Interconnection
robotics all depend on real-time data - field operational and environmental conditions are far from ideal. Equipment might have to tolerate extreme temperatures, dirt, and windstorms without losing signal integrity and speed. All hardware equipment - down to the connectors used for communications, networking, data, and power transmission in the field - needs to be ruggedized.
Exacting specifications for rugged connectors
Not all rugged connectors are the same; a variety of operating conditions dictates connector characteristics. A few best practices before choosing a connector include: The end-use application: It is important to consider whether the connector will be used in medical settings - in which case it might have to withstand sterilization - in a military war zone, or underwater. ITT Cannon’s CA/5015 connectors, for example, are rugged interconnects designed for the most demanding applications. Originally developed for commercial aviation, these connectors are now widely used in the military, transportation, industrial, and heavy equipment sectors.
Weight of final system: Weight can affect the performance of a connector simply by increasing pressure on the ends and causing wear and tear. Weight also matters for battery-powered systems like robots or semi-autonomous machines, as the power needed to lug extra weight can shorten battery life. Weight also determines the material of the shell casing for the connectors. Housings made of lightweight aluminium decreases the final weight.
Cybersecurity and the need for stealth: Military operations especially call for systems that can avoid detection by the enemy. This requires specialty shielding techniques in rugged connectors. Full- metal backshells preserve electronic signals and prevent electromagnetic
Figure 1: ITT Cannon’s TBF10SL-4PS-B rugged circular connector uses a bayonet locking mechanism. (Image Source: ITT Cannon, LLC)
interference. ITT Cannon’s CA/5015 series offers an extensive range of backshells with connections using individual wires or jacket cables in shielded or unshielded versions.
Connector shape: Connectors come in a variety of shapes, including circular, rectangular, blade, or modular, to name just a few. The circular connectors are the most common variation to transmit power, signal, or data. It is easier to align pins during mating, and the circular design provides compact sealing. Circular connectors have many pins or contacts arranged in a specific grid pattern to accommodate the various kinds of connections needed, such as power or data.
Kinds of locking systems Once the connector links two systems, it needs to be locked into place so the connection does not come loose and affect the transmission of power, data, or signal quality. The most common locking systems include a screw-like threaded coupling
mechanism to hold connections firmly in place, and push-pull where connections lock together when pushed and release when pulled. Connectors like the TBF10SL- 4PS-B from ITT Cannon (Figure 1) have a bayonet mechanism, which has pins and grooves that lock into place with a twist. Of these, the threaded coupling mechanism offers superior vibration resistance, which is especially useful in aerospace and military applications.
Mating cycles
A mating cycle is the process by which the plug and receptacle connect and disconnect. Repeated plugging and unplugging of equipment can cause wear and tear on leads in the connector. As a result, connectors are rated by the number of mating cycles they can withstand. A reliable unit can handle hundreds of such couplings without significant damage.
Ingress protection The International Electrotechnical
Commission (IEC) instituted a series of ratings to gauge the effectiveness with which electrical equipment can ward off hazards like dirt and water. These ratings are especially important in military operations where equipment must function in severe conditions like dust and hailstorms, and where performance is tested routinely. Repeated exposure to abrading sand or water can corrode electronic leads, lead to poor signal transmission, and create barriers that prevent strong connections. Extreme environments typically demand connectors have a rating of IP68 or higher. These stipulations and a host of others are ones that military specification (MIL-SPEC) connectors pass. Circular connectors typically embrace MIL-SPEC standards like MIL-DT-5015, which the ITT Cannon’s CA/5015 connectors meet (Figure 2). These circular connectors function well across a wide range of temperature conditions from -55°C to +200°C.
ITT Cannon’s CA/5015 connectors are suitable for defence, rail, aerospace, and industrial applications, as well as factory automation and robotics. The series offers five different polarizations through which users can ensure that the components are mated in the right orientation to prevent damaging circuits. The connectors come in a variety of plating options: cadmium, TinZinc (J plating), ZincNickelBlueGen, ZincCobaltBlack, and nickel compositions. The connectors also comply with RoHS (Restriction of Hazardous Substances), a European Union regulation that oversees the use of certain hazardous materials in electrical and electronic equipment.
Conclusion
The vital functioning of electronic and electrical equipment in severe environments is becoming increasingly necessary across various sectors, including discrete manufacturing, oil and gas plants, solar and wind technologies, and industrial operations such as mining. Given that many of today’s industrial and military operations run on real-time data, computing hardware and sensors need frontline-tested equipment to support a robust field infrastructure. Rugged connectors such as the CA/5015 Connector Series from ITT Cannon play a key role in carrying out this mission of data-driven operations in all sectors.
Figure 2: ITT Cannon’s CA/5015 connectors are rugged and versatile solutions for demanding environments (Image Source: ITT Cannon, LLC)
www.cieonline.co.uk https://www.digikey.co.uk/ Components in Electronics April 2025 45
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