Page 11 - ConnectorSupplier.com - How-to-Specify Handbook

Additionally, it’s important to note that current ratings are intended as general guidelines for low-power electronic communications and control applications. Current ratings for power applications are generally set by regulatory agencies, including: UL, CSA, NEC, and others.
Data Speed
The focus on data speed has signi cantly increased over the past few years. Devices are now expected to transmit massive amounts of data to other devices connected by local area networks and the internet using speci c protocols (e.g., USB 3.0, HDMI, or Ethernet). Additionally, when it comes to the critical applications that rugged connectors are typically employed in, the data transfer not only has to be accurate and without interference, but also has to be fast enough to trigger actions within fractions of seconds to ensure the safety of both people and equipment. As such, it is recommended that, when designing for data speed, specifying engineers engage in two rounds of design and testing — rst via software and then by physically testing the chosen connector and cable combination.
Design Simulation and Testing
Designing a connectivity solution for a speci c data protocol requires optimizing the design of both the connector and the cable, but the rst condition for a functional solution is a connector that is capable of handling said protocol. Each protocol requires speci c connector design rules, and multi-protocol connectors combine all of these speci c rules. So, software simulation is the perfect tool for successfully navigating this design process, as it allows product engineers to verify the compatibility of their selected connector and cable assembly with the targeted protocol. Software simulation also allows the effects of design modi cations to be immediately evaluated in both time and the frequency domain, enabling the achievement of optimized designs coupled with a high con dence level regarding the connector’s ability to perfectly match the desired protocols.
Once a design has been optimized for a de ned protocol, a physical product prototype needs to be tested to validate the full characterization using a network analyzer. These devices measure and compare the S-parameters of a cable assembly with the target values de ned in the protocol speci cation, and if one of the parameters falls, make an iteration loop on the design until the cable assembly ful lls all protocol requirements. At this time, the product can be declared protocol compatible.
The second condition for functional connectivity solutions compatible with speci c data protocols is a cable that meets ISO/IEC 11801 speci cations for general-purpose telecommunication cabling systems and delivers high performance as de ned by parameters including: insertion loss (IL), return loss (RL), near-end crosstalk (NEXT), and far-end crosstalk (FEXT). Rugged interconnect solutions also often require cables that are capable of achieving certain speeds, such as USB 3.0 (5Gb/s). In these cases, it’s best to request speci c cable recommendations from the connector supplier, as they have already gone through the trouble of multiple trial and error processes to identify the best cabling solutions for
Figure 2: Characterization and quali cation.
their connectors.
Terminations
Once the electrical and data transfer needs of rugged connector solutions have been addressed, and the foundation of the design has been simulated and tested, it’s time to select terminations. This is an important step because termination types have a direct effect on a connector’s assembly process and sealing capabilities. For instance, connectors with solder contacts are typically easier to seal against moisture ingress, while crimp contacts may offer better eld reparability. However, there are several tradeoffs between the two, including: initial setup cost, suitability for low and high production levels, operator learning curve, heavy metals exposure, and process control. It’s also important to know exactly how and where the connector will be used and whether eld reparability is a requirement, as these
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