Interconnection
Next-generation Ethernet connectors
By Christian Achimov, business development manager at Hirose Electric Europe & Willem Rodenburg, marketing manager at Hirose Electric Europe
W
ith the continued growth of the industrial automation market and need for sophisticated monitoring and
sensing technology, Industrial Ethernet has become the preferred method for integrating industrial automation control devices. Compared to other technologies like fieldbus, Industrial Ethernet offers a wide range of benefits including lower costs, higher data rates, and data transmission volume enhancements. In addition, Industrial Ethernet is designed for harsh environmental conditions often found in Industry 4.0 applications like factory automation, robotics, and machine vision. As industrial automation systems expand in complexity and sophistication, so do the demands for higher density connectivity solutions. High bandwidth Industrial Ethernet connector solutions must now combine rugged, EMC-resistant performance with smaller footprints to meet Time-Sensitive Networking (TSN) requirements in today’s smart factories.
Market background
According to MarketsandMarkets, the Industry 4.0 market was valued at $73.90 billion USD in 2022 and is expected to reach $165.50 billion USD by 2026. The emergence and implementation of IoT, IIoT, artificial intelligence (AI), machine learning,
3D printing, cloud services and 5G into manufacturing processes are key factors driving market growth. These technologies enable OEMs to create smarter factories with more connected automated devices that transfer higher volumes of data.
Challenges
Implementing a reliable network of industrial equipment responsible for complex operations and data transmission speeds at upwards of 10 Gbps is no easy task. Most industrial applications operate
in harsh environmental conditions of some kind. Industrial facilities and equipment are often subject to signal or data interference, dust and moisture contaminants, extreme temperatures, shock and vibration, and other challenges.
Size constraints, particularly in IoT, robotics and machine vision applications, are also a considerable design hurdle. Not only are devices getting smaller, but higher data throughput requirements typically equate to more connection points in a connector. Simply put, smaller connectors offer more design flexibility on the board to add functionality or decrease the size of the device. However, smaller connectors often come with a compromise in ruggedness.
The old guard
Previously, standard I/O connectors could be employed in industrial process and automation equipment. However, modern
32 November 2023 Components in Electronics
industrial hardware features increased I/O requirements and mechanical robustness demands that legacy connectors cannot meet. Many legacy I/O connection points are prone to damage during handling and installation.
Modular jack solutions, which dominated the data and networking market, were employed instead to meet many Industrial Ethernet application requirements. Sealed RJ45 connectors enable point- to-point connectivity for uploading and downloading data without requiring machine shutdown. The rugged RJ45 housing protects against exposure to dust, dirt, liquid, and other harmful substances present in industrial environments. However, standard RJ45 connectors are not resistant to shock and vibration. Contact- to-contact motion from vibration can cause micro fretting, leading to premature failure. RJ45 jacks, and particularly the high-density connector versions, are susceptible to crosstalk. The signal and return arrangement of a standard RJ45 jack causes two current loops to overlap. This affects signal integrity and reliability. RJ45 connectivity also limits the miniaturization of devices. Specialty industrial RJ45 connectors are available to reduce micro fretting, but the versions are expensive and still sensitive to interference. As a result, new connector technologies have been established to meet design requirements.
The next-generation
Since its release in 2017 by Hirose Electric, the ix Industrial Ethernet connector has been used in a variety of industrial markets. Multiple suppliers offer a wide range of availability and second source strategy to customers. The ix Industrial connector has been adopted for smart factory equipment due to its space-saving and durable Ethernet connection design. Offering a receptacle volume reduction of 75 per cent compared to conventional
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