Supplement: Interconnection


Specifying connectors for harsh environments


David Phillips, managing director of binder UK, discusses how increasing automation and computerisation of heavy farming and construction equipment leads to the growing demand for connectors capable of withstanding extremely harsh operating environments.


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n recent years has been a dramatic shift in the design of heavy outdoor machinery and equipment with a move from mechanical and hydraulic components to electro-technical devices incorporating sophisticated, computer-controlled electronics and telematics systems. Such innovation has dictated the increasing need for “harsh environment” connectors suitable for use in these difficult conditions.


Ensuring reliability whatever the conditions


Serving as vital links for power and signal transmission in numerous applications, harsh environment connectors are essential in modern engineering. In harsh, outdoor conditions, where materials and designs are tested to their limits, the reliability of these connectors is critical. These connectors must possess unique characteristics and meet stringent requirements to ensure the reliability of applications across demanding sectors.


What are "harsh environment" connectors?


Harsh environment connectors and weatherproof cable connectors are specifically engineered to perform reliably under conditions that would challenge standard connectors. They can withstand extreme temperatures, high humidity, chemical exposure, dust, and physical stresses like vibration and shock. These connectors are crucial in industries such as industrial automation, agriculture, automotive, heavy machinery, renewable energy, aerospace, military, and marine, where failure is not an option. There are various types of harsh environment connectors, each designed to meet specific application requirements. At binder, we specialize in circular connectors, known for their ease of connection and frequent use in industrial settings. Other connector types available include rectangular connectors, which


30 June 2025


offer high density; fibre optic connectors, which enable high-speed transmission in telecommunications; and coaxial connectors, which are used in communication systems.


The key characteristics required Outdoor electrical connectors for harsh environments must possess several key characteristics to ensure performance and reliability. Durability is crucial for connectors used in extreme conditions, requiring robust materials and construction techniques to withstand physical and environmental stresses such as shock and vibration. The choice of materials is vital: metals like stainless steel, aluminium, and brass are chosen for their strength and corrosion resistance, while high-performance polymers such as PEEK (Polyether ether ketone) and PTFE (Polytetrafluoroethylene) provide excellent chemical resistance and mechanical properties. Rubber and silicone are used for their flexibility and sealing capabilities,


Components in Electronics


Harsh environment connector solutions


ensuring effective ingress protection and long-lasting durability.


Sealing is equally crucial, and harsh environment connectors must achieve high IP ratings IP67, IP68 or IP69K to protect against water, dust, and other contaminants. These connectors must also demonstrate high resistance to chemicals, damp heat and extreme temperatures ranging from -40°C to 100°C, and other mechanical impacts. Above all, reliability is essential, ensuring consistent performance under continuous use and extreme conditions for long-term functionality. Connectors must comply with standards and certifications to ensure they meet performance criteria. Industrial standards, such as ingress protection ratings, indicate the levels of protection against environmental factors and ingress.


In explosive environments, classified as “Class 1, Division 2” (C1D2) according to international standards, it is crucial for harsh environment connectors to ensure safety, durability, performance, and compliance. These connectors are often installed in areas where flammable gases, vapours, or liquids might be present under abnormal conditions. Additional standards focus on material resistance to salinity, enabling connectors to withstand saline environments like saltwater.


As a specialist in circular connectivity, binder provides harsh environment connectivity solutions designed to endure extreme conditions. The HEC series 696 (Harsh Environment Connector) is the top choice for robust outdoor connectors. Available in square flange and cable versions with an integrated protective conduit, this power connector offers protection up to IP67, and up to IP69K when mated. It is uniquely UV-resistant and has VDE and UL approvals. The high mechanical load capacity is demonstrated by over 500 mating cycles for the 12-pole version and more than 1,000 mating cycles for the 5- and 8-pole versions. The rapid growth in use of sensors in outdoor harsh environments means the “go-to” industrial standard M12 connectors are increasingly being used for outdoor applications. Given binder’s long history in being a market leading manufacturer of M12 for indoor applications, it is no surprise that there are M12 connectors specifically designed for outdoor use in harsh conditions. These connectors feature stainless steel locking mechanisms, with options for either stainless steel or UV-resistant plastic housings and offer protection up to IP69K. A distinctive feature of our M12 connectors for outdoor applications is the protective cap, which ensures resistance to dust and water when unmated. Additionally, these connectors are temperature and chemical resistant. Connector manufacturers like binder are meeting the challenge of increasing automation and digitisation in all industries and providing reliable power, signal and data interconnect solutions for equipment used in harsh environments. With innovative design and the careful selection of materials it means however tough the application or demanding the conditions may be, there is a connector solution to suit.


www.binder-connector.co.uk www.cieonline.co.uk


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