Interconnection
Common myths about custom connectors
Often there is a reluctance to consider a custom interconnect for a design until it is clear there is little alternative. This is largely due to the widely-held view that custom connectors are expensive, the process of customisation would add unacceptable delays to the project and lastly, relying on one manufacturer is risky. These three common perceptions have little or no basis in reality, says Phil McDavitt, MD, Nicomatic UK
Myth 1 - Custom design is too expensive
It is easy to simply compare a quotation for a custom connector design with a standard solution and conclude that the custom route is too expensive, but the real cost of the whole solution and its integration into the system, including “hidden costs” should be calculated in order to arrive at an accurate comparison.
A fairly typical example was a Nicomatic customer that tried to link a PCB board in a box to a panel connector on the other side of the box. Using a standard connector, the customer designed a system with a complex harness between the two connectors and added a cover to provide EMI protection. Using a standard connector solution was complex, requiring the integration of several pins. It used extra space on the PCB and the harness and cover added cost. Approached towards the end of the project for customer support, the solution was a custom connector with a unique pin. This freed up nearly 30 per cent of the board space to be used for additional functions, needed no harness and avoided all the complex
operations. In addition, Nicomatic’s custom connector incorporated an EMI backshell. Space and weight is a critical factor for some markets, especially aerospace. Cost per kilogram should be taken into consideration, for example, fuel consumption is important in defence and civil aviation applications and especially so for space launches - every additional gram means more fuel is needed. Miniaturised custom interconnects enable additional functions in the same space, improve technical performance and enable a higher specification product.
Projects can also have hidden time. A single supplier can not only design a custom interconnect but also enable access to a complete solution, even including different brands of connectors. Managing a single supplier saves valuable project management hours, streamlines processes, simplifies communication and should also reduce lead time.
Collaboration at an early design stage saves cost. Some manufacturers will send an engineer to customer premises to work within the customer team, which is a good
cable or small customisation and 12 weeks for a full custom connector. Speed is achieved due to the capability to machine parts quickly and simultaneously develop a mould – machined parts are used for the prototypes and production switched to moulded parts when higher volumes are needed.
Myth 3 – A mono-source solution is a bad idea
way to achieve an optimum solution within a customer’s technical specification and budget.
If a customer needs to replace obsolete parts, it is less expensive to re-engineer an existing solution than re-design a complete system. This can also be an opportunity to improve overall system performance and integration within the same overall dimensions.
Myth 2 – Customisation takes too long and is too complex How long does it take to produce a custom connector from scratch? Of course, that depends on whether the specification is clearly defined and the capabilities of the chosen manufacturer. Once a custom solution is decided on, the project timeline should be clearly agreed with the supplier. Nicomatic received 1000 customisation requests in 2020 and responded to 90 per cent of these within five days, despite the difficulties of the pandemic. Average lead time was between three and 12 weeks. Usually design work takes one to two weeks, then production takes three to 12 weeks depending on complexity – for example, three weeks for something like a
40 December/January 2022 Components in Electronics
A unique solution makes your design exclusive and keeps you ahead of your competitors. Although it is tempting to think about having more than one supplier to safeguard against supply chain issues, engineers are increasingly inclined to go for a unique solution, which makes a design exclusive and can provide a major technological advantage to keep ahead in competitive markets. However, innovative ideas need the right manufacturing partnership to make them real. Choose a reliable connector partner with technical expertise, experienced in customisation, with multiple production sites and in good financial health. Its production process should be integrated, plus the manufacturing partner should be certified to EN9100 or relevant standards and importantly, be committed for the whole duration of your projects – there must be no sudden obsolescence.
Conclusion
By recognising early that a custom design may be required and opening discussions with an experienced and reliable manufacturing partner, cost, time and inconvenience can all be saved. Co-designing a solution is increasingly undertaken to achieve competitive edge and here the technical expertise of the manufacturing partner is crucial.
www.nicomatic.com
www.cieonline.co.uk
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