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Table 3
Another requirement to consider is whether the connector will need to deliver consistent, stable performance in harsh and extreme environments. Connectors designed for indoor environments generally won’t deliver the same performance when exposed to extreme outdoor conditions. Table 4 contains information about various characteristics that should be taken into consideration when selecting rugged connectors for use in harsh environment applications.
Miniaturization
All of the previous design selections will impact just how small the connector can be and what level of functionality one can expect from it. Currently, there is not a single industry that isn’t demanding that new equipment designs are smaller, lighter, and more functional, and frequently while remaining cost-effective as well. Connector design and selection should be addressed early in the product design process to take full advantage of the newest, smallest, and highest-functioning designs available on today’s market.
Table 4: Characteristics and considerations for rugged connectors employed in harsh-environment applications
Great strides have been made with regard to miniaturization in recent years. Today, a single connector can solve connectivity challenges that would have required two or three connectors only a year ago — but it’s important to exercise caution. Specifying engineers should closely examine all aspects of each miniaturized connector, as the effects of these details become magni ed as the voltage and current increases. To ensure suitable selections, compare models for pin size, number of pins, and functionality. Miniature connectors have compact packages that t nicely in small places, but only a few can carry both power and signal. If the pin size is too small, it may not carry the amount of power required or its signal may be more susceptible to interference. Additionally, as connector packages get smaller so does their withstanding voltage. Miniature connectors are also extremely dif cult to terminate, so miniature plugs and receptacles are often sold pre-wired to maintain reliability.
Figure 3: The Fischer MiniMaxTM Series offers miniature connectors that combine signal and power while maintaining rugged characteristics.
Combining miniaturization and data speed is tricky, and only partially due to connector design. If a supplier claims that a connector can deliver data at a certain speed, always request test data and verify. Suppliers should be able provide evidence of achieving certain data speeds and supporting protocols such as USB, Ethernet, or HDMI, as well as to suggest appropriate cable designs or provide fully assembled connector and cable solutions. It’s also important to remember that the combined connector and cable solution must deliver the required speed for a miniaturized solution to make sense for an application.
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