Interconnection
How to meet Industry 4.0 high density and robust connectivity requirements
By Rolf Horn, applications engineer at Digi-Key Electronics T
he need for high-density, fast and reliable Ethernet connectivity is growing in Industry 4.0 applications like robotics, machine vision,
controllers, servo amplifiers, and servers. Ethernet connections in Industry 4.0 devices need to support communications speeds up to 10 gigabits per second (Gbits/s), be protected from electromagnetic interference (EMI), provide secure mating and locking mechanisms to prevent unintended cable removal, be able to withstand high vibration conditions, and have long mating/ unmating lives. These connectors must be compact enough to support the increasing interconnect and system densities of Industry 4.0 applications.
While legacy RJ45 Ethernet connectors can satisfy some of these requirements,
they are relatively bulky and do not provide the installation flexibility required for today’s designs.
To meet these challenges, designers can instead turn to ix industrial connectors for high-speed Ethernet cables, including Cat5e (1 Gbit/s) and Cat6a (10 Gbit/s). These connectors are 75 per cent smaller than RJ45 connectors, provide high levels of EMI protection and electromagnetic compatibility (EMC) for secure data transmissions, and comply with IEC 61076- 3-124 requirements.
This article begins with a comparison of RJ45 and ix industrial connector options. It then looks at type A and type B ix connectors for Ethernet and non- Ethernet connectivity, and reviews the variety of configuration options available for ix connectors, along with some
Figure 2: Five through-hole tabs on the socket protect the signal contacts, enhance shock and vibration performance, and improve the EMC performance of ix connectors. (Image source: Hirose)
representative connectors from Hirose. It closes by presenting tools for the assembly and testing of ix cables to ensure correct implementation.
RJ45 versus ix connectors Many Industry 4.0 applications need modular connectivity for rapid deployment and reconfiguration. These systems often combine legacy equipment with new designs. They use high-speed industrial Ethernet and other protocols that require interoperability and high availability. So- called registered jack (RJ) connectors are common in legacy equipment, with eight- pin, eight-contact (8P8C) RJ45 connectors for basic Ethernet connectivity. Emerging Industry 4.0 systems require increases in interconnect densities and flexibility. In addition to being 75 per cent smaller than RJ45 solutions, ix connectors enable parallel 10-millimeter (mm) pitch mounting, and six ix connectors can fit into the same printed circuit board (pc board) space as three RJ45 connectors (Figure 1).
Rugged and robust
Figure 1: Their 10 mm mounting pitch allows six ix connectors to fit into the same pc board space as three RJ45 connectors. (Image source: Hirose)
34 February 2023 Components in Electronics
IEC 61076-3-124 provides the specifications for the dimensions, mechanical,
electrical, transmission characteristics, and environmental requirements for ix connectors. The ix connectors from Hirose go beyond IEC 61076-3-124 and meet the requirements of JIS E4031, the Japanese industrial standard for shock and vibration testing of railroad rolling stock equipment. They also meet the GigE Vision camera interface standard that supports the use of Gigabit Ethernet for fast image transfer using very long and low-cost standard cables. Their high-current contacts support the use of power over Ethernet (PoE) and PoE+ applications as specified in IEEE 802.3af and IEEE 802.3at.
The ix connector system was designed with industrial applications in mind from the outset, while the RJ45 connector was initially developed for use with consumer and business telecommunications equipment and has been adapted for use in industrial settings. For example, ix connectors have two snap-in locking hooks made of metal that provide both haptic and audible feedback to confirm a secure connection between the plug and socket. Industrial RJ45 connectors have a single locking hook.
The shell design of ix connector
www.cieonline.co.uk
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