FEATURE CABLES & CONNECTORS THE CIRCULAR ROUTE
David Phillips from binder UK guides us through how to select the best-fit circular connector for an application
T
he most common connector type used in many industrial and instrumentation
applications is the multi-pin circular connector. Originally developed some 70 years ago for use in aircraft, they have been continuously refined and improved since to cope with emerging applications in many industry sectors such as communications. Among the versions currently available are connectors designed for use in harsh and dirty environments, medical equipment, and applications where features like the ability to withstand high pressure washing and reliably carry fast data rates are important factors. Up to the 1990’s it is likely that around 80%
of all connectors used in industrial applications were hard wired, with the other 20% supplied connected to a cable assembly. Today, probably only 10% are still hard wired with some 90% supplied pre-assembled. Today’s general purpose moulded cable assemblies are manufactured as commodities around the World – binder also produces cable assemblies - but binder is also a leader in field-attachable circular connectors offering specialised connectivity for more complex and demanding systems. While the rapid development of M2M
communications (the IIoT, for example) has led to many changes in industrial and IT connectivity, there remains many applications where a reliable, robust, hard-wired alternative for signal and data connections will be required – and all systems require a safe and secure power connector. At binder, we divide our circular multi-pole
connectors into five groups: subminiature, miniature, power connectors, connectors for medical applications and specialised versions for harsh environments. There are four main mating methods common
across all connector ranges, offering variations in convenience, access and security: • Snap-In connectors – are simply connected with a straight push, and unmated with a straight pull. This connection form is useful where space is limited, or connectors are densely packed.
• Bayonet connectors – have a simple push and twist-to-lock mating design.
• Push-Pull connectors – provide a strong locking mechanism which released by squeezing the connector body.
• Screw locking – features a very secure screw locking mechanism.
SUBMINIATURE CONNECTORS These are specified for the many applications where size and signal integrity are important. Mating options can include snap, bayonet and push-pull locking, as well as screw locking which
18 MARCH 2021 | DESIGN SOLUTIONS
POWER CONNECTORS Power connectors are required on almost every product or system and are available to suit virtually every low or high voltage application. A variety of contact arrangements are available, some with +PE (protective earth). Solder, screw terminal, crimp connection and moulded cable options facilitate ease of system integration. Shieldable versions are available to meet the requirements of the most extreme EMI environments, with protection options from IP40 to IP69K for both indoor and outdoor conditions. Straight and right-angled cable and flange versions may be specified, and approvals will include UL, VDE and ESTI+ approval.
CONNECTORS FOR MEDICAL APPLICATIONS Medical versions of some industrial snap-in and bayonet connector systems have been developed
can provide better environmental protection. Typically, subminiature connectors are available with from two to eight contacts, in different formats like straight or angled versions and as flange connectors. The different models have a dip solder or solder connection and can be supplied with moulded cables in different lengths. High-quality materials should be specified with the housing and contact bodies made from PUR or PVC, and the contacts made of gold-plated bronze or gold-plated brass offering up to 1,000 mating cycles.
MINIATURE CONNECTORS Offering a greater number of contacts, from two to 24, miniature connectors provide a wide range of connection types such as crimp, dip solder, screw clamp and solder connections, and can allow the use of both stranded wires and moulded cables. Environmental protection to classes IP40, IP67, IP67 shielded or IP68 are available, as are a number of connection options, and straight and angled mounting forms as well as panel mounting. Many are UL and VDE approved and some are ASIG compliant. Gold- or silver-plated brass and bronze contacts are available, typically offering greater than 1,000 mating cycles.
binder connectors for automation applications
binder’s ELC connector system for medical applications
for this specialised application. Made from high quality materials, they provide the quality and reliability required in the medical field and offer up to 5000 mating cycles – which is ideal for many medical systems. binder’s medical connectors offer three to 12 poles with solder and dip solder connections and will meet IP54 up to IP67 environmental protection. Usually available in grey/white material to match medical systems, other colours may be specified.
HARSH ENVIRONMENTAL CONDITIONS Where a conventional circular connector will not be robust enough for harsh environmental conditions such as agriculture and other outdoor applications, specialised connectors will be required. Our harsh environment HEC connectors feature a secure bayonet thread, are rated up to 32A at 600V and are available with five (4+PE), eight (4+3+PE) or 12 power or signal crimp contacts. The connectors are UV-resistant, withstand more than 1000 mating cycles and are VDE and UL approved. Available as square flange and cable versions, they feature an integrated protective conduit which can protect cables up to IP67 and, when mated, up to IP69K.
CONCLUSION Key considerations when specifying a circular connector depend on the application and factors such as operating environment, IP protection if required, number of poles, straight or angled form, choice of locking mechanism and lifetime. Over the years, the versatility of the circular
connector has continued to increase, not only with new pin counts but with methods of termination including crimp, screw, solder and wire clamp, and shielded versions to cope with increases in communications data-rates and the growing requirement for pre-wired connector assemblies. Circular connector specialists like binder
manufacture connectors that can be integrated into equipment or PCB mounted, and accommodate a wide variety of cable types and sizes, increasing still further the range of applications that suit this high- performance connector. As new applications requiring a robust and reliable power, signal or data connection continue to increase, the circular multi-pin connector will remain the go-to solution for the global electronics industry for many years to come.
Binder
www.binder-connector.co.uk / DESIGNSOLUTIONS
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