Interconnection
it is difficult to miswire, reducing the need for skilled labour. So, using connectors to replace hardwired cables—called connectorization—offers many long-term benefits.
If modular connectors are used, it increases the flexibility of the installation. Consider a modular connector that can handle power, sensors, analogue and digital signals, and even pneumatics (Figure 1). There are a wide variety of modules available. The example shows an RJ45 and a USB serial data bus, three multi-pin modules with a range of pin diameters, and a module with triple pneumatic lines.
Modular connector configuration There is a simple nomenclature of the various components of a modular connector shown in Figure 2. The fixed portion of a base connector is a housing. The mating end of the mobile part is a hood. Frames fit within the housing or hood and serve to lock the modules in place. Connectors can be configured with extra space for future expansion by using dummy modules. The two mating connectors are fastened together using a screw or latching lever lock. Hoods can have top, multiple top, side, or multiple side cable access. The housing can be accessed from either the top or bottom.
Given the large number of available modules, housings, hoods, and other connector elements HARTING provides, it can be a complex undertaking to select the right options. HARTING simplifies this process with an online configurator that makes it easy to select and design a modular connector (Figure 3).
The configurator guides the designer in the selection of wire, data, optical, and pneumatic elements for the connector. Each element presents choices for the user to match with the intended design. In this example, the electrical elements are chosen. The user enters the number and types of wire media, the current-carrying requirements, and a few other design related questions. The configurator quickly shows a few possible configurations, listing the parts while also providing an isometric drawing of the assembly (Figure 4). The design is fully documented with downloadable parts lists, 3D models, data sheets, type sheets, and product declarations.
In the example shown, the questions included the type of base, desired lock, the number of conductors, maximum current and voltage levels expected, and the
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Figure 3: The HARTING Han online configurator user interface simplifies the design and selection of modular connector components. (Image source: HARTING)
environment. The resultant configurations included the HARTING 09400060311 panel- mounted base. The base is diecast aluminium using screw lock and is rated for harsh environments. This base was mated with a HARTING 09140060371 dual module, hinged, heavy-duty retaining frame. This frame has space for two modules. The
Figure 4: A configurator rendering of a six-pin wire plug and base receptacle, along with its associated base, hood, and cable clamp. (Image source: HARTING)
module chosen was a six-position female module, the HARTING 09140063101. The associated silver crimp pin sockets are the HARTING 09330006220 for 20 AWG wire. The cable side of the connector is based on the diecast aluminium HARTING 19400060411 connector hood with its associated HARTING 09140060361 heavy- duty, dual-module retaining frame. This frame accepts the HARTING 09140063001 male module with HARTING 09330006121 20 AWG silver crimp pins. The hood assembly is topped off with a HARTING 19000005090 brass cable 9-16 clamp. The base and hood accommodate two modules, so any unused positions can be filled with dummy modules, such as the HARTING 09140009950.
Environmental protection All the HARTING Han HPR components operate over a temperature range of -40°C to +125°C and are sealed and environmentally rated at up to IP68 and IP69K.
The ingress protection (IP) ratings, defined under IEC 60529, express the degree of protection that the connectors’ components offer from external effects. External effects include mechanical shock, foreign bodies, humidity, dust, and liquids like water, fuel, cleaning fluids, coolants, and oils. The first number in the IP rating is the resistance to solids. The rating can vary from 0 to 6. The number 6 represents the highest level of protection. Connectors with a 6 rating are dust tight and offer full protection against solid particulates. The second number in the IP rating is the
resistance to liquids. This number ranges from 0 to 9. A rating of 8 means the device is watertight and protected from water pressure. The 9K rating indicates protection from steam jet pressure cleaners and similar pressure-driven liquids. Therefore, a rating of IP68 or IP69K is excellent.
The HARTING Han HPR series is intended for harsh outdoor environments. The diecast aluminium hoods and housings have an epoxy powder-coated finish giving them excellent corrosion resistance, while also being well-sealed against wet conditions. The metal components provide excellent electromagnetic compatibility characteristics.
For multiple installations using the same connectors, this series of connectors offers up to sixteen coded keying positions to assure correct cable mating. Additionally, the HPR compact series saves space and reduces weight by being up to 25 per cent lighter than corresponding HPR standard connectors.
Conclusion
Ensuring connection integrity, flexibility, and expandability—while conforming to form-factor requirements and the rigours of industrial environments—can be challenging for designers. As shown, connectorization based on a highly configurable, compact and modular approach, with an easy-to-use online connector element selection tool, greatly simplifies the process.
https://www.digikey.co.uk/ Components in Electronics June 2023 63
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