TECHNOLOgy REvIEW > continued


What makes an electrical connector suitable for transportation applications?


The modular nature of the heavy|mate connector design provides


Figure 3: Amphenol “heavy|mate” modular metal connector


frames that accommodate either 2, 3, 5 or 7 modules and allows for hybrid connectivity, supporting multiple-pin power or control connections at high voltage (up to 1000V) and high current (up to 240A) as well as signal interconnections including fibre optic, RJ45 and CAN- Bus type connectors. Available contact technologies include machined contacts or lower-cost stamped contacts based on a vibration-proof, double-crimp design using a quality bronze material combined with partial plating to save money. Machine-crimping assembly can deliver further wiring cost savings at breakeven volumes around 60,000 compared to solder, screw or hand-crimping. The insulated body of the connector guides the mating of stamped contacts, preventing contacts bouncing or being pushed out.


connector housing, a metal cable connector shroud and metal locking levers, all contributing to a highly robust design that provides secure, vibration resistant connector mating. Corrosion resistance is achieved with different case coatings to meet various performance specifications and, where competitor parts exhibit surface peeling and rivet corrosion after 100-hour salt spray tests, Amphenol’s highly-resistant coating can protect against much more extreme conditions.


Not all applications require the same level of environmental protection so, where it is not necessary, choosing a lower specification may make sense. For example, the IP67 version of heavy|mate connector saves cost with a more compact design that uses potted rivets and a collar to avoid sealing movement while still maintaining a compatible panel cut. As well as sealing, the heavy|mate connector design also addresses electromagnetic compatibility (EMC) requirements with a special EMC housing that incorporates shielding plates and collars.


Figure 4: Radsok®- technology for high power contacts


High power contacts are provided by using Amphenol’s Radsok®- technology, which enables high current in a small diameter by providing a large contact surface. Figure 4 shows how this low insertion force contact design absorbs vibration and provides a self-cleaning action. The same Radsok®-technology is also used in Amphenol’s “Wall- bushing” power distribution connector shown in figure 5 that provides a high-current, sealed connection through a bulkhead.


Figure 5: Amphenol’s “Wall-bushing” power feed through connector


Connector technology seems simple in principle but is complicated by demanding performance requirements and detailed technical specifications. This article has attempted to unravel some of the issues concerning connectors for transport applications but is by no means a definitive guide. Considerations that may need to be explored further include aspects of reliability and safety, such as how many mating cycles must a connector guarantee or whether approval to VDE, UL or CSA standards are mandated by the target application. Hopefully though, an appreciation of some of the products serving the transport market will help guide the selection process.


www.avnet-abacus.eu 14 focus magazine - issue 15


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16