Interconnection


Addressing a diverse market


Kevin Canham explains how using connectors incorporating a variety of inserts can meet the needs of rugged device interfaces for data, power and signals in the industrial space


T


he interconnection of different industrial devices or the communication within items of equipment demands versatile device interfaces. Equipment may be used within a factory environment, in harsh environments or outdoors; the device interfaces may have to carry power, data and signals; and the interconnection systems must be easy to install and integrate.


This article explains how it is possible to meet these diverse requirements by using connectors that incorporate a variety of inserts to handle the different signal types, while also being specifically designed to meet the demands of harsh industrial environments. With this approach, it is also possible to add new elements whenever required so that sustainability is also guaranteed.


The demands made on device interfaces


are diverse. A multitude of different requirements have to be taken into consideration and co-ordinated with one another during development, particularly if


diverse environmental requirements placed on these interfaces. The interfaces must withstand various environmental and climatic influences, particularly for use outdoors. Varying climatic impacts require a large operating temperature range, resistance to moisture and hence a high degree of protection. For use outdoors, the interfaces that are employed must also be resistant to ultraviolet radiation, ozone and corrosive environments. In industrial applications, further requirements regarding shock and vibration resistance and resistance to chemicals, oils, greases, cooling agents, cleaning agents and other working materials also play a role. This list of possible environmental influences demonstrates the complexity of the process for selecting a suitable interface family, and indicates the time that must be expended in order to consider and check all conceivable influencing factors.


Proven in practice


PushPull connectors have been successfully used for many years by both device


interfaces in industrial controllers, sensors, drives and frequency converters. PushPull interfaces represent an ideal solution for many tasks because of the simple, positive and intuitive operating concept, the compact and rugged construction with


separate parts for the user. To install the connector, the individual crimp contacts are inserted into the pre-assembled insulation insert, and simply pressing down on the insulation insert causes it to lock into its final position while fixing the crimp


Figure 2. The Han PushPull range comprises inserts for power up to 690 V/16 A, for optical data transmission with LC-Duplex and SCRJ, for Ethernet up to 1/10 Gbit with RJ45 and USB 2.0/3.0, and for signals


IP65/67 protection and the availability of function containers for data, signals and power supply. A typically modern range of PushPull connectors comprises inserts for power up to 690 V and 16 A, optical data transmission with LC-Duplex and SCRJ interfaces, Ethernet connection up to 1/10 Gbit/s with RJ45, and USB 2.0/3.0 for signals (Figure.2). Thanks to these function containers, it is possible to adapt the PushPull connector system to the changing application areas and market requirements simply and swiftly.


Figure 1. Developers of the HARTING Han PushPull interfaces have paid special attention to simple device integration


the devices are going to be used in harsh industrial environments or outdoors. The selection of the right functional insert for data, power and signals is then a relatively simple task when compared with the


24 October 2014


developers and end-users (Figure.1). Typical applications are data interfaces in surveillance cameras, solar inverters and base stations that are deployed directly in outdoor areas, or power and signal


Components in Electronics


This concept is continually being enhanced. The latest step is the integration of 10-position signal inserts with which the manufacturer supports the system’s sustainability. The PushPull Signal connector transmits nominal currents of 5 A on ten contacts with conductor cross- sections up to 0.75 mm2. To ensure EMC interference immunity, the contact inserts are fully shielded like RJ45 data connectors and it is possible to connect shielded cables.


One important customer requirement is simple conductor connection in the field: To meet this need, the PushPull signal connector is assembled before delivery, a process that minimises the number of


contacts in place (Figure.3). The user can easily rectify incorrect insertions that are spotted after the installation when loading the insulation insert.


Typical application areas Typical application areas for these signal connectors are the transmission of serial bus signals such as Profibus, CAN bus, analogue sensor signals or status messages. PushPull Signal connectors can also be used to implement hybrid applications. For example, a part of the mating face can be used to transmit power while other contacts are ready for communication. PushPull Signal connectors are available in the PushPull variant 14 and variant 4 series as defined by IEC 61076-6- 107.


The Han PushPull variant 14 is the


preferred connector for data transmission and for supplying power to peripheral Profinet field devices in accordance with the guidelines of the PNO (Profibus User Organization) and AIDA (Automation Initiative of German Automobile Manufacturers). This is particularly significant in highly automated automotive body construction, where special-purpose tools and equipment for joining


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