Interconnection
Designing for remote monitoring applications
As remote sensing becomes more popular Gavin Mintern looks at how a custom connector design was able to provide for both high performance and a harmonious design
R
emote sensing applications are becoming increasingly popular, as they eliminate the need for costly
regular manual measurement-taking, and the data that is collected enables planned intervention and correction in hazardous installations such as chemical installations, industrial plant, oil and petrochemical processing and water switching and monitoring.
An example of a wireless corrosion monitoring system is discussed below. The development of a series of multi-pin connectors were designed and intended to be positioned alongside the standard RF connectors providing a range of products that not only compliment the aesthetics of the equipment, but also provide excellent technical performance.
The Custom 4 way multi-pin waterproof connector has been designed to compliment existing TNC waterproof connectors. The remote sensing system employs a range of permanently installed wireless enabled ultrasonic thickness gauges to constantly measure the thickness of pipes and other critical equipment, and is designed to detect any corrosion or erosion degradation. Intelliconnect has built a good
reputation for its range of waterproof RF connectors and was approached to see if a similar design of connector could be developed for the signal lines. The remote monitoring system had already been designed to use
Intelliconnects’ Pisces connectors for the RF signals. These connectors are waterproof rated to IP68 – and can in fact withstand immersion in 20m of water in their unmated condition for a period of 4 hours.
20 February 2012
This extreme resilience to immersion catered for every possible application of the remote monitoring system; from inland petrochemical plants to offshore oil platforms.
The design brief was to provide a connector capable of handling 3 amps of signal current, with the most important criteria being that the connector should be rated to IP68 in its unmated condition. The connector was to sit alongside the RF antenna terminations which use a waterproof TNC connector, hence the need for a uniform look. The 4 contact pins required needed to be installed into the same style connector shells the RF connectors already specified. To allow for all possible environmental conditions from sub-zero arctic-like conditions in places such as Russia and Alaska to the other end of the temperature spectrum such as the heat of Texas or Saudi Arabia an operating range of -65C to + 165C was a mandatory requirement. In some instances, the signals may be
required to switch or actuate some physical devices so the connector had to be designed to be able to handle power as well as low voltage signals. The maximum space between the contacts in a TNC body shell allowed for the operating voltage to be rated at 300v RMS, along with an allowance for a dielectric withstanding voltage (DWV) of 1000v RMS. The insulation resistance of the connector was defined to be 5000 Mohms, to enable use in a variety of high altitude or high humidity applications. The insert design is keyed to allow easy mating and eliminate the possibility of damage by miss-mating.
Components in Electronics
The durability rating allows for 500 cycles minimum, however in most applications the only need for mating and un-mating is for scheduled servicing. The design allows for use in future applications where the need for several mating and un-mating cycles could be envisaged. All other parts of the connector were designed around the standard material: nickel plating over a brass body to meet TNC specification Mil-prf 39012. This enabled both the 4 way quadraxial connector and the RF TNC connector to be fitted into the equipment and ensure the appearance of a uniformly designed system. The required aesthetics and design functionality were both satisfied, ensuring not only excellent technical performance but also a good looking and functional piece of equipment.
Using this bespoke requirement as a starting-point Intelliconnect have since grown their multi-pin connector range to include a range of multi-pin waterproof connectors from 2 way up to 14 ways. All of these designs are rated to IP68 ensuring they are waterproof in their unmated condition to a depth of 20m for a period of 4 hours minimum. They may be specified into a very wide range of applications from military
communications, to rail traction and the product range is still growing. Intelliconnect design and manufacture a very wide range of standard RF, multi-pin connectors and cable assemblies in their Harlow factory and offer a custom connector design service.
Intelliconnect (Europe) Ltd |
www.intelliconnect.co.uk
Gavin Mintern is Sales Manager, Intelliconnect (Europe) Ltd
www.cieonline.co.uk
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