Interconnection
How to save connector space while preserving flexibility in harsh industrial environments
By Rolf Horn, applications engineer, Digi-Key Electronics I
n the industrial environment, devices that are wired are challenging to replace or upgrade because it is difficult to remove and reinstall wires and cables reliably. Similarly, adding new sensors, a processor, or other components, often requires complete replacement and rewiring.
In addition, the sizes of industrial devices keep getting smaller, limiting available space for multiple connectors. At the same time, an efficient layout for good panel density requires smaller connectors that allow a combination of multiple types of connections within a single connector. The industrial environment poses its own challenges when it comes to maintaining the integrity of devices: it’s important to keep liquids and dust from gaining access and damaging delicate components. Connectorization—replacing hardwired devices with modular connectors—resolves all these problems. These connectors, available in compact forms, allow the combination of multiple wiring types into
Figure 1: A modular connector can handle signals, power, digi- tal communication interfaces, and even pneumatics, all in a single connector. The modules can be quickly and easily changed as required. (Image source: HARTING)
a single connector. In modular form, these connectors can quickly be reconfigured to accommodate modifications and updates without requiring device or cable replacement. Also, environmentally hardened modular connectors seal out dust and liquids, as well as the impact of high- pressure water jets used for sterilization. This article examines the basics of modular connectors, showing how they are chosen, assembled, and utilized. Along the way, it introduces exemplary connectors from HARTING that designers can use for their next industrial system design.
Connectorization using modular connectors
There are two ways to wire power, signals, and digital data into an industrial device or application.
The cabling can be either permanently hardwired, or it can be installed using a connector. The choice depends on a couple of factors. Probably the most important is how frequently the device will be
disconnected and require reconnection. If the hardwired device must be reconnected, each wire needs to be carefully removed and reconnected, resulting in substantial labour costs. The chance for miswiring is high, and
it can take hours of troubleshooting to repair an error.
Using connectors may initially cost more, but once that decision is made, rewiring becomes a plug-and-play scenario where
Figure 2: The nomenclature of the HARTING modular connector components. The frames retain the modules and fit within the housing or hood. The connectors can be opened easily, and modules rearranged, added, or deleted for any required modifications. (Image source: HARTING)
62 June 2023
Components in Electronics
www.cieonline.co.uk.uk
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