Page 6 - ConnectorSupplier.com - How-to-Specify Handbook

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How to Specify Signal Connections
Loreen Katz, Product Marketing Manager – Industrial Field Connectivity, Phoenix Contact USA
Where are signals found in industrial and semi-industrial settings? Everywhere. Devices such as sensors, actuators, switches, valves, and cameras need signal connections to execute control and monitoring processes. As smart devices continue to be added to plant oor operations in ever-increasing numbers, secure, reliable connections will become even more critically important. Today’s devices must handle a wide variety of functions and include features that ensure cost ef ciency, reliability, and safe operation.
When selecting the appropriate connection technology for signal lines, design engineers and device manufacturers have many factors to consider. Aspects including: cost, environment, vibration, connector density, signal integrity, installation methods, and safety requirements should be key factors in the speci cation of appropriate signal connections.
Cost, while an important factor, is often not evaluated regarding applied cost versus simple component cost, and it should be. Engineers and buyers consistently desire cost-effective connectors that perform well and meet application requirements. However, it’s also important to consider the entire process, spanning procurement and manufacturing through to onsite installation and maintenance. The cost of the labor and equipment downtime required for lengthy installations and troubleshooting processes — for instance, identifying and resolving signal loss — can add up quickly, and can be signi cant compared to component price. When selecting connection technology designed for ef ciency, the bene ts of time saving installation processes and long-term operational uptime achieve the lowest applied cost.
Figure 1: HEAVYCON modular connectors from Phoenix Contact offer multiple functions within a single housing to save space.
The overall trend in device manufacturing to reduce size and increase pin count has inspired connector manufacturers to offer high-density products. Signal terminations often need to be made in space-constrained applications, so connector density and the combination of signal wiring with power or data lines have become increasingly important. Choosing connectors that combine functionality with a modular design can provide a serious space-saving advantage.
The environment surrounding signal connections often affects the reliability of the signal. Elements including: dirt, moisture, oils, chemicals, high and low temperatures, and UV and ozone exposure all play a signi cant role in the selection of the materials and sealing capability of signal connections. Additionally, electromechanical interference (EMI) emitted by nearby drives, motors, and other noise-producing equipment can cause signal loss or unreliable signal transmission if the connection is not properly shielded. Using connectors and cabling that offer shielding of the signal from end-to-end will eliminate EMI concerns and support signal integrity.
Many connections in industrial applications are also exposed to mechanical shock and vibration, and the stress of such forces on the connector contacts, wire terminations, or PCB solder joints can cause intermittent to complete signal loss. When selecting connections for high-vibration applications, review the connector design for vibration-resistant construction elements such as: locking screw