step is to determine
whether it has undergone the prerequisite safety and quality assurance testing to prove that it satisfies the required
standards and design expectations necessary for the data center to operate at optimum performance. Depending on
the specific connector application within the data center, different safety standards can apply, both for the connector
as a component, as well as for the overall circuit and system in which it is installed. Examples include materials
used, blade/prong configuration, current rating, and whether it has a locking feature. Also, safety standards such as
UL1977/EN61984 may apply for connectors in data, signal, and power applications.

Because the field environment in which the data center systems operate will also affect the reliability and functionality
of the connector over the course of its life cycle, some indicated tests are required to satisfy those differing
environmental conditions. Examples of such tests include high humidity tests, necessary for applications requiring a
waterproof function, or corrosive tests, which are mandatory for high pollution environments. The connector materials
also need to adhere to standards for flammability (ex: UL94 V0 or V2) and may need to be certified as halogen-free
or RoHS-compliant.

» BizLink’s 745-07A/07B/07F/07G Series AC High-Power Whip Connectors, with maximum 32A/10AWG and 50A/8AWG cables,
are designed for AC inputs for power shelves of standardized servers in data centers.
14

Other characteristics and features

The final step for selecting a high-power connector for a data center is to identify any remaining key characteristics
and features that will influence or affect the application design. These include cost savings, flexibility in assembly,
and ease of maintenance. For example, the basic standards of UL1977/EN61984/EIA-364 include requirements for
temperature, contact resistance, and current de-rating, and these standards detail the testing procedures and criteria
for specific applications. OME potential questions are:

• Is this connector compatible with a hot-swappable system, meaning that the connector can be removed and
replaced without shutting down or rebooting the data center?
• Is the connector type suitable for a wide range of applications?
• Depending on the operating environment, does the connector need a waterproof rating?
• Is a connector locking feature required?
• How will both the highest and lowest ambient temperature affect the connector’s performance?

These are all important questions to consider when deciding which high-power connector is the best fit for your data
center applications.

Connector suppliers should also provide detailed test reports to assure that their connectors meet or exceed the
requirements established for the safety standards, as well as the application requirements, including group testing
and third-party agency test results.

The electrical and mechanical requirements, quality assurance, and other relevant characteristics and features of
high-power connectors for data centers vary widely, giving designers a range of options that can meet the needs of
many different types of applications and facilities. It is important that each of these factors are considered to ensure
optimal, high-reliability performance.

Visit BizLink to learn more.

 15

Innovative Connector Solutions from

Industrial to UxV
Steven Lassen, Senior Customer Application Engineer, LEMO

Industry-standard connectors certainly have their place, but sometimes a bit of innovation is required to solve unique
design challenges for reliably conveying power and data. Here is a look at some distinctive connector designs that
help design engineers in the Industrial and unmanned and autonomous (UxV) sectors achieve their goals.

Anglissimo – B and T Series

Cable management is important for applications with
limited space. Industrial controls often have many
cables that must be managed to minimize flex and
wear. Similarly, in UxV applications connectors and
cable routing must fit into very tight spaces. Ordering a
traditional elbow connector plug with a fixed cable exit
angle can limit cable management options. One remedy
is to rotate the receptacle to achieve the desired cable exit
angle. However, this may be a challenge if the PCB has
already been produced. With a more unconventional but
more versatile choice, such as the Anglissimo push-pull
plug, the cable exit angle can be selected for any of eight
different angles during assembly. Even after assembly,
the cable exit angle can be adjusted by removing the
shell and re-positioning it to the desired angle.

Multi-Concentric – S and E Series

Blind mating must be done when a connection needs
to be made in dark or difficult to reach locations. Keyed
connectors have forms that enable a connection to be
made by feel alone, but irregular connector housing
shapes can present a challenge in tight spaces. A multi-
concentric insert can also be mated by feel within a
round interface, and this design allows the connector to
be rotated once mated, or even during mating. This can
be helpful in an industrial control application where a
twisted cable can easily be straightened by rotating the
connector. Another benefit is that the connectors can be
mounted in a tube and engaged axially or during rotation.
Most industry-standard multi-concentric connectors are
available in coax or triax configurations which only allow
two to three contacts. The multi-concentric product is possible for up to 10 contacts, plus an outer shield. The larger
surface area of the contacts also allows for higher current in a small package for power applications.

HALO LED – B and T Series

Connection status can add real-time feedback to those using industrial control equipment. How do users know the
connector is properly mated, power or data is properly flowing through the connector, or if the device at the other
end of the cable is functioning properly? A quick check of the panel receptacle indication lights can provide a lot of
16

information. The HALO LED product integrates active LEDs right into the receptacle flange. They can be programmed
to light up when connected, flash if there is an open or short circuit, or even change color by means of pulse width
modulation circuitry designed into the PCB. Over a million color options are included, as well as three LED options:
full 8 LEDs, a small single LED, or a small ring of light.

Limitations of M8 and M12 Type Connectors

Industry-standard M8 and M12 connectors are widely used across industrial, transportation, and other heavy
equipment markets, but they also leave a lot of room for improvement. Traditionally, these connectors have simple
threaded coupling and only handle a few signal contacts. However, the terminations may be overmolded, which limits
the ability to repair a cable if needed. Also, the contacts may be stamped and rolled, which can limit cycle life and
reliability. (Contacts that are machined from solid brass or bronze have much greater durability.)

To improve performance for threaded coupling connectors, the use of a detent or ratchet coupling can be incorporated
into the connector design. Insulators can be designed to accommodate signal as well as power and even fiber optic,
high voltage, or fluidic/pneumatic functions. Utilizing a single connector solution to incorporate all design elements
saves space and helps the end user quickly connect or disconnect the cable.

Connector suppliers continually create new products to help engineers design streamlined and effective wiring
architectures. New concepts are developed in partnership with customers and design engineers whose challenges
might lead to the next great connector innovation.

Visit LEMO to learn more.

 17

Work Harder and Smarter: Four Electric

Powertrain Considerations for Warehouse
Automation Applications
Daniel Walldorf, Strategy and Business Development Manager, TE Connectivity

COVID-19 has altered every aspect of life, and the industrial space is no exception. The pandemic has rapidly
accelerated the adoption of e-commerce, with demand for quick delivery skyrocketing as consumers increasingly
prefer to shop online. This has placed pressure on warehouses to deliver on rising product demands without sacrificing
quality of work.

Simultaneously, warehouses face severe labor shortages and high employee turnover. As labor-intensive fields,
manufacturing and logistics are dependent upon a workforce to perform tasks ranging from picking line items to
managing groceries in cold storage. Currently, there are not enough workers available to meet mounting pressures.
A potential solution? Increasing automation by incorporating electric forklifts, autonomous guided vehicles (AGVs),
mobile robots, or even fully automated storage and retrieval systems.

» As manual labor in the warehouse market decreases, incorporating more automated solutions is essential to meet productivity
demands.

With this growing automation, the performance requirements for the system’s electric powertrain — consisting of
a charging station, a battery and battery management system, a power distribution unit, a motor controller, and a
motor — dramatically increase. The electric powertrain essentially acts as the lifeblood of the equipment, powering
the automation systems. Therefore, it is essential to increase the powertrain’s efficiency and durability for long-term
gains.
18

To improve the total cost of ownership for the warehouse operator, equipment OEMs need to invest in improved
electric powertrain systems as necessary groundwork for tomorrow’s innovations. When designing electric powertrain
systems for warehouse automation equipment, there are four considerations to keep in mind to increase durability,
efficiency, and productivity.

1. Leverage industrial expertise

Warehouses often operate 24/7, so solutions must be reliable and low maintenance. Furthermore, the designs need
to be rugged enough to withstand an environment where heavy packages and pallets are handled as well as special
environments like cold storage warehouses. As a result, designs and components need to be shock and vibration
resistant as well as durable enough to withstand dust and frost.

» Developing rugged components able to withstand harsh environments is central to advancing electric powertrain equipment.

Often, components used in industrial environments have been repurposed from other demanding applications. While
these components have to be adapted to fit the requirements and landscape of warehouse automation, leveraging
advances in other technologies, especially those from automotive electric vehicles, is highly recommended.
 19

2. Adopt enhanced battery technologies

New battery charging strategies increase power efficiency and reduce equipment charging time (and therefore
downtime).

Traditionally, lead-acid batteries have been used in forklift and AGV applications for power storage. While these
batteries offer a good solution for traditional forklift designs, usage, and charging strategies, new lithium-ion technology
provides significant advantages for the warehouse automation space.

Adoption of lithium-ion batteries for the rugged warehouse market is widespread. These batteries enable opportunistic
charging — when equipment is repowered rapidly and for short periods of time when convenient for the operator
throughout the day. With enhanced battery systems, equipment no longer needs to rest for hours at a time to charge.

» Enhanced lithium-ion battery technology decreases charging downtime, which improves overall efficiency.

Instead, operators can charge technology while stepping away for a few minutes.

Lithium-ion batteries are smaller, and a more compact solution reduces weight and energy consumption. These
effects reduce downtime and enhance overall productivity.

3. Prioritize ergonomic solutions

The need for frequent charging has led to significant changes in the design and specification of the electric powertrain.
These effects include the need for sophisticated battery management systems, demand for increased charging
power, and a higher number of charging cycles for the charging infrastructure (for example, charging connector
mating). At the same time, operators want to limit the manual labor involved in charging operations, which leads to
the requirement for AGVs and AMRs to be charged autonomously at docking stations.

With opportunistic charging, chargers are plugged into the equipment three to four times more than with traditional
charging strategies. Not only does this create heavy wear and tear on the connector, it also places strain on the
operator. The connectors are large and push high amounts of electrical current, which makes connecting and
disconnecting the charging cables difficult. Suppliers are increasingly searching for solutions with less mating force,
more flexible cables, and easier to handle connectors.
20

» Improving operator use must be a focus for future design development.

In the case of autonomous charging, the connector design needs to be completely rethought. There are four different
options to address this problem:

• Sliding contacts mounted on the floor or wall offer a reliable and compact solution.
• Wall-mounted docking connectors enable the transfer of power and data. This method is also more forgiving
regarding misalignment.
• Wireless charging can offer increased reliability in difficult environments and can withstand a larger margin for
misalignment.
• Robotic charging utilizes multi-axis robotic arms to plug in a charging connector. While sophisticated, this
method is still in the early stages of development.

With new battery technologies come unique benefits and challenges, all of which will continue to evolve with the
powertrain.

4. Develop with end-to-end design in mind

The electric powertrain contains five core components: a charging station, a battery with a battery management
system, a power distribution unit, a motor controller, and a motor. Typically, the design process for an electric
powertrain begins with defining the system requirements and functional specifications of parts. Then, details and
component choices are typically designed in isolation. A more holistic approach, however, can be far more beneficial.
When designing with end-to-end in mind, efficiencies can be identified across components. For example, similar
contactor circuits can be used in charging stations, battery management systems, and power distribution centers.
Signal and power distribution connectors can be harmonized. Working with a big picture view leads to a reduction of
engineering and qualification work, optimizing the entire system.
 21

The future of electric powertrains in warehouse automation

For manually operated equipment, ergonomic solutions will continue to be a focus in order to improve working
conditions for operators and increase efficiency. For autonomous systems in particular, miniaturization will play a
more prominent role as high-density storage is needed. Furthermore, as charging power will only increase, the
need to design reliable connectors that can withstand high mating cycles will be essential. Autonomous charging
requirements will continue to evolve and solutions must evolve with them.

By working with a supplier that can provide all the components needed for an end-to-end electric powertrain,
customers gain access to a one-stop shop for application expertise and technical support.

Explore TE Connectivity’s end-to-end electric powertrain portfolio for warehouse automation.

Visit TE Connectivity to learn more.

Supplying Power & Data
for Transportation
 23

Solutions for In-Vehicle Tactical Communications

and Power Interconnectivity
Robert S. Grzib, Marketing Manager, CDM Electronics

The increasing demand for mobile tactical power and communications capabilities for military use presents new
interconnect and cable assembly design challenges. In addition to demanding the utmost in durability and universal
connectivity, military requirements make the optimization of finite in-vehicle space critical. Alternative interconnect
designs and MIL-spec components maximize performance while addressing the Department of Defense (DOD)
requirements for powering in-vehicle radios, GPS devices, and chargers.

Legacy in-vehicle communications and power systems’ size and capabilities

Single-channel vehicle-mounted military radios were developed in the 1930s to supersede visual and light signals,
foot and motorbike couriers, homing pigeons, and messenger dogs. These early tactical communications radios
were big, heavy, and bulky and therefore commonly mounted in Jeeps, armament carriers, and trucks. Their outsized
physical dimensions, high-current power demands, and complexity relegated their usage mainly to single-purpose
“signal corps” vehicles. For situations in which longer-range communications capabilities were needed, radios were
installed in special “radio vans,” the predecessors to today’s military mobile radar vehicles.

In-vehicle communications and power systems optimize

performance and limited interior space
The vehicle that initially compelled engineers and military contractors to create application-specific power interconnect
components was the U.S. military’s High Mobility Multipurpose Wheeled Vehicle (HMMWV), commonly referred to
as a Humvee. First introduced 1988, over 280,000 Humvees were manufactured. The vehicles were specifically
designed for the SINCGARS (Single Channel Ground and Airborne Radio System) family of VHF-FM combat-net
radios (CNR) to provide the primary means of command and control for infantry, armor, and artillery units. The radio
had no charging or additional ancillary systems requiring power. Over 500,000 SINCGARS were manufactured
in a variety of form factors and were typically employed in military vehicles. As they were strategically installed in
the center of the vehicles’ forward dash, they eventually began to encroach into the driver compartment. Despite
multiple attempts to re-configure the available mounting area in so many units, it was determined that optimization
of the existing space was significantly more cost-effective. Any solution would require standardized MIL-DTL-55181
connector interfaces and similar performance specifications (e.g., voltage drop, contact compatibility, shell plating
equivalency, and environmental durability).

OVER 15 MILLION NEW

CONNECTORS IN STOCK
877.386.8200
www.cdmelectronics.com
24

The JLTV (Joint Light Tactical Vehicle) program is the current U.S. Armed Forces and United States Special Operations
Command initiative to part-replace the Humvee in frontline service. These state-of-the-industry combat vehicles need
multiple auxiliary power sources for additional radios, chargers, and accessories. While radio installation in the JLTV
is more integrated, the vehicle’s crew compartment is narrower than the HMMWV and requires specialized space-
saving power source multiplication. Though a vertical stacking design is most regularly used, a JLTV-specific, side-
by-side, cable-mounted connector box is frequently specified to optimize limited space and support heat dissipation.

Vertical-stacking cable-mounted
connectors
Cable-mounted MIL-DTL-55181-compatible stacking
connectors were developed to minimize footprint
while maintaining both plug and receptacle contacts.
The stacking connector’s front-mounted plug contacts
can be mounted to a power receptacle, which
allows additional plugs and cables to be mated to
the connector’s rear-mounted receptacle contacts.
When mated to a battery, power is distributed to the
cable attached to the stacking connector and the
“piggybacked” cable. Notably, the stacking connector
can also function identically to a standard plug when
a secondary piggybacked cable is not connected.
This enables the removal of the battery powered by
the stacked cable for use in another vehicle to further
maximize the safety of ground troops.

Single-point-mounted dual-exit splitter

As multiple designs are required to address the divergent applications,
dual-exit, single mounting point plugs were developed to provide a
straightforward, low-cost alternative to traditional “Y” cables. This design
incorporates a single-plug MIL-DTL-55181-compatible body mounted
on a permanent interconnect to distribute power to two exiting cables
connected to ancillary radios or chargers. While the single-point-mounted
dual-exit splitter is less space-efficient than the stackable design, it is a
more efficient solution for applications in which standard cables are utilized
regularly as a fixed configuration within the vehicle. In addition, the single
connector interface supports mating and un-mating as needed.
 25

Connector head splitter

Dual head splitter receptacles enable the powering of two devices from a single cable, without requiring additional
interior vehicle space. The configuration allows two sets of MIL-DTL-55181-compatible receptacle contacts to share
power from one source cable. As this innovative interconnect is a single-piece design, it is a simpler and lower-cost
solution to multiple external “Y” cable assemblies.

Multi-power access units

These engineered components provide two power outputs from a single input. The unit’s body incorporates a cable
adaptor and a MIL-spec-style receptacle to facilitate power splitting from a single MIL-DTL-55181-compatible plug
connected to the power source. This is an ideal configuration for height-constrained applications or when a preexisting
preconfigured cable or wire harness is needed (mating interface to the receptacle interconnect). While versatile, the
units’ physical size and functionality are more permanent than those previously discussed.

Alternative orientations for cable plugs

Conventional QPL-qualified MIL-DTL-55181 connectors are configured for 90° mounting to the source interconnect.
This configuration is less than ideal due to dashboard or panel-mounting space constraints or overlapped “wire
stacking,” which can induce electromagnetic interference (EMI). The connectors’ right-angle orientation is also
impractical for in-line cable interconnection. Straight-backshell MIL-DTL-55181-compatible versions of right-angle
interconnects were engineered to avoid the obstruction of other installed power connectors, and to provide an optimal
solution for in-line and extension cable interconnects.
26

Interconnect innovations driven by military ground vehicle development

Up-armoring programs such as Armor Survivability Kit (ASK), and Fragmentary Armor Kits (FRAG5 and FRAG6) did
not allow conventional signal and power interconnects to be utilized for dismounted soldier connectivity. Extended-
body MIL-DTL-55116-compatible interconnects allowed for conventional interior termination while providing exterior
mating and enhanced survivability.

HUMMWV interior designs evolved as a result of multiple armed conflicts that highlighted advantages to mounting
bulkhead feed-through interconnects, now a requirement. An easy to install and terminate extended body MIL-
DTL-55116-compatible bulkhead connector is now available which accommodates the increased thickness of the
vehicles’ interior surfaces.

The future of ground vehicle tactical power and communications connectivity

Advances in computer design, contractor prototype evaluations, and ancillary power requirements for tactical
communications devices are now commonly preconfigured in most military vehicles and armor. Additionally, USB
and quick-charge mobile interconnects are also included in tactical radio designs, as are traditional MIL-DTL-55181
interfaces. However, it is estimated that it will take the military over a decade to field roughly 58,000 JLTVs to the
Army and Marines. As this number is significantly below the quantity necessary to totally replace the Humvee, the
solutions explored in this article are offered to help MIL-spec component specifiers and design engineers today and
in the foreseeable future.

Visit CDM Electronics to learn more.

 27

IDT Meets SKEDD: Superior Benefits

for Many Industries
Ulrich Schmidt, Managing Director, Lumberg

The international terminal block standard for consumer appliances, RAST (Raster Anschluss Steck Technik or Raster
Connection Plug Technology) connectors have been in widespread use since their invention in 1986. While some
assume that the technology has reached the end of its life cycle, the system is more relevant than ever and has
moved beyond white goods. More and more sub-assemblies in the automotive industry are produced by Tier 2
suppliers yet must plug and play with primary wiring systems and PCBs in the final production process. RAST
connectors can be used as a direct mating system on the edge of the PCB, which is difficult for crimp connectors,
saving costs and installation space, and coordinating easily with other systems.

RAST 5 connectors with a 5 mm pitch are designed to cater to currents that draw up to 16 A and 2.5 mm pitch
connectors can relay signal and small load currents of up to 4 A. RAST connectors tend to rely on insulation
displacement technology (IDT), which offers a budget-friendly production solution for cable harnesses of industrial
quality. This explains why RAST connectors have become the standard for several sensor, switch, actuator, and
motor control lines that can be connected directly or indirectly to the PCB or its components. They are particularly
dominant in vehicle lighting, LED headlights, LED taillights, and interior lighting.

The dilemma facing direct connectors for modern applications in white goods, heating technology, and automobiles
is that the edge of the printed circuit board is full! This is where evolution meets revolution: a direct connector is
needed that can assume any position on the PCB, without soldering and, of course, without being plugged onto a
corresponding part. In addition, the connector needs to be plugged-in and plugged-out several times. IDT allows all
the advantages of automated cable assembly and also accommodates these goals.

IDT provides direct connection

This is made possible by the SmartSKEDD connector. SKEDD technology can be seen as an extension of press-fit
technology and uses reversible contacting in the plated-through PCB hole. The individual contact comprises two
spring-loaded symmetrical contact tongues which retract when inserted into a plated-through hole in the PCB. The
contact pressure from the two tongues then creates a steadfast mechanical-electrical connection inside the hole with
no need for soldering.

The connectors can mate and lock without using tools, which is especially convenient when mounting entire sub-
assemblies. This enables completely new designs. The connectors can mate right in the center of a printed circuit
board, or even on the reverse side, if the edge and surface of the PCB are already full.

Smart
direct connectors

directly mating without counterpart

anywhere on the PCB, even from the back side
no soldering process

reversible for multiple mating and unmating

secondary locking
proven IDT connection
www.lumberg.com
28

Reversible mating also makes it possible to easily replace components. With the reduction of installation space and
weight, an electrical interface, and a contact resistance, a potential source of error as well as an assembly process
are omitted. The thermal load of an FR4 printed circuit board, caused by a soldering process or the use of additional
devices for a press-fit process, is also eliminated.

Robust and reliable locking system

The SmartSKEDD connector comes in two model versions. Both direct connectors are exceptionally robust.

Three solid pins on each housing guarantee secure positioning and prevent mismating. Each side of the connector
features two snap-fits that lock the connector tightly onto the PCB. The geometry of the snap-fits also varies to hold
firmly on different board thicknesses. To release the connector, simply press on this primary lock. The retaining forces
are roughly more than 50 N.

If a secondary lock is needed, as is the case for many automotive applications under the LV 214 standard, or the
application just needs that extra measure of retention, the second SmartSKEDD model features a pre-assembled
central pin. This pin increases the retaining force of the entire system to almost 100 N. Again, this assembly is tool-
free; it is delivered and pinned in the locked position. This central pin then additionally locks into the printed circuit
board and reliably secures the connector. During servicing, a simple screwdriver is sufficient to turn the pin from the
“lock” position to the “release” position.

In general, the connector was designed to be holistically robust throughout the connector life cycle. In particular, the
focus was on tolerance management (production, assembly, contacting), assembly, packaging, and transport. The
spring contacts are also geometrically optimized (spring leg symmetry) and have a silver coating.

IDT provides superior benefits for many industries

Whether board-to-board, wire-to-board, or component-to-board, directly pluggable and detachable connections can
be made anywhere, including novel locations such as on the center or the rear of the PCB. The advantages in series
processing are enormous, due in part to eliminating the need for soldering.
 29

Advantages of IDT Over SKEDD

Direct Mating Cost savings of material and process/benefits:

§ No pin header required:

- less installation space and weight

§ Eliminated:
- one electrical interface
- one contact resistance
- one potential source of defects

§ One mounting process less

§ One press-fit or soldering process less:

- no thermal stress for the PCB
- no additional devices as required for press fit due to
high insertion forces

§ No additional technical requirement for the FR4 PCB

Reversibility § Designed for a minimum five mating cycles

§ No special tools required

- easy manual connector plug-in and plug-out by hand (using a

screwdriver if pin version)

§ Easy exchange of complete components possible, e.g. for

maintenance and servicing

§ Disconnect feature supports sustainable recycling

Positioning § Arbitrary mating: anywhere, even on the reverse of the PCB

- new design possibilities for applications, e.g. a PCB can be used

for different device models if all holes are arranged accordingly
for SmartSKEDD

- if a PCB’s topside is fitted to capacity with components, the

connector can mate on the reverse

§ Customizable for board-, wire-, and component-to-board

connections

IDT § Single and flat ribbon cables possible

§ Cable harnesses can be pre-assembled with highly-automated

machinery

§ Assemblers can rely on over 30 years of know how in proven IDT

assembly
 connector can mate on the reverse
30 § Customizable for board-, wire- and component-to-board
connections

IDT § Single and flat ribbon cables possible

§ Cable harnesses can be pre-assembled with highly-automated

machinery

§ Assemblers can rely on over 30 years of know-how in proven IDT

assembly

§ Cable assembly can be processed on tried and tested knuckle

joint presses, semi-automatic machines, and fully-automatic
machines

- zero-defect quality during cable assembly

- assembly machines have testing stations which

eliminate all defects

- highly-efficient cable assembly for any lot size

Housing § Connectors with positioning pins and snap-fits

- secure positioning and protection against mismating on

PCB

- durable and secure retention on the PCB

§ Keying options via keying pins in housing

- keying option: zero-defect quality during device

assembly

- protection against mismating prevents accidental mix-

ups and faulty connections

§ Halogen-free material

§ Glow wire resistant material

[Suggestion here:

LUMBERG_1_SmartSKEDD Connector with up to 13 poles.jpg

and

LUMBERG_2_SmartSKEDD with Secondary Locking acc. to LV 214.jpg]

Both SmartSKEDD direct connectors have a 2.5 mm pitch and come with numbers of poles from 3 -
11, in the version without pin even up to 13 poles. Designed for the temperature range from -40 to
Visit Lumberg to learn more.
130 °C, the housing is halogen-free in PBT V-0 according to UL94, while the copper-tin contacts are
always silver-plated. The contact resistance at Tamb 20 °C is ≤ 5 mΩ, the rated voltage at 50 V AC and
the rated current at 4 A (Tamb 85 °C).

www.lumberg.com
 31

Smiths Interconnect Helps Keep

Rail Passengers Informed
Chiara Pieri, Marcom Manager, Smiths Interconnect

As sophisticated as rail services have become, the hyper-connected nature of this mode of travel means that even
the slightest hitch with one train or line can have a ripple effect on the overall timetable.

Train operators meticulously prepare for such inevitabilities. Part of their fastidious response in such a situation is to
keep the passengers regularly informed. As a result, over the last couple of decades both network (infrastructure)
and train (service) operators have invested greatly to advance passenger information systems (PISs).

While the PIS at stations and transfer facilities provide visual and audio information to commuters, the PIS onboard
the train updates passengers during their travel through a variety of connected devices such as cameras, display
monitors, and signal control systems, all controlled from a few cabinets.

This is more than just interesting information. It helps keep passengers informed about their journey and general
safety, which is vital for passengers’ satisfaction, and ultimately contributes to the overall increase in rail use.

A reliable onboard PIS is, therefore, essential to the commercial success of a modern train manufacturer.
32

The challenge
Although rail technology has progressed by leaps and bounds, the operating environment for communication
technologies still presents extreme challenges, with the ever-present dust, moisture, dirt, and oil, as well as heat,
electromagnetic interference, shock, and vibration all vying to disrupt or fatally corrupt the connections.

In one such example, a China-based manufacturer of high-speed trains was struggling to establish a stable
communication signal. The root cause turned out to be the connectors: The components originally specified were
failing to withstand the continuous jarring movement of the train. This not only resulted in signal failure, but also in the
rapid deterioration of other components within the circuit, which led to high maintenance costs.

The manufacturer identified the need for more resilient interconnect technology to incorporate into the design of their
PIS cabinets. This meant connectors that are robust, lightweight, compact, easy to assemble, and configurable for
different applications and models.

The solution
M12 compact connectors, based on the Hypertac Hyperboloid contact technology, are one option that has been
designed for challenging operating conditions. Their design provides continuous points of contact and a unique side-
loading contact retention system that minimizes friction through even the roughest rides. Meanwhile, an IP67 metal
shell and 360° EMI shielding give them a comprehensive seal. All this enables them to provide unparalleled immunity
to shock, vibration, and environmental impacts to ensure uninterrupted signal integrity. The series includes up to
eight insert options, with both crimp and solder contact terminations. The design complies to global rail requirements
and comes in A and D coded versions.

The high-speed train manufacturer wanted to incorporate the M12 connectors into its cabinets quickly. Smiths
Interconnect’s team drew on its knowledge of ruggedized connector technology to help the customer reconfigure its
PIS cabinet to better meet its requirements. Valuable suggestions such as a color mark identification and improved
instructions helped speed up the assembly process.

The win-win collaboration has given the manufacturer an important competitive advantage through a reliable and
durable interconnect solution while enabling the passengers to have a pleasant and satisfactory travelling experience.

Visit Smiths Interconnect - Connectors for Railway Applications to learn more.

 33

4 Connectivity Solutions to Optimize

Cost and Design Flexibility for Automotive
On-board Power and Data Electronics
Wally Wang, Associate Vice President Marketing, Greenconn Corporation

Vehicle electrification is an unstoppable trend – one that revolutionizes not only the source of energy that propels our
automobiles, but also the transmission of information integrated inside them. According to market research, the global
vehicle electrification market is expected to reach $140.24 billion by 2027 [1]. Meanwhile, the global automotive
cockpit electronics market is expected to reach $39.5 billion by 2026 [2]. With an influx of competitors ready to seize
this lucrative market, companies must stay competitive to gain a larger market share.

Along with this, increased requirements for data and power connections demand that on-board electronics become
even more intricate. The challenge of complex design can be confounding even to experienced designers. Being cost
competitive while maintaining design flexibility has become a topic worth exploring.

Design with embedded components

Although it seems easier to pick connectors available off the shelf, having predetermined form, fit, and function is not
necessarily more convenient or efficient for the PCB design. For starters, that might restrict the space and layout of
the PCB to what off-the-shelf connectors offer, which jeopardizes design flexibility. Secondly, connector specifications
exceeding design requirements will result in redundancies of materials or over-designing of components. Polarization
— removing selective pins — is not an effective way to resolve this issue either, since it often creates additional
processes during connector manufacturing.

For seasoned engineers, design with embedded components could be a better way to solve this issue. There are
three ways to approach this:

1. Consolidation
Component costs come from two main sources: materials and manufacturing. By combining multiple connectors,
the material required is reduced, and processes are merged, which greatly decreases the cost. Some NRE (non-
recurring engineering) costs might occur, so accounting should be done diligently. Caution should also be taken
since cumulative tolerances could result in mating compatibility issues in the future.

» 7-in-1 Consolidated connector solution

34

2. Integration
Integrating connectors into the product structure can enhance design flexibility by relieving space constraints.
Connector shrouds, shielding, and strain relief systems can conjoin together with the product itself, eliminating
material interference and freeing up more space. As a result, engineers have more options to realize their
designs.

» Connector integrated radar box

3. Customization
Redesigning connectors to meet the exact electrical requirements can eliminate waste on material cost.
Incorporating additional elements might even improve the design.

Flexible PCB

Upper Cover

Connector

Shroud and Latching

» Customized shrouded connector with FPC & latching features

 35

Eliminate component redundancies

Thanks to improved technology and machine precision, simpler connectivity designs can be just as robust. Certain
parts of the original component design could be rendered obsolete. Removing such redundancies can save material
costs or even eliminate an assembly process.

One example is the RAST connector. RAST IDC connectors were originally developed for household appliance
applications but have since been adapted for wire-to-board connections within the automotive industry. They can be
mounted directly onto the PCB, eliminating additional receptacles traditionally required for wire-to-board connections.

IDC Crimping

» RAST IDC crimping process

Another example would be press-fit

technology. Press-fit technology is a solder-
less termination technology in which pins
can be mounted directly onto a PCB. The
elasticity of the contact material and its unique
shape apply a normal force on the plated-
through-hole enabling a reliable mechanical
and electrical connection. Subsequently, the
PCB Mounting convenience and reliability enabled by this
technology help to lower costs and enhance
the overall design.

» RAST PCB mounting process

» Press-fit mounting process (left) and pre-assembled press-fit terminals (right)

36

Reduce line down risk for automatic substrate assembly

High requisites of data and power for on-board electronics result in ever more complex electrical layouts. The
number of interconnects required on the PCB substrates are also increasing. To avoid line down and rework costs
for automatic substrate assembly, certain connectors, such as floating connectors, have been developed for this
specific purpose.

Floating connectors are an effective solution to absorbing alignment errors and cumulative tolerances, thereby
increasing production efficiency and cost-effectiveness in automated PCB assembly. The spring-like contacts reduce
the stress applied to the mounted parts and enhance the connector’s reliability by preventing solder cracks. These
contacts reduce the chance of misalignment and tolerances during the process and in doing so, enhance the design
flexibility.

Self-Alignment

» Floating connector mating during substrate assembly

Choose your cross-mated components wisely

Cross-mating components is a widely practiced cost-reducing solution. Cross-mating means each side of the
connector comes from a different manufacturer. However, on-board electronics are often modules that must be
connected to the vehicle mainframe through cable assemblies, which means compatibility of the mating connectors
on the module side is of the utmost importance. If connection is lost, all is lost. Therefore, a few considerations must
be addressed before deciding which component to use:

1. Tolerance
Tolerance is a range indicating how much a dimension could vary from the nominal measurement. When tolerances
of two mating connectors are controlled by separate manufacturers, the risk of compatibility issues increases.
This is the first possible cause of quality issues when using cross-mated connectors. Dimension specifications
should be diligently communicated during design-in, and the precision capability of the manufacturers must be
thoroughly audited.

2. Contact structure and material

A contact system is the main determinant of power and signal integrity. Its structural design has a great influence
on the electrical performance which is amplified particularly during high-speed transmission. The contact
material acts as the transmission medium which determines the deterioration of electrical transmission. The
detail technicality is beyond the scope of this article. However, we suggest thorough design simulations and
laboratory analytics to prevent possible failures.
 37

3. Patent infringement
In today’s business climate, the global supply chain means that connector patent rights are often granted in
multiple countries. A product free of component patent infringement in one country can trigger lawsuits in another
when exported. Be sure to consult patent engineers and attorneys to avoid legal issues.

Amid the trend of vehicle electrification, on-board electronics are a quickly evolving segment of the automotive
industry. Compounded with ever more demanding electrical performance, attaining competitive advantages in
cost and design is crucial. Connectors are the gateway linking electronic modules to the vehicle mainframes,
meaning that optimizing connectivity solutions during the design and manufacturing processes is the key to
success.

Visit Greenconn to learn more.

Citation:

[1] O. Bachal and S. Mutreja, “Vehicle Electrification Market Statistics – 2027,” alliedmarketresearch.com, Nov. 2020.
[Online]. Available: https://www.alliedmarketresearch.com/vehicle-electrification-market.

[2] StrategyR, “Automotive Cockpit Electronics: Global Market Trajectory & Analytics,” 2021. [Online]. Available:
https://www.strategyr.com/market-report-cockpit-electronics-for-automotive-forecasts-global-industry-analysts-inc.
asp
38
Innovative Connectivity for
Innovative Technology
40

M16 8-Pin Connectors: The Right Solution

for 5G applications
Paul Pulkowski, Marketing Manager; Maciek Czerwinski, Director of Sales and Business Development;
and Rick Lopez, Sales Engineer and Project Manager, binder USA

The fifth generation of cellular network technology,

or 5G, offers many significant improvements over
previous generations. Perhaps most impressive
is the speed – 5G is expected to deliver data 100
times faster than the average 4G network [1].
Infrastructure to accommodate 5G technology is
being built as rapidly as possible, as businesses
around the world work to upgrade their systems. In
2020, the global 5G service market size was valued
at $41.48 billion, and global tech analysts expect
the market to grow at an estimated compound
annual growth rate (CAGR) of 46.2% within the
next seven years [2].

» 4G and 5G wireless communication tower.

Through advanced antenna design, cell tower improvements, and greater frequency rates, 5G provides bigger
channels that speed up data, lower latency, reduce energy consumption, and lower maintenance costs. It also
increases capacity for the IIoT (Industrial Internet of Things), empowering companies to connect more sensor and
smart devices at once. A recent report by Frost & Sullivan predicts that 90% of industrial enterprises will use edge
computing by 2022 [3], requiring the connectivity, speeds, and low latency that only 5G can provide. The result is a
dramatic impact on a broad range of industries, including manufacturing, energy and utilities, IT, transportation and
logistics, aerospace and defense, agriculture, construction, and healthcare. Basically, any application that requires
instantaneous communication will benefit from a robust 5G network.

Smaller, more advanced cells power 5G

Compared to other wireless systems, 5G uses higher (and less cluttered) radio frequencies, allowing it to carry
more information at a much faster rate. Because higher frequencies are easily blocked by physical objects such as
buildings, and may be negatively impacted by weather conditions, 5G uses a higher number of smaller transmitters
to boost signals and capacity across the network. 5G cells contain the equipment needed to transmit data between

M16-X M16 thread with X-Coding

Data transmission up to 10Gbit/s
Female socket, front fastened,
dip solder contacts
Cable outlet 5,5 – 9 mm
Diameter of thread 16 mm
8 contacts
IP67 in mated condition
www.binder-usa.com
 41

connected devices. “The antennas within the small cell are highly directional and use what’s called beamforming to
direct attention to very specific areas around the tower. These devices can also quickly adjust power usage based
on the current load. This means when a radio is not in use, it will drop down into a lower power state in just a few
milliseconds, and then re-adjust just as quickly when more power is needed…. At a minimum, 5G must support one
million devices for every square kilometer (0.386 square miles),” wrote Tim Fisher on Lifewire.com [4].

Updated AISG connector standards

Connectors act as the vital link between the cables carrying data and the devices that record and communicate
information. For cell tower antennas, the demand for faster and more reliable data transmission has driven the
development of products able to support the specific connector requirements set by the Antenna Interface Standards
Group (AISG). The AISG defines the communication interface for “remote electrical tilt” (RET) of the mobile phone
antenna. The AISG standard helps to define the AISG connector for RS-485 (AISG C485), which is used for outdoor
applications [5].

The AISG standard has been redefined in terms of electrical and mechanical characteristics, environmental conditions,
and materials. (See Figure 2.)

Electrical characteristics:

• Rated voltage of 32V

• Current carrying capacity of 5A per contact
• Contact resistance (≤ 5mΩ)
• Insulation resistance (≥108 Ω)

Mechanical characteristics:

• IP68 protection degree

• >100 Mating cycles
• Insertion and withdrawal forces of 60N max
• Keying method
• Vibration and shock resistance
• Cable retention force of 80N

Environmental conditions:

• Harsh environment resistance (protection against temperature, salt mist, sunlight, and rain exposure)

Material and other characteristics:

• Housing surface of nickel is recommended

• Contact plating of gold or silver
• Crimp or solder termination
• 8 pins with 4 to 5 pins used
• M16 x 0.75 screw locking system
• EMC shielding

» binder’s 423 and 723 series M16 connectors are AISG compliant with an 8-pin DIN variant that supports all wireless networks,
including 5G. Rugged metal shells, 360° EMI shielding, and IP68-rated protection fulfill the AISG standard for harsh environment
resistance.
42

M16 connectors and 5G applications

Different M16 connector styles are used within the control infrastructure of antennas and antenna line products, such
as RET, tower mounted amplifier (TMA), sensor, and monitoring devices. Cable assemblies fitted with these M16
connectors connect the mobile phone base station to an electric motor mounted on the base of the antenna. Outdoor
applications like these need connectors that provide reliable protection against environmental conditions to ensure
waterproofness.

The number and variety of applications well suited to the M16

connector have greatly increased over the years thanks to a higher
pin count, compact size, and improved levels of protection. The latest
5G applications are the perfect example of the M16’s adaptability
to new performance and environmental challenges. The M16
connector is an excellent alternative to more expensive connector
systems, offering a rugged and reliable design at an affordable
price. Contacts with gold plating offer a protective coating to help
ensure the connection is free of any corrosion. Nickel plated brass
outer housing/shell offers environmental protection, as well as high
vibration and shock resistance.

EMC shielding
Millions of cell phones, computers, and smart devices create
significant potential for electromagnetic signal interference (EMI) and
data disruption. The most effective defense against EMI is filtering
at the connector interface [6]. Optimized 360° EMC (electromagnetic
compatibility) shielding for M16 connectors provides the highest
integrity for sensitive signal and power connections. Shielding is
metal and available as a cable clamp or shielding ring.
» 5G smart cellular network antenna base station.

Effective shielding meets the attenuation requirements of the DIN 47250-6 standard. Attenuation is the loss of signal
strength in network cables or connections during transmission. It is typically measured in decibels or voltage. (See
Figures 4a and 4b.)
 43

» Attenuation curves per DIN 47250-6 standards for male connectors with shielding ring vs. female connectors with cable clamp.
Source: binder USA.

» binder M16 IP67 shielded 8-pin connector for 5G applications.

5G networks represent a genuine revolution in mobile connectivity: lightning fast connection speeds, lower latency, and
greater device capacity that empower consumers and businesses alike. The IIoT may approach its true potential with
significant advances in automation, efficiency, and productivity. Industries as diverse as manufacturing, healthcare,
transportation, oil and gas, aerospace, and defense will be impacted.

Of course, 5G is only as reliable as the components and systems that power it. Reliable connections require state-
of-the-art shielding and protection levels. Connectors – and their ability to ensure signal integrity, performance, and
EMI shielding in the face of harsh outdoor conditions – are critical to the success of 5G. Forward-thinking companies
have already designed their products to ensure they can handle 5G (and future) requirements at a competitive cost
that allows the world to connect.
44

To sum it up, these are the 5 reasons of why M16 connectors are the right fit for 5g Applications:

1. High number of poles

2. Compact in diameter and length
3. Optimized 360° shielding
4. Protection rating to IP68
5. Cost effective

Visit binder to learn more.

References

[1] C. Eastman, “The Road to the Future? What to Expect from 5G,” Tech Native. April 7, 2020. [Online], Available:
https://technative.io/the-road-to-the-future-what-to-expect-from-5g/.

[2] Grand View Research, “5G Services Market Size, Share & Trends Analysis Report By Communication Type
(FWA, eMBB, uRLLC, mMTC), By Vertical (Manufacturing, IT & Telecom, BFSI), By Region, And Segment Forecasts,
2021 – 2028,” March 2021. [Online], Available: https://www.grandviewresearch.com/industry-analysis/5g-services-
market.

[3] A. Gulli, “The Critical Role of 5G In the Future of Work,” Forbes. Jan. 27, 2021. [Online], Available: https://www.
forbes.com/sites/googlecloud/2021/01/27/the-critical-role-of-5g-in-the-future-of-work/?sh=6b9736c16619.

[4] T. Fisher, “5G Cell Towers: Why You See Them and How They Work,” Lifewire. March 24, 2021. [Online],
Available: https://www.lifewire.com/5g-cell-towers-4584192.

[5] AISG Standard No. AISG C485 V1.1. June 17, 2016. [Online], Available: https://aisg.org.uk/files/AISG-Connector-
specification-C485-v1.1.pdf.

[6] L. Smith, “Three Key Considerations When Selecting EMI/RFI Shielding Solutions for Aerospace and Defense
Applications,” April 6, 2020. ConnectorSupplier.com. [Online], Available: https://www.connectorsupplier.com/three-
key-considerations-when-selecting-emi-rfi-shielding-solutions-for-aerospace-and-defense-applications/.
 45

QUESTIONING
your power supply?

Sager Power Systems offers over 30,000 world-class AC-DC and DC-DC standard
solutions, the widest range of modular power supplies available in North America
and custom design services.
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a team of dedicated power sales engineers and a 20,500 SF value-add Power
Solutions Center, we’re here to help.

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46

Configurable, Modular Connectors

Provide Design Expedience
John Froustet, Director of Device & Field Connectivity Division

Digitalization encompasses both digital and physical interfaces. More and more devices are being networked together
to communicate with each other. Connection solutions need to meet the mechanical and data-carrying requirements
of the end product as well as relevant standards for the specific market. For example, PCB connectors must have
all relevant approvals according to UL 1059 and IEC 61984 for industrial applications. Connectors that combine
functions or expand capabilities provide product designers with performance and flexibility.

In the industrial market, generating data is nothing new. Gigantic amounts of data are already produced and collected
in manufacturing and utility facilities. Innovative connection technologies simplify this process. These include
connectors that combine a future-oriented and configurable product design with efficient connection technologies
and fast delivery of data.

Flexible options for interface design

Modular connector designs provide engineers with the ultimate degree of flexibility. A flexible device connector
designed according to the modular principle offers numerous possibilities for designing and updating electronic
products and systems. The basic structure of a connector that is configured through individual modules offers the
developer diverse and flexible options for interface design. This gives users enormous flexibility in the development
process and allows them to adapt their designs at short notice or for a specific customer update or specialized
requirement.
 47

Shorter product life cycles mean that engineering processes must also be faster, more precise, and more economical.
A connector that can be individually assembled down to a batch size of one still requires an adapted design process.
Digital configuration tools accelerate selection, project planning, and ordering, and offer a preview of the product to
check the configuration and prevent possible errors.

Customized production and delivery can take place within a few days and the connector is available to the developer
for the design-in process.

A new connection technology for PCB

connectors
In industrial environments, there is an increasing trend
towards automatic wiring. For these automatic processing
steps, a corresponding connection technology is required.
For example, the products must be delivered with open
terminal points (wire-ready), which are ready for connection.
A new connection technology for PCB connectors is the
innovative SNAP IN connection technology. This technology
allows flexible, fine-stranded conductors to be simply
plugged into the open connection point without crimped-on
wire-end ferrules. The connection is secure and withstands
even difficult environmental conditions, such as operating
environments with a lot of shock and vibration.

Tradition and future: single-pair Ethernet

Digitalization has a major impact on the development of PCB connectors. Hybrid connectors meet the needs of current
systems and have the flexibility to support system upgrades and improvements in the future. Classic connectors
are evolving into hybrid options that can support next-generation communication technologies such as single-pair
Ethernet (SPE).

SPE communication technology, originally developed

for automotive applications, is based on a single pair of
wires, and ensures continuous, scalable, and deterministic
networking from sensors to the cloud. SPE interfaces
are a response to the need for improved industrial
communications in smart factories and IIoT networks. This
miniaturized and standardized interface is considered a
megatrend in industrial data transmission. Without gateways
or a multitude of protocols, processes can be economically
visualized and optimized across the entire plant.

SPE’s advantages are especially significant in the use

of robotics, which require extremely flexible wiring in
combination with the shortest possible response times.
Newly developed IP20 connectors with a pitch of 7.62
mm are only half the size of an RJ45 connector. Thus, two
single-pair Ethernet ports can be installed in the space required for one RJ45 PCB connector, doubling the port
density. These very compact interfaces can, therefore, also be easily integrated into a modular system for PCB
connectors. This connection solution works for many devices and is simple, compact, and pluggable.

PCB connection technology must not only support the design-in process, but also consider future connection and
communication technologies to ensure the longevity of the system. To achieve this, innovative connection technology
must meet innovative modular product design.

Visit Weidmüller to learn more.

48

5G Small Cell Deployments are Booming —

and Redefining the Requirements for
Coaxial Cables and Connectors
Kevin Moyher, Product Manager, Times Microwave

Global connections and data sharing needs are growing by the day, making a high performance communication
infrastructure vital to support economic, social, and infrastructure activities. 5G has emerged as a network that offers
a high level of interconnectivity with the promise to deliver increased peak data speeds, ultra-low latency, enhanced
reliability, enormous network capacity, and increased availability.

However, this revolutionary technology requires substantial expansion and upgrades to existing network infrastructure.
For example, to deploy 5G, the network must be densified, which means more cell sites in more locations to get the
signal closer to users. Small cells are one of the most practical means of attaining this densification.

5G small cell applications use MIMO antennas to enable the delivery of data in the millisecond speed range with low
latency. This type of antenna has multiple-in/multiple-out feeds, which has led to substantial growth in the number of
RF ports, making installation increasingly complex. Furthermore, 5G antennas are also shrinking in size as higher
frequency bands are used to accommodate larger bandwidth requirements, which translates into more antennas —
as well as the corresponding RF cables and connectors needed to attach them — in a much smaller space.

The cables, connectors, and RF solutions deployed in 5G applications are integral for successful signal transmission
with minimal loss or interference. Emerging bundled coaxial cable and cluster connector solutions support the high-
density infrastructure needed for 5G. Key considerations for optimizing RF interconnect systems to accommodate
the unique requirements of 5G deployments include component density and low PIM performance.

Component density
In urban and suburban areas, direct line-of-sight MIMO antennas are capable of
meeting the speed, coverage, and latency requirements of 5G, but operating at
millimeter wave frequencies, their range is short and thus requires a dense network
of antennas. These small cells are also packed much closer than traditional telecom
towers were years ago; some are only about 100 yards apart.

This densification creates numerous challenges related to installation, torquing,

ensuring proper weather sealing, and more. Designing a crucial interconnect system
that will perform well and withstand extraordinary environmental and technical
conditions, reliably and consistently over long periods of time, involves many critical
decisions. In addition, 5G small cells have limited space for equipment so minimizing
 49

size and weight are also key goals. Cable assemblies must be designed to perform reliably while assuming the
smallest footprint possible. Furthermore, with so many components in such a small space, maintenance can be very
challenging. If an interconnect fails, it can be hard to troubleshoot the exact failure point.

The majority of 5G small cell applications are installed outdoors — around lamp poles, rooftops, and telephone poles
— and may be 30-40 feet or more above the ground. As a result, 5G antennas require a lot of RF cable feeds, RF
jumpers, jumper cables, and feeder cables, which can visually create a rat’s nest if not installed properly. All these
cables must be designed to withstand the weather and other elements.

Moreover, installation can be a time-consuming, labor-intensive, and logistical nightmare, creating the potential for
cables to be the weakest link in the system. There are numerous variables to consider. Is it the right cable or the
right port? Is that connector properly terminated to that cable? Is the coupling properly torqued down? Is the whole
assembly properly weather sealed? Are those cables properly captivated? Are the cables properly secured to the
structure? Do they have the proper UV resistance?

Passive intermodulation
Passive intermodulation, or PIM, is a type of distortion that may occur in passive, non-linear components such as RF
cables and connectors. In dense 5G systems, heavy customer usage can generate competing signals. When two
or more signals mix, they can produce an additional undesired frequency. Cables and connectors play a large role
in PIM, which may occur because of something resistive in the interconnect, the junctions between different types
of passive components such as the connector and cable, ferrous materials, inadequate tolerance, or poor torquing.

While PIM is an issue for almost every wireless system, it is more noticeable in cellular applications such as 5G
because the frequency bands used are very close to each other. PIM can create interference that limits receiving
sensitivity, lowering the reliability, data rate, and capacity of the cellular system. This has the potential to result in
decreased system capacity and data rates, as well as dropped calls. To prevent this, carriers often require low-PIM
coaxial cables to ensure the cable and connectors are performing properly and are free of interference.

The solution: bundled coaxial cable and cluster connectors

The cable
A bundled cable design can help create the perfect flexible antenna jumper for applications requiring multiple runs,
such as on 5G small cells located on towers or building-top sites. A spiral configuration of multiple flexible and ultra-
flexible, low-PIM, plenum-rated jumper cables can be created under a common polyurethane outer jacket to promote
ease of installation and improved operation. The individual coaxial cable runs are spun together in such a way that
the combination easily flexes, essentially creating a bundle, which is then run through a large jacket extruder where
a rip cord is placed. This enables four or five individual cables to be fed into the back of a cluster connector. By using
this method and creating a round cable bundle, a seal is also formed to provide extra protection, as the inner cables
are protected by the outer jacket.
50

The connectors
As mentioned above, high coverage antennas like those used in 5G applications have led to substantial growth in
the number of ports on antennas and RF devices. Hooking up the right cables and ports, and proper torquing, are all
concerns in this scenario. Proper weather sealing is also a necessity; a good, but not over-torqued, seal is imperative.

The use of MQ4/MQ5 connectors is an optimal solution as this type of “RF cluster connector” incorporates multiple
RF ports. Bundle cable designs manufactured with standardized MQ4/MQ5 connectors encompass a four-contact
connector and a five-contact connector. These can greatly reduce the number of cables that have to be hooked up,
saving a lot of labor, and creating a more rugged solution. They also make the assembly more weatherproof and UV
resistant.

Using the four or five connector solution eliminates the need to create five individual weather seals, resulting in
tremendous labor savings. Furthermore, this reduces the need to worry about coupling torque. This is critical because
all it takes is any kind of error on just one weather seal to create a point of ingress for water that could create a
multitude of problems. With this cluster connector solution, any potential system troubleshooting becomes much
easier.

Finally, the possibility of hooking up the wrong cable to the wrong port is eliminated. The solution is keyed, so the
cables can only be hooked up a certain way — no torque wrenches, know-how, or special techniques required.

Additionally, the standardized four-contact and five-contact connector designs use a spring outer contact so that PIM
performance is not tied to how well the tip of the outer contact is engaging with its mate. The connection between the
male and female cluster connectors is sealed to IP67 as are the connector bodies and the transition from the cluster
connector to the bundled cable. In addition to the male-to-male bundled harness, the female bulkhead connector
can also be built as a finished assembly that is ready to be installed into the box and engaged with the printed circuit
board.

Finding and qualifying an RF interconnect supplier for 5G applications can be a lengthy and costly process. When
it comes to selecting RF cables and connectors, look for a supplier with a long history of building quality cable and
connectors, along with the skill, processes, techniques, and materials to bring custom solutions to life.

Visit Times Microwave to learn more.

 51

A New Breed of Hybrid Connectors for

IoT and Machine Learning Systems
Bob Stanton, Director of Technology, Omnetics Connector Corporation

Connectors are supporting a dynamic era of technological advancements that center on the need to see, measure,
store, process, and transmit ever-increasing amounts of data. IoT and machine learning systems combine, compare,
and respond to multiple streams of information simultaneously. The latest sensors collect a wide range of information
that was undetectable a few years ago and connect high-speed, low-voltage digital signals to central logic processing
centers.

» An automatic eye data system

Many of these new information networks can no longer follow the long-established standard for wiring and
connections. Their complexity has increased ten-fold while they must also become smaller and more flexible. Today’s
data acquisition methods from sensors, transducers, MEMs, and other membrane-controlled field effect transistors
require their own custom interconnection and power sources.

Connectors and cables must do more than ever

To meet the multiple signal demands of these new networks, hybridized connectors and matching cables combine
power and multiple signal types. Starting with experience and test standards for performance and reliability,
miniaturized cable and connector designs are customized for the form, fit, and functions needed for each network.
Some of the conduit systems must provide power to multiple sensors and collect information from various detection
methods including mechanical, analog, digital, and RF.

» This modified Micro-D connector offers over 5 A of power to a network of sensors. Its 24 pins are spread out to collect data
from multiple sensors. A specially designed cable contains separate sections shielded from each other to handle both digital and
analog data.
52

New learning machines, for example, can offer hyperspectral surveillance, a scanning technology that uses sensors
to identify objects in a spectral image. It can be used to monitor conditions and elements in the food production and
agriculture industries and on satellites for defense purposes. In this process, the surveillance sensors receive analog
data and rapidly convert it to differential digital signal information for transmission. Pressure transducers sense and
send pulse modulation signals from MEMs chips to a central system. Laser focus and position controllers use pulsed
phased-array control signals to pin-point optical information in the field.

These circuits require high density connectors and cable

with special insulation to avoid cross talk from burst signals
within the array. As artificial intelligence and neuromorphic
processing systems grow, specially defined connectors and
cables will be needed to handle each unique sensor within
a system. This might include simultaneously collecting
video imaging from cameras and analog information from
speakers, detecting odors or radiation, measuring tactile
data, and monitoring human health and well-being.

Man-to-machine learning systems may need a wired

connection to perform sensitive procedures. Customized
cabling and connectors can match unique and flexible
machinery configurations.

» Teaching a welding device hybrid circuit modules

Hybrid circuit sensors are designed to fit portable devices for data collection. Hybrid circuits often include a variety
of circuit chips producing different signal types and speeds including digital, RF, and analog information. Micro
and nano-sized connectors are used to pinpoint data and route it to central collection points while simultaneously
delivering power to the sensors. The low-power hybrid circuits save space and weight, and fit well with micro-cable
and connectors that are specifically designed to support signals from the various boards within the many hybrid
circuits used in the machine or system.

Size and shape

Reducing the size and weight of the connector and cable system
supports the placement of sensors and detectors in many
places, including on mobile equipment. Each interconnect
system is designed by first listing the electronic requirements
of the circuit, how it will be used, and what environment it
will be exposed to. Fortunately, many digital sensors can be
served with one independent wire set of 32 AWG insulated
wiring wrapped in differential signal pairs supported by a
dedicated drain wire of similar size. Multiple differential
signal sets fit easily into highly flexible shielded cable. Hybrid

connectors are easily formatted for the number of digital sets

needed and can allow room for a power supply pair on one end
of the connector insulator.

Connector shapes and mounting system formats are fit to match

the form and function of the machining devices. For example,
narrow jaw systems in robotic assembly often reach into narrow
positions to achieve the last stage of assembly. Low profile
rectangular connectors can be flat-mounted on the side of the
robotic arm, saving space.
 53

Small but mighty

Connector bodies or shells may have to withstand very rugged abuse. Modified standard designs of popular Micro-D
and Nano-D connectors combine higher current capacity for power and data pins to control position and force, and
return data to the control machine. Low-profile, metal connectors that contain coax, power, and digital signal capacity
are being used more frequently.

» The hybrid connector shown here is similar to the Micro-D form and offers 19 signal pins, four power pins, and three coax
connections.

Miniaturized circular connectors based on the standard 38999 connector are being designed with a smaller diameter
for better size and fit. Miniaturized hybridized circular connectors are also frequently designed with insulator sets that
offer a mixture of coax and digital signal transmission.

Finding a supplier for custom connectors

Begin by choosing a manufacturer with connector experience in
the key area of interest. The company should have worked with
the combination of micro-miniature sizes, ruggedized reliability, and
multiple designs using power inside miniaturized connectors. Check
for examples of current products that handle both power and digital
signal in one connector and ask for examples of signal integrity and
test capability. System designers should ensure that their design and
manufacturing supplier establishes and tracks test requirements and
quality assurance standards.
» Coax Plus in shielding

For higher digital signal speeds, request high-speed test data, simulations, and eye diagrams of products from
the supplier’s signal integrity engineer. Higher digital signal speeds can generate their own noise and harmonic
interference within the signal pair. Test engineers can help in the design and placement of each signal within the
connector and cable construction.
54

For shape or size changes, a solid model of the design can be quickly completed online by the system engineer and the
connector design team. After the design is approved, 3D printers or smart tooling machines can produce a first-article
connector. The connector supplier’s prototype lab can pre-order cable and assemble a first-article interconnection
system to ensure that fit and function meet the full requirements of the system before volume production begins.

» On-line solid modeling team

A Hybrid Connector Design Check List

Details of the How will the connector mount on the instrument:
Application. -Bolted, epoxied, or clamped
-Panel mount receptacle through a hole
-Header soldered directly to a circuit.
-Edge card assembly

Application -Level of shock

Environment -Degree of vibration
-Temperature range
-Moisture or salt exposure

Cable Questions -Size and shape of route the cable must run
-Size and weight of cable
-Flex cable instead of wire?
-Wire gauge to handle current levels
-Any high vertical reach or drop?
-Flex rate and bend radius for applications
-Cable jacket abuse or friction
-Cable jacket touching humans

Connector -Number of separate circuits

Electronics -RF signals, signal speeds, and impedance
-Digital signals enclosed in coax
-Any pulse or burst signal or power
-Number of high speed digital signals with drain wires
-Analog signals included?
-Power for instruments in the same cable

Connection -Number of mates/de-mates per use

methods -Round or rectangular
-Threaded or ratchet locking
-Twist locking
-Jack screw rectangular
-Quick latching rectangular

Shielding/ -Cable and connector metal shields

Materials and -Amount of EMI or cyber-intrusion protection needed
protection -Metal shells vs polymer
-Overmolded strain relief from connector to cable
-Do materials need to meet NASA or military specifications?

Visit Omnetics toVisit Omnetics

learn more.to learn more.
 55

Rise of the Connector as Modern Day

Digital Influencer
Varun Chandramohan, Amphenol ICC

Today, we exist in an increasingly connected world of products, services, communication tools, and transportation
networks that are designed to help increase our standard of living, make us smarter, and bring us closer to the people
and places we care about.

Fundamental to this is electronics, which have evolved over the past four decades per Moore’s Law, an observation
that the number of transistors inside of chips will expand two-fold every two years. As a result, transistors are
packaged far more densely than ever and breakthrough nano-scale devices are now assembled on multi-layer circuit
boards.

Beyond the chip, other components play critical roles as well. What if boards weren’t tethered by wires? A car’s audio
system, for instance, won’t function if PCB-wire bonding is broken due to shock, strain, or vibration. Connectors,
however, add durability and reliability. In a smart watch, connectors sewn into tiny boards enable it to provide reliable
heart rate readings, for example, and connect to the Internet of Things (IoT), the connected technology that makes
cities smarter, vehicles safer, and factories autonomous.

» Miniature connectors inside a smart watch (Courtesy: ifixit)

Connectors are making inroads into the furthermost corners of our lives as digital influencers.

5G, IoT, and data center

5G, the fifth generation mobile technology standard, caters to smart phones and also to a vast collection of nodes
and sensors in devices used in the commercial, transportation, and medical sectors. These IoT devices are deployed
with specific IP addresses and constantly communicate with each other using low amounts of power. Numerous
traffic channels are simultaneously processed and routed through 5G antennas, baseband units, long haul fiber
optic cabling, and edge-based data centers. Bandwidth must be adequate to prevent latency, as lags in data transfer
would negatively impact performance across the network.

All this cloud-based connectivity depends on data centers. Initially, data centers were complex and centrally located.
Modern data centers are decentralized and compact, providing greater computing power with a lower carbon footprint
and reduced user costs. Hyperscale virtual computing based on commercial off-the-shelf servers replicates the
nuances of compute, storage, and networking handled by dedicated hardware like SAN, NAS, routers, or switches.
This promotes the scalability, modularity, and simplicity required for edge colocation deployments. Open standards
56

from consortia like the OCP and ODCC optimize power distribution to promote energy efficiency and minimalize
environmental impact.

Smart cities and buildings

With 5G and IoT, smart cities are now even smarter. Sensors and cameras installed on poles, traffic signals,
billboards, rooftops, building walls, and underground use ultra-low power protocols like LoRaWAN, where they
monitor and manage public assets related to lighting, environment, weather, traffic, and parking, as well as metering
and monitoring air, gas, water, or energy. Individual buildings are becoming greener through automated HVAC,
lighting, and energy metering. Either fixed or airborne, these systems use AI to remotely process data rather than
waiting to hand it over to the central cloud, creating instantaneous communications that help critical entities like
disaster management respond on time. Early warning systems that alert motorists that pedestrians are present,
streetlamps with information displays, driverless taxis, hassle-free public transportation, and protection of civilian
identity are a few examples of how machine-to-machine communication enriches life in smart cities.

For the consumer

Consumer electronics are smarter than ever. Content streams across HDTVs, game consoles, and virtual reality
headsets. Powerful software and HD cameras on smartphones, tablets, and notebooks can make anyone a creative
artist. Cordless toothbrushes, trimmers, and premium hair dryers spruce up personal care routines. Even our clothing,
watches, wallets, and glasses can have smart capabilities.

Smart technology adds safety and convenience to homes. Garages and doors detect homeowners and let them in.
Thermostats, lights, and blinds adjust to environmental conditions and individual tastes. Smart speakers respond
to commands and remotely operate appliances, entertainment systems, and smart meters. Sensors, plugs, and
switches with AI detect fire or burglary. Smart meters inform utilities of power consumed from the grid or fed back
from shingled solar panels. Smart homes are no longer science fiction, but a commercially viable reality.

Autonomous and e-mobility solutions improve personal transportation. Cameras, lidar, UV, and ADAS steer cars
through lanes, obstacles, and traffic. Charging stations provide fast and wireless EV charging. Light-commute e-bikes
with pedal-assist and on-board computers are joining bicycle sharing programs.

Industry and Energy 4.0

Process-controlled factory automation in the food and beverage, automobile, and material and goods industry involves
industrial PCs and programmable logic controllers (PLC) working servo drives, motors, valves, and actuators using
protocols like industrial Ethernet, TCP/IP, Modbus, and Profibus. Now, Industrial Internet of Things (IIoT) and Industry
4.0 can empower AI to accomplish tasks such as:

• Read and control each traditional PLC, Ethernet switch, PC, or gateway from any corner of the world through a
mobile device or a smart speaker.
• Equip robotic arms to go collaborative and fenceless through dynamic trajectory adjustments to promote worker
safety and save installation costs.
• Bring Ethernet connectivity to each smart sensor or actuator to form an IIoT system and channel their diagnostic
data to the cloud for live tracking and predictive maintenance.
• Perform failure traceability to detect faults and order replacements for worn-out parts.
 57

The renewable energy sector follows industry closely. Wind turbines and solar farms supply fluctuating AC/DC
power to intelligent conversion systems and large reservoir batteries before feeding metered energy to the smart
grid. Numerous intelligent electronic devices (IED) in the grid monitor voltage, phase, current, and frequency of
transformers and circuit breakers and feed diagnostic data through Ethernet gateways to the cloud. Big data and AI
bring efficiency and reduce carbon emissions by effectively managing all aspects from generation to storage, and
from transmission to distribution.

Role of connectors
Interconnect manufacturers work closely with equipment manufacturers and component suppliers to propose, develop,
and test innovative prototypes and solutions that favor commercial rollout. High-speed data, high-power transmission,
and space-savings are priorities, with an emphasis on how electromagnetic susceptibility, thermodynamics, and air
flow affect contact pins, board traces, wires, and housing. Cost-to-performance ratio is tested with varying compositions
of precious-metal-alloy plating. Recent advancements in interconnects like PCIe 6.0 and DDR5 have mirrored
developments in peripheral and memory technologies. Encoding schemes like PAM4, and electro-magnetically
compliant signaling rates as high as 50 GHz, have influenced form factors and interfaces like the QSFP-DD and MPO
32 Fiber. High-performance computing has influenced performance-oriented architectures like orthogonal midplane,
overpass cabling, and cabled backplane systems.

» Amphenol’s Paladin Cabled Backplane solution » This 400Gb/s QSFP DDR8 transceiver is suitable for
transmits around 112G over PAM4 coding. high-end data center applications.

Some connector suppliers even double as system integrators of data center racks and switching cabinets by choosing
the type of fiber, transceiver, cable length, or multiplexing scheme that can be scaled up to 400 Gb/s of bandwidth if
the customer prefers a high-end solution.

Looking inside each sensor, driver, controller, meter, camera, plug, switch, or thermostat that mobilizes smart cities,
buildings, and smart homes, we see connectors placed on or near motherboards, power supplies, batteries, keypads,
radios, speakers, or motors. Some are input-output types like the USB or HDMI, some are board-to-board and wire-
to-board, some are lighting socket compliant drivers based on Zhaga, and some are protected against harsh climates,
water, and dust ingress.

» Zhaga-based FLS Series lighting receptacles from Amphenol.

58

Application diversity is required because not all connectors can withstand shock and vibration inside cars. They must
pass USCAR2 tests and sport error-proof, mis-mating, and floating tolerant designs. Some must meet ADAS-friendly
protocols like Gigabit Ethernet. For e-bikes, connectors sourcing power from battery to motor must have waterproof
sealing.

» Flexible printed circuit connectors can be extremely small » Amphenol’s single-pair Ethernet (SPE) connectors with IP20
with 0.21mm pitch sizes like Amphenol’s product (above). sealing can be used for industrial and automotive wiring.

Connectors are essential to every aspect of electronics, every level or hierarchy, in each industry and application,
from data centers to wireless infrastructure, from factory floor to wearable electronics. As technology influences
connector development, so connectors influence technology. Their simplicity has inspired developments on both a
holistic and revolutionary level. They are vanguards of refinement, precision, durability, and reliability on which novel
designs are conceived.

Visit Amphenol ICC to learn more.

References

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13, 2019. [Online], Available: https://www.mckinsey.com/industries/advanced-electronics/our-insights/capturing-
value-at-scale-in-discrete-manufacturing-with-industry-4-0.

M. Fritsche, et al., “Single-pair Ethernet: The Infrastructure for IIoT,” Automation 2021: IIoT & Industry 4.0 – Fueling
Post-Pandemic Prosperity. June 28, 2021. Available: https://www.automation.com/en-us/products/forms/automation-
2021-iiot-industry-4-0-volume-3.

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A. Varghese, “Why Are Automotive OEMs Asking For Multi-Gig Automotive Ethernet.” Keysight. Jan. 6, 2021. [Online],
Available: https://blogs.keysight.com/blogs/inds.entry.html/2021/01/05/why_are_automotiveo-9SVA.html.

A. Moel, “The Fallacy of Fencelessness and Why Cage Free is Best.” Veo Robotics. Sept. 4, 2020. [Online], Available:
https://www.veobot.com/blog/2020/9/3/the-fallacy-of-fencelessness-and-why-cage-free-is-best.

K. Silverstein, “Solar-Powered Electric Vehicle Charging Stations Are Just Around the Corner.” Forbes. Feb. 10,
2020. [Online], Available: https://www.forbes.com/sites/kensilverstein/2020/02/10/solar-powered-electric-vehicle-
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L. Critchley, “Where Nanotechnology, the IoT, and Industry 4.0 Meet.” Mouser. Jan. 3, 2019. [Online], Available:
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desigo.html.

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nanoelectronics.php.
60

Conforming to IEC Standards: Next-Generation

Ethernet Connectors
Jeremiah Stanek, Technical Marketing Specialist,
Industrial Segment at Hirose Electric USA

Ethernet technology continues to blossom in industrial applications to support real-time control and determinism
of advanced manufacturing systems. Industrial Ethernet delivers a wide range of benefits including lower costs,
higher data rates, and data transmission volume enhancements compared to other technologies, such as fieldbus.
In addition, Industrial Ethernet can handle harsh environmental conditions often found in Industrial 4.0 applications
like factory automation, robotics, and machine vision. As industrial automation systems expand in complexity and
sophistication, so do the demands on higher density connectivity solutions. Once exclusive to networking and
datacom applications, high bandwidth Industrial Ethernet connector solutions must now combine rugged, EMC-
resistant performance with smaller footprints to meet requirements in today’s smart factories.

Market background
According to Mordor Intelligence, the Industry 4.0 market was valued at $86.03 billion USD in 2020 and is expected
to reach $267.01 billion USD by 2026 with a compound annual growth rate (CAGR) of 20.71% over the forecast
period. The increase in the number of connected devices, combined with the massive growth in the volume of data
from field devices and the changing technology landscape, has made it essential for companies to quickly adapt their
products and services to the digital world. Technologies included in the forecast include industrial robotics, IIoT, 3D
printing, artificial intelligence, and machine learning.

» Hirose ix60G Series is a horizontal mount PCB connector that supports space-constrained applications requiring Cat.6a
Ethernet cabling

With the continued growth of the industrial automation market and need for sophisticated monitoring and sensing
technology, Industrial Ethernet has become the preferred method for integrating industrial automation control devices.
Ethernet has evolved from coaxial cables running at 10 Mb/s to a twisted pair capable of data rates up to 10 Gb/s.
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Ethernet can support the vast uploading and downloading activity required for programming, updating, and operation
of industrial equipment. As a result, Industrial Ethernet has simplified the process of equipment programming, as it
can easily be achieved onsite in less time.

Challenges
Implementing a reliable network of industrial equipment responsible for complex operations and data transmission
speeds at upwards of 10 Gb/s is no easy task. Most industrial applications operate in harsh environmental conditions
of some kind. Industrial facilities and equipment are often subject to signal or data interference, dust and moisture
contaminants, extreme temperatures, shock and vibration, and other challenges.

Size constraints, particularly in IoT, robotics, and machine vision applications, are also a considerable design hurdle.
Not only are devices getting smaller, but higher data throughput requirements typically equate to more connection
points in a connector. Simply put, smaller connectors offer more design flexibility on the board to add functionality or
decrease the size of the device. However, smaller connectors often come with a compromise in ruggedness.

Out with the old

Previously, standard I/O connectors could be employed in industrial process and automation equipment. However,
modern industrial hardware features increased I/O requirements and mechanical robustness demands that legacy
connectors cannot meet. Many legacy I/O connection points are prone to damage during handling and installation.

» The ix industrial right angle version eliminates cable bending when space on the interface connection side of the device is
limited. The new connector type allows the cable to be pulled out at a right angle in respect to the mating axis, reducing the
height of the equipment interface connection and making it easier to route the cable in tight spaces.

Modular jack solutions, which dominated the data and networking market, were employed instead to meet many
Industrial Ethernet application requirements. Sealed RJ45 connectors enable point-to-point connectivity for uploading
and downloading data without requiring machine shutdown. The rugged RJ45 housing protects against exposure to
dust, dirt, liquid, and other harmful substances present in industrial environments. The rugged RJ45 connectors are
also resistant to shock and vibration, and IP67/68 versions are specified for both indoor and outdoor use. However,
standard RJ45 jacks, and particularly the high-density connector versions, are susceptible to crosstalk. The signal
and return arrangement of a standard RJ45 jack causes two current loops to overlap. This effects signal integrity and
reliability. RJ45 connectivity also limits the miniaturization of devices. As a result, new connector technologies have
been established to meet design requirements.

» Supporting CAT5e and Cat6a Ethernet cabling, the ix80 Industrial Series I/O connector offers vertical mating for design
flexibility in next-generation industrial modules
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ix Industrial
Since its release in 2017, the ix Industrial Ethernet connector has been used in a variety of industrial markets. The
ix Industrial has been adopted for smart factory equipment due to its space-saving and durable Ethernet connection
design. The ix Industrial offers a size reduction of 75% compared to conventional RJ45 modular solutions. The ix
Industrial also supports 10 mm pitch parallel mounting. The narrow width of the receptacle is particularly beneficial
when multiple connectors are positioned on a single PCB side-by-side. The reduced mounting space enables a high
degree of board design freedom in applications like servo drives and robot controllers. Either more functionality can
be added to a device in the same footprint or the entire device can be made smaller.

The ix Industrial connector plug comes in straight and right angle versions, while the receptacle is available in a
vertical, upright, and horizontal right angled versions to offer even more design flexibility and space-saving options.
The connector is also offered in two keying options (A and B type) to meet application requirements.

Featuring a rugged and reliable design, the snap-in I/O connector has a positive metal lock with a preload spring
mechanism that provides a clear tactile click and ensures complete, secure mating. The preloaded springs are
designed to prevent unintended cable removal, and to extend the operating life to more than 5,000 mating/unmating
cycles.

The receptacle shell is mounted on the PCB via a through-hole solder leg to enhance PCB retention and to resist the
wrenching of the cable assembly, protecting the SMT leads. The wire-termination unit and cable clamp are integrated
into a single plug shell, which prevents the connecting part of the cable assembly from being affected by the load on
the cable.

Because the ix Industrial connector’s receptacle supports THR soldering as a substitute for manual soldering, the
receptacle can be mounted on the PCB containing both THT and SMT components in a single SMT process. This
also contributes to the high PCB retention force. The ix Industrial connector technology features an EMC resistant IEC
PAS 61076-3-124 design supporting Cat.5e (1 Gb/s) and Cat.6A (10 Gb/s) high speed performance. In addition, the
connector also passes Power over Ethernet (PoE++) IEEE802.3bt testing requirements.

The PoE capability and the optimized 360° shielding design, which eliminates EMC and ensures secure high-speed
data transmission, makes the ix Industrial an ideal solution for factory and process automation, machine-to-machine
communication, robotics, sensors, human-machine interfaces (HMI), and other devices needing Ethernet IIoT
connectivity in an automated industrial environment.

In the machine vision market, the ix Industrial has been certified as a GigE Vision standard connector. This global
interface standard developed by the Automated Image Association (AIA) is widely adopted for Ethernet (IEEE 802.3)
communication standards.
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PROFINET
Created by PROFIBUS and PROFINET International (PI), PROFINET is one of the most popular Industrial Ethernet
protocols. The most recent PROFINET Cabling and Interconnection Technology Guideline has recently designated
the ix Industrial mating face as a new standard for Ethernet applications. Published in June 2021, Version 5.0 of the
PROFINET Guideline offers updated standards for PROFINET-compliant cabling use in industrial environments.
The ix Industrial interface is a vital component in the SPC (Specific Passive Components) section for Ethernet
transmission. Using the ix Industrial connector, manufacturers of PROFINET-compliant devices can create smaller,
more compact devices to save valuable installation space in the control cabinet.

The importance of reliable communication and data exchange between industrial equipment has increased with
Industry 4.0. Developed for use in industrial automation and manufacturing environments, the rugged ix Series
combines high-speed performance and a compact design with high reliability and design flexibility. With an innovative
design that is ideal for daisy-chaining applications, the space-saving ix Series connector can facilitate a significant
size reduction of industrial machine vision modules.

Visit Hirose to learn more.

 Power & Data Connectivity Products

Connectivity solutions optimize the delivery of power and data while meeting increasingly
demanding requirements. On the following pages, suppliers with proven expertise present
a range of products to meet numerous application and environmental challenges in support
of today’s connected systems. The products showcased here – including miniature connec-
tors, hybrid connectors, magnetic-based connectors, Ethernet solutions, modular jacks, and
much more -- represent the best of the connector industry.
AMPHENOL ICC
USB 4 Gen 3 Type C connectors combine
power charging, tunneling USB, PCIe
data transfer, and DP video and audio
capability. A power rating up to 100 W
means high-speed data transmission up
to 40 Gb/s, ideal for storage, laptops,
tablets, docking, peripherals, automotive
infotainment, home entertainment, and
more.
BEL MAGNETIC SOLUTIONS
Discrete LAN Magnetics features
magnetic-based solutions for high-
speed computer and networking
applications, focused on devices
compatible with the bandwidth
required to support voice/video/
data networking, high-performance
computing, and storage traffic within
the enterprise space industry and data
centers.
AMPHENOL ICC
ComboStak (hybrid) and PowerStak
(power) are compact board-to-board
connectors. ComboStak combines
existing BergStak 0.8 mm pitch signal
pins with 2.00 mm pitch power blades.
PowerStak is the power-only version.
Both provide high signal and current
density with a wide range of stack
heights.
BINDER
The 818 Series M8 D-Coded connectors
connect miniature sensors to Ethernet
networks across applications that use
the latest automation technology. They
support the high data bandwidths
common in today’s smart factories and
protect from demanding industrial
environments. When mated and locked
they protect to IP67.
AXON’ CABLE
AxoMach are multi-gigabit data rate
links designed to transmit up to 10
Gb/s per lane. They are used for the
interconnection of high-definition
imagery sensors in satellites. AxoMach
cable assemblies are made with low
loss microwave coaxial cables and can
be terminated with different Axon’
Micro-D based connectors.
BINDER
Miniature M16 IP67 circular connectors
according to DIN EN 61076-2-106 are
available with straight and angled cable
or flange versions, and with 2 to 24
contacts with dip solder, crimp, screw
clamp, solder and stranded wires, or
a molded cable. Some versions are
shieldable. Users can expect over 500
mating cycles.
BIZLINK
BzKlip300 is especially designed for
power distribution of data center servers,
hyperscale computing architectures,
modular power supplies, rack-mounted
high-power systems, and industrial
applications. Low contact resistance, gold
plating, and high conductivity ensures
high reliability and system efficiency.
CDM ELECTRONICS
CDM’s extensive wire harness
manufacturing expertise includes a wide
range of wire harness assemblies such
as discrete wire, open bundle, closed
bundle, and waterproof harnesses
for commercial, medical, military, and
aerospace applications.
BIZLINK
The AC Power Whip Connector-
745-07A/B/F/G series high-power
connectors with maximum 32A/10AWG
and 50A/8AWG cables are designed
for AC inputs for power shelves
of standardized servers in data
centers. They are designed for server
powerwhip 600 VAC input, especially
for Open Rack V2/V3 or customized
projects.
GREENCONN
The floating mechanism is characterized
by the absorption of alignment errors
at the contact point of the receptacles.
The dual contacts shift with respect
to the movement of the connector,
thereby achieving flexible range of
motion.
CDM ELECTRONICS
MIL-DTL-55116 QPL connectors from
Amphenol PCD, Eaton, and Power
Connector Inc. provide audio/video/
signal for tactical communications
applications with crimp, solder cup
and solder tail termination options.
Alternative-back-end configurations are
available for most formats of tactical
communications connectors.
GREENCONN
The RAST 2.5 IDC connector is capable
of mating directly or indirectly to a PCB.
It reduces the number of components in
the cable assembly thus saving material
costs and offering design flexibility in
products ranging from home appliances
to automotive lighting.
HIROSE
Hirose ix60G Series is a horizontal
mount PCB connector that supports
space-constrained applications
requiring Cat.6a Ethernet cabling.
I-PEX
LIGHTPASS-EOM 100G for internal
optical cable connections has an
extremely small footprint and transmits
100 Gb/s up to 300 m over multimode
fiber cable. Electrical-to-optical and
optical-to-electrical conversion close
to the processor dramatically reduces
signal loss between the processor and
the edge of the board.
HIROSE
Supporting CAT5e and Cat6a Ethernet
cabling, the ix80 Industrial Series I/O
connector offers vertical mating for
design flexibility in next-generation
industrial modules.
LUMBERG
SmartSKEDD direct connector features
insulation dis¬place¬ment technology
(IDT) with keying pins, positioning
spigot, and locking on the printed
circuit board. Contact pitch 2.5 mm.
INTERSTATE CONNECTING
COMPONENTS
MIL-DTL-28840 connectors, commonly
used for shipboard applications, offer
a high-density insert arrangement
and high-shock performance. They
feature RFI/EMI shielding, scoop-proof
shells, and corrosion-resistant materials
and finishes. They offer maximum
protection against fuels, oils, coolants,
and cleansers.
LUMBERG
SmartSKEDD direct connector features
insulation dis¬place¬ment technology
(IDT) with keying pins, positioning
spigot, and central pin for double
locking on the printed circuit board.
Contact pitch 2.5 mm.
METZ CONNECT
M12 X-coded IP67Jack, for field
assembly, is a connecting link for
system cabling and free cable
connection, suitable per category 6A
for data transmission up to 10 GBit.
With its complete metal shield, it can
be used under difficult transmission
conditions, including applications in
the industrial controls, robotics, and
agricultural controls.
OMNETICS CONNECTOR CORP.
Power Micro-D connectors in sizes 9,
15, 21, 25, 31, 37, 51 are available
with two contact rows. Mating pin and
socket models are available. RoHS is
available upon request.
MOUSER
Amphenol ICC USB 4 Gen 3 Type
3 connectors are compatible with
Thunderbolt 4 interfaces and provide
power charging, tunneling USB, PCIe®
data transfer, DisplayPort video, and
audio capabilities. These connectors
also offer a power rating of up to 100W
and a 40Gb/s data transmission rate.
OMNETICS CONNECTOR CORP.
Hybrid Micro Circular connectors
contain power and signal contacts,
and offer combo connector options
to handle higher power needs and
maintain a rugged lightweight micro-
miniature size. Configurations are
available in various pin sizes and counts
including custom sizes and Micro-D
combo configuration.
MOUSER
Harwin SMT Spring Contacts allow for
flexibility when creating electrical and
grounding connections. With many
configurations and working heights,
these spring contacts provide an ideal
solution when space constraints are an
issue. They are ideal for blind mating
and tolerant to both wiping and sliding
actions.
PHOENIX CONTACT
The single-pair Ethernet (SPE)
connector profile is 50% smaller than an
RJ45 connector. It is easy to integrate
into devices and simplifies circuit
layouts. SPE can achieve Ethernet
transmission up to 1 Gb/s or up to
1,000 m and transmit up to 50 W of
power in a broad range of applications.
SMITHS INTERCONNECT
HBB Series high-power, quick-release
harsh-environment connectors have
compact robust RoHS design in a
metal shell with polarization, push-lock
mating, and quick-release unmating
mechanisms, sealed IPx7 and IP6K9K
when mated, high-reliability Hypertac
hyperboloid contacts rated for up to
500A, and 360º shielding.
TE CONNECTIVITY
Industrial RJ45 rectangular data
connectors are designed for Ethernet
networking in industrial applications
and support data rates of 10/100 Mb/s
and 1Gb/s. Ethernet magnetics allow
for customized Ethernet port layout
optimized for EMC and overvoltage. All
Ethernet Magnetic parts are SMD and
reflow solderable.
SMITHS INTERCONNECT
With Hypertac hyperboloid contact
technology, the NXS system can
withstand data rate application up to
10 Gb/s (per channel) requirements,
including extreme levels of vibration,
shock, and climatic testing above
2100 G. It is designed in a robust
construction with 4 or 12 high speed
quadrax (dual-twinax) modules.
TE CONNECTIVITY
M8/M12 cable assembly solutions (M8/
M12 circular connectors overmolded
to a cord set) safely and reliably ensure
communication between devices and
across networks within an industrial
environment. The ready-to-plug
solution quickly and easily establishes
versatile systems.
STEWART CONNECTOR
The Essential Line of modular jacks
are ideal for common modular
jack applications and support the
transmission of Gigabit Ethernet signals
targeted to hubs, switches, and routers.
This line includes both right angle and
vertical thru-hole mount options for 4,
6, and 8 position unshielded modular
jacks.
TIMES MICROWAVE
INSTABEND are flexible, coaxial
microwave assemblies designed for
interconnects between RF circuit
cards, modules, and enclosure panels.
The cable can be bent very closely
behind the connector, simplifying cable
routing.
TIMES MICROWAVE
The Clarity 70 test cable boasts
steel torque, crush, and overbend
protection with abrasion resistance,
without compromising flexibility. It
is ultra-stable through 70 GHz with
exceptionally low attenuation. The
design includes an ergonomic, stainless
steel protective barrel strain relief and a
hex coupling nut.
WAGO
These three new PFC200 controllers
include a standard version and two XTR
versions for harsh work environments.
Each come with two standard RJ45
Ethernet ports and two 100 Mb/s
SFP slots for fiber optic modules,
helpful where high electromagnetic
interference is a concern or for long
distance networking.
WEIDMÜLLER
Instead of two or four pairs of
wires, Single Pair Ethernet cabling
requires just one pair of wires
for the transmission of data and
power. The simple design and the
associated reduction in weight, space
requirements and installation costs
offer many advantages in an industrial
environment.

WEIDMÜLLER
RockStar® ModuPlug sets new
standards. The modular connector
system solves space problems by
offering increased functionality with
reduced installation space, which in
turn also helps keep the weight down.
And all this with more convenient
installation. Simply more of what you
need and less of what you can do
without.
Multi-protocol, high-speed USB solution for
next-generation designs
USB 4 Type C connectors are compatible with the Thunderbolt 4 interface and
combine power charging, tunneling USB, PCIe® data transfer, DisplayPort video, plus
audio capability in a single Type C connector for all-in-one simplicity. Other features
to note include:

• Power delivery up to 100W

• High-speed transmission up to 40Gbps
• Reversible plug & cable orientation
• Support 4K UHD 60Hz display

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Ed. 11/2021