COVER STORY
Specifying connectors for harsh environments
As technology advances, connectors are increasingly called upon to operate in harsh environments where traditional designs falter. These environments can expose connectors to extreme temperatures, chemicals, high vibration, and mechanical shocks.
It is pivotal to understand the growing demand for connectors capable of withstanding the challenges posed by harsh environments. Whether in industrial automation, automotive systems, or outdoor installations, these applications can test the limits of traditional connector designs, therefore reliability is paramount to ensure uninterrupted operation. This is where Hirose Electric excel with their extensive expertise in connector design and manufacturing processes which allows them to deliver robust, innovative solutions tailored to meet these demands without compromising design flexibility or performance.
In this month’s edition, Anglia explores the key considerations designers must make when specifying connectors for harsh environments and some of the innovative solutions available from Hirose Electric.
Environmental resistance: Connectors in harsh environments must not only provide robust environmental sealing, but they must also retain their performance over years of exposure. Mechanical durability: Mechanical robustness is equally critical for ensuring long-term reliability of the connector and system in which it is used. Mating cycles: Connectors may need to endure 5,000– 10,000 mating cycles without degradation to ensure they are suitable for repeated use in test and industrial environments. Retention force: The design of the connector must prevent cable disconnection under tension, retention forces exceeding 40N can be a common requirement for rugged applications.
A harsh environment can be characterised by several physical and chemical stressors that challenge standard connector performance: Extreme temperatures: Automotive and industrial connectors often need to operate in -40°C to +125°C conditions, with some applications requiring up to +140°C tolerance. Ingress protection (IP): Environments which will expose connectors to dust, moisture, and water require IP67 or higher-rated connectors. In marine or heavy industrial settings, the highest IP69K rated protection against high-pressure, high-temperature water and steam cleaning is critical. Chemical and UV resistance: Connectors used outdoors must be able to withstand prolonged UV exposure, while those used in industrial systems may also require resistance to oils, solvents, and corrosive chemicals.
10 March 2025 Components in Electronics
Vibration and mechanical shocks: Applications including robotics & automotive control systems can expose connectors to vibration levels up to 50G and may require compliance with ISO 16750-3 or USCAR-2 standards. These environments necessitate connectors designed with advanced materials and engineering innovations to maintain reliability under shock and vibration conditions. Compliance with ISO 16750-3 ensures connectors can maintain electrical integrity under sinusoidal and random vibration, while shock resistance protects against impacts from heavy machinery or collisions. Thermal stability: Material selection is critical for thermal stability; materials such as liquid crystal polymers (LCP) and flame-retardant resins can be employed to provide dimensional stability and electrical insulation at high temperatures.
As well as the environment the connectors will be operating in, the system designer also needs to carefully consider the performance requirements of the connectors, some key requirements include:
Hirose’s wide portfolio of connectors include products which are designed to operate reliably under harsh conditions. By leveraging decades of expertise in connector design and manufacturing, Hirose has developed a comprehensive range of solutions tailored to overcome the challenges posed by harsh environments. Their portfolio addresses the critical requirements of automotive, industrial, and outdoor applications with innovative features that deliver unmatched reliability, compactness, and durability. Following is a selection of Hirose connectors that have been designed for harsh environment applications.
The ZE05
series, initially designed for automotive applications,
provides a compact, low- profile solution without sacrificing reliability. With a 2 mm pitch, this miniature
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