Miniature Cable and Connectors for Extreme Environments

Miniature Cable and Connectors for Extreme Environments

By Omnetics Corporation

Miniature Cable and Connectors for Extreme Environments: A Guide by Omnetics

The rapid evolution of silicon chip technology has expanded the horizons of electronic systems. From end-of-arm robotics to deep-sea surveillance, from Mars rovers to military tech in challenging terrains, the demand for durable miniature cable and connectors is on the rise. Omnetics, an industry expert, sheds light on the design essentials for these critical components.

Understanding the Environment

Before diving into design, it’s crucial to understand the environment the equipment will operate in. While industry standards like Mil-DTL-83513 for Micro-D connectors provide a general guideline for rugged performance, many applications demand connectors that can withstand conditions far beyond these standards.

Designing for the Extreme

Extreme performance doesn’t always mean the harshest conditions. Sometimes, it’s about enduring high-speed motion or millions of operations daily. To ensure optimal performance:

  1. Develop a Checklist: This should detail potential hazards and help in selecting the best materials, latching methods, sealing, and insulation techniques.
  2. Custom Design: Often, standard connectors might not fit the bill. Leveraging modern design systems like 3-D modeling can help in creating application-specific connectors and cables. Collaborating closely with connector designers can lead to a prototype in just a few days.
  3. Key Considerations:
    1. Mechanical: Shock, vibration, physical abuse, locking mechanisms, water seal specifications, corrosion resistance, etc.
    2. Electrical: Signal integrity, EMI protection, connection reliability, electrical breakdown resistance, etc.
    3. Environmental: Temperature fluctuations, UV exposure, chemical exposure, dust, explosion-proof requirements, etc.
    4. Cable: Bend radius, motion stress, crush resistance, immersion type, salt exposure, etc.

Case in Point: Petroleum Development

In industries like petroleum research, equipment often faces temperatures up to 250 degrees centigrade. Designers must account for the duration and intensity of such exposures. As temperatures rise, electrical resistance increases, affecting circuit conductivity. Connector insulators must withstand these temperatures without deforming. Additionally, cables should be made of the right metal alloys and be insulated with specialized jacketing to prevent brittleness.

In Conclusion

Designing connectors and cables for extreme environments is a meticulous process. By understanding the specific challenges and focusing on preemptive design and material selection, one can ensure optimal system performance. Trust in industry experts like Omnetics to guide you through this intricate journey.




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