Feature: Interconnects
Connectors made by a 3D printer
by the RRT quickly and easily in the CAD model, and a new prototype generated if needed. Te final discussion related to anticipated production volumes
takes place at the end of the prototyping stage, and the project moves into full production. Recently, the RRT team dealt with an agricultural monitoring
Custom connectors
can then easily be added. Connectors can be over-moulded to give a strong, sealed and professional appearance to the cable assembly, and other components (such as ferrite beads) can be incorporated, saving PCB real estate – a significant benefit in modern high-density designs. All custom cable designs are fully optimised to ensure they meet performance and cost objectives and, before shipment, a comprehensive test is conducted on each and every assembly, assuring a perfect product.
The process Over the years, Bulgin’s RRT (Rapid Response Team) has simplified the process of specifying a custom interconnect product, thereby making it accessible to everyone – even those with no prior experience. In all cases, the process begins by engaging with the RRT to
discuss the interconnect needs and the application. Te more information provided at this stage, the better the RRT is able to provide value-added advice and suggestions. RRT defines a design concept for the customer. Once signed off, RRT then creates one or more prototypes using the SLS 3D printing process. Following a trial and testing by the customer, these discrete connectors or cable assemblies are tested in the end application. Any required modifications can be implemented
system that required EEPROM to be embedded in each connector. Whilst the design of a robust solution was relatively simple, there were concerns about the manufacturability – primarily whether the heat of the over-moulding process would damage the EEPROM. Several prototypes were made and subjected to field testing that showed the over-moulding did not affect the device, and the project soon saw widespread implementation. Equally, when a remotely-operated vehicle (ROV)
manufacturer needed a custom connector, it approached Bulgin. Te ROVs had to operate 7000m underwater. To cope with the extreme pressures, a custom connector was developed with substantial waterproofing, that conveyed power and data to and from the surface. Perhaps the greatest innovation of this project was a dynamic
pressure-balancing mechanism that allowed the free flow of dielectric oil from the surface to the connector.
Customising connectors with CAD tools
www.electronicsworld.co.uk February 2022 39
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