INTERCONNECTION Designing Custom Connectors and
Cables for Modern Applications Scott Unzen, Director of Marketing and Market Development
T
he rapid advancements in electronic devices are revolutionising industries, driving new capabilities and enhancing our lives. Modern technologies in image collection, data acquisition and signal processing demand faster information routing systems with minimal delays. As industries digitise, from machine-learning robotics to laser data transmission and automated single-board computers, the need for specialised connector and cable systems becomes critical.
Diverse Applications Requiring Tailored Connector Designs
Tailored connector designs are essential for a wide range of applications, from medical devices to defense systems and space technology. In the medical field, sensors have evolved from measuring EEG and ECG to being applied to almost every body function. Neuromorphic computing devices, which mimic the human brain’s high-speed, parallel processing, are being developed for medical use.
In industrial settings, machine-learning computers are now employed in factories to assemble automobiles and other equipment using image and sense-controlled systems. Hyperspectral imaging from orbital surveillance sensors collects digital data in three dimensions, identifying various material types within images. In defense, satellite constellations continually scan the Earth and relay massive amounts of data through high-speed laser transmission systems, far surpassing the older microwave radio communications.
Remote robots and autonomous weapons, controlled from safe distances, rely on high-speed digital control and position information. In all these applications, there is a critical need for ruggedised miniature connector and cable systems. Designers require connectors that offer specific attributes, such as size, weight, latching mechanisms, mixed signals and shielding.
The Process of Tailoring Connectors
Identify Specific Needs: Define the size, shape, weight, wire count, signal types and mounting or latching requirements. Review Existing Designs: Explore proven products and materials that match your
Case Studies in Custom Connector Design
One example of custom connector design involved a high-speed digital communication system for dismounted soldiers, which
30 JULY/AUGUST 2024 | ELECTRONICS FOR ENGINEERS
needs. This initial review helps in identifying solutions that may already exist or need slight modifications.
Request 3-D Models: Obtain rapid 3-D parts based on solid models that fit your design. This step allows for visualising and testing the design before committing to full-scale production.
Prototype Development: Get a one-off real product from the prototype group for testing and refinement. Prototyping helps in identifying potential issues and making necessary adjustments. Finalise Design Requirements: Specify current and voltage levels, exterior jackets, shielding and other attributes. Consider factors like limpness, flexibility, exterior exposure and the number of connectors and leads.
Testing and Production: Request electrical tests and data from early models or order a low-volume production run for full testing and QA. Early collaboration with the electrical design team can identify existing cable designs that meet the requirements, such as using higher impedance coax signals for protection from EMI or cyber issues.
required rugged, lightweight cables and connectors. The design needed a combination of power pins and USB-signal pins. The design team, including electrical and mechanical engineers, collaborated with defense designers, reviewed current products and shared solid models online. Prototypes were constructed, adjusted for signal speed and sent for testing, solving the problem of wearing a communication cable on the battlefield.
Another example involved a high-density circuit board with a camera lens mounted for a low-weight, rugged robotic arm. The design required 16 pins and wires and the solution employed a Nano-sized pin to socket system proven in military quality testing.
Importance of High-Density Connectors
For high-density single-board computers, standardised Micro and Nano-sized connectors have proven performance during lift-off and in orbital satellites. These connectors are critical for communication systems that beam signals to Earth. High-speed digital communication systems often require differential signal pairs with individual drain wires within shielded sets, emphasising the need for managing impedance and matching electrical lengths for optimal performance.
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