What’s Inside...

2. Why do connectors fail? 9. The 6 biggest dangers of

counterfeit connectors
3. Selecting the correct spring-
loaded connector for modern 11. Making connections in
interconnect applications harsh places

7. Four tips to avoid counterfeit and more...

connectors

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Why do connectors fail?
Ideally, your connectors perform to their rated lifecycles. For industrial
machinery, improper designs and other factors can cause connectors to fail
prematurely, which can cause costly machine damage. Here’s a look at some
common causes of failure and how to prevent them.
Wear and tear — Like the example above,
repeated connection and disconnection
of a connector can cause the metal on the
contacts to wear and corrode if exposed to
water, dust, dirt and other harsh elements.
As a result, the mating pins may not properly
engage when inserted into the connector
shell. Always choose connectors rated for
the required mating cycles you will need.
Improper selection — Environments where
there may be moisture ingress require
special connectors. If a standard connector
is used in place of one with an IP68 or
IP69 rating or a hermetic design, water
can cause the connector to fail. Choosing
an undersized connector can also reduce
efficiency, thus making the connector work
harder to keep up with demand. This will
decrease connector life.
Extreme temperatures — If connectors
are not rated for extremely high or low
temperatures, they will eventually fail. If not
rated for high temperatures, the insulation
fails and conductivity will also spike. If
operated at continued high temperatures,
these spikes will add to the temperature
elevation, which can cause corrosion and
eventually, reduced contact force. This can
impact the electrical signal traveling through
the connector and cable assembly, which in
turn can create an open circuit.
While cold temperatures do not impact
connectors as harshly as hot temperatures do,
low-temperature designs should be considered
if you know your application will require them.
Exposure to continued low-temperatures can
cause tin-plated connector materials to soften,
which in turn increases contact resistance. In
addition, cold temperatures can impact other
parts of the connector, like making plastic
shells go brittle.
Improper design and installation — If an
application will experience shock, vibration and
other damaging motions, it is important to find
secure designs that create a strong latch. If not
securely mounted, the connector contacts, the
mating shells and even the cable could suffer
damage. In addition, connector and cable Failure is not an option
assemblies must have proper strain relief and in aircraft connectors.
installation routing — using guided troughs, Illustration courtesy of
Cleaver Brinkerhoff.
cable carriers and cable glands help to ensure
rated assembly life.
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Selecting the correct spring-
loaded connector for modern
interconnect applications
Spring-loaded connectors are available in
multiple high-quality precision-machined
solutions to give designers extensive choice.
CONNECTIVITY IS CRUCIAL in modern
design. The availability of highly reliable
and proven connector technologies that
facilitate miniaturization and connectivity
make a significant contribution to the
growth of modern portable devices and
other applications. Designers must achieve
the right balance between reliability,
suitability and cost for the connectors
they specify. Therefore, the application
and connectivity requirements need to be
clearly understood.
In some applications, the connector is
mated only once; in others—such as
docking stations or chargers—the connector
is integral, meaning that each of these
applications requires a different solution.
In all cases, a correctly applied connector
functions better and lasts longer.
There are several methods for creating
connector pins although the most
dependable is precision machining as it
provides excellent quality and reliability. The
process is highly accurate with exceptional
repeatability. It also offers significant design
and material flexibility, allowing designers to
specify connectors to suit their exact needs.
Typical high-precision pins have a basically
cylindrical geometry and are sometimes
called ‘turned’ pins.
Typical turned pin sizes range from 0.008
to 0.250 in. (0.2032 to 6.35 mm) with tight
tolerances of ±0.0005 in. (0.0127 mm) on all
features that are critical to using the pin as a
connector.
Specifying spring-loaded connectors
The main component in spring-loaded
connectors (SLCs) are the spring-loaded
pins (sometimes called spring-loaded
contacts, spring probes, or Pogo Pins)
that provide a highly reliable, interconnect
solution for many demanding applications.
3
The spring is the
critical component
in an SLC
Each pin is precision-machined to ensure a
high quality, low resistance and compliant
connector, thereby giving it an edge over
other technologies.
Spring-Loaded pins typically comprise
at least three machined components
assembled with a spring allowing a range of
movement. Each component is electroplated
with gold over nickel ensuring excellent
electrical conductivity, durability and
corrosion protection for life.
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Selecting the correct spring-loaded connector for
modern interconnect applications
Many options requiring should be
considered when specifying SLCs, including
the basic requirements of voltage capability,
current handling and contact resistance.
While vertical mounting is most common,
certain applications require the horizontal
mating of two (or more) boards. Right-
angle pins and targets (both through-hole
and surface-mount) on a 0.100 in. (2.54
mm) or 0.050 in. (1.27mm) pitch solve this
challenge.
SLCs often carry both power and signals
within the same assembly. Standard power
pins carry currents up to 9 A with only a 10°C
rise above ambient. Where higher current (or
lower temperature rise) is required, pins may
be doubled up, or larger pins used, especially
for ground connections.
Specifying different length spring pins
in an array allows ‘make-before-break’
connections. This is especially useful where
power needs to be applied to a circuit
before signal connections, or key signals
need to mate sooner or later, based on the
application requirements.
Depending upon the application, different
travel distances or spring forces may
be required. For complex, multi-board
assemblies, double action SLCs are available.
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SLCs are able to mate with many
different surfaces as a good
connection is made when the
plunger/piston contacts any
flat or concave plated surface.
Spring pins can mate with non-
parallel surfaces, provided the
mating force is applied axially
to the piston/plunger. Lateral
engagement or side-loading may
Spring-Loaded pins are available in many shapes
cause damage.
and sizes to suit a wide variety of applications.
By using spring-loaded
connectors and mating with PCB
pads, one side of the ‘pin and
SLC technology is inherently versatile; socket’ combination is eliminated, leading to
pins with solder cups or crimp barrels savings in component cost and production
are suitable for wire termination.
Various sizes are available offering
the ability to accommodate wires up
to 16 AWG, with 9 A current handling
capability.
Generally speaking, it is best to operate
SLCs around mid-stroke, with 25-
75% compression, although ‘one-time
compression’ applications often benefit
from maximum compression. For very
low profile spring pins, 50 to 85%
compression is preferred. Good design
practice in less-controlled applications
includes incorporating a stand-off to Click to view Mill-Max’s
provide mechanical support.
Spring-loaded Pin Options
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Selecting the correct spring-loaded connector for
modern interconnect applications
time. Although mating with gold-plated
PCB pads is most common, other options
are available. A dedicated through-hole
nail head pin, surface mount target pin,
low-profile, gold-plated discs or a variety of
target connectors can be used. All provide
a highly conductive, wear resistant solution.
Combining spring pins with targets allows
different mating distances to suit any
application.
Reliability is required
Poor quality connections negatively impact
overall system reliability, making reliability
crucial to specifying SLCs. As such, when
specifying SLCs, designers should review all
available test data.
IEC 60512 has been the definitive standard
for connector testing since 1976. It includes
multiple tests to ensure that the connectors
will give long-term reliability in real-
world applications. Spring force, contact
resistance, random, half sinus and sinusoidal
vibration, rapid temperature change, dry
heat, cyclic damp heat, cold test and current
carrying capacity are examples of included
tests.
Applications of SLCs
SLC applications are only limited by the
specifying designer’s imagination, although
the most popular remains connectivity
between two or more PCBs.
CONTINUED
As modular designs become more
popular, the number of PCBs in products
is increasing. Versatile SLCs are a viable
solution for parallel or perpendicular,
vertical or horizontal boards and allow
multiple boards to be combined easily,
accommodating tolerance stack-ups due to
non-parallel fixing or PCB warpage.
Board stacking combined with limited
design space is making ‘blind mating’
more common. However, engagement
Typical right-angle board-
to-board SLC solution
5
misalignment may lead to damage and
poor connections with common socket and
header combinations. SLCs are ideal here
as no insertion is required; connection
is made when the plunger contacts a
conductive surface. Mating surfaces
are usually larger than the spring pin,
eliminating alignment concerns.
While SLC’s simplify the manufacturing
assembly process on the inside of the
product they are also beneficial when
designed as the interface to the outside
world. In the example of handheld devices,
utilizing spring-loaded pins in the battery
compartment of the device eases the
installation and removal of batteries,
while positioning them in docking stations
facilitates charging and signal functions.
Easily integrated into any system with
numerous options for height, travel and
spring force, SLCs provide a durable,
consistent connection, allow blind mating
and permit some misalignment when
placing the battery or device in the cradle.
This makes them the preferred choice for
applications where the end user makes the
connection.
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Selecting the correct spring-loaded connector for
modern interconnect applications
Spring-loaded contacts with solder cups
or wire crimp terminations can be used in
harness applications by having them over-
molded or press-fit into a plastic housing,
thereby creating a cable terminated
connector. This is excellent for blind mating
and quick connect cable applications,
especially as SLC performance under shock
and vibration makes them a good fit for the
constant handling and jostling of cables.
However, SLCs are not only used in end
products. Many test departments rely on
them for ‘bed of nails’ automated functional
testers where they provide an easily
accessible yet high tolerance and reliable
means of quickly mounting and de-mounting
the board to be tested.
Technology examples
Mill-Max Mfg. Corp. is at the forefront
of standard and custom spring loaded
connector solutions with a comprehensive
range of standard spring loaded contacts
and connectors that comprises more than
70 different product families covering almost
every conceivable configuration, alongside
45 different target connectors (and 28 loose
pin target products).
The range includes single and double
row headers suitable for through-hole,
surface mount and wire termination that are
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The larger 08xx series of
power spring pins shown
alongside standard 09xx
series contacts
available on 0.100 and 0.050 in. and 2 mm grids with various force,
stroke and height options. In addition, bulk and tape-and-reel
packaging is offered to suit a wide variety of production processes.
For rugged applications Mill-Max currently offers nine spring
loaded pins designed to withstand side loading, blind mating,
over compression, high shock and vibration and other general
rough handling by end users. These pins in the 0850 series
feature 20 micro-inches of gold plating over nickel giving durable
performance up to one million cycles and have extended bearing
surfaces and ample body wall thickness as well as solid plungers
and stainless steel springs.
The high force spring provides
SUMMARY
double the force of standard spring
pins at working travel and allows In modern applications, space is at
for strokes up to 0.090 in. (2.286 a premium and reliability is critical.
mm), allowing the SLCs to excel in Precision-machined SLCs bring
rugged environments, operating a unique combination of quality,
from –55° to 125°C. The low contact reliability and versatility to a wide
resistance of 20 mΩ (maximum) range of applications, thereby solving
allows for currents up to 9 A to be many of the connectivity-related
handled, with temperature rises challenges faced by designers.
below 10°C.
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Four tips to avoid
counterfeit connectors
Low-quality counterfeit parts can threaten circuits boards and
embedded systems with the potential to fail at the worst possible
times. One of the only sure-fire ways to avoid threats like this is
using the most reliable parts at the design phase. Herew are four
tips to avoid counterfeit connectors.

CONSUMERS PURCHASE counterfeit products
everyday, such as handbags and watches. And
while it doesn’t hurt the consumer, the biggest
issue with counterfeit goods comes in the loss
of intellectual property and money to the real
designers. Not so with counterfeit connectors.
While it may save the buyer money in the short
term, purchasing counterfeit connectors not
only hurts the real engineers and companies
who have designed them, but it can also be
downright dangerous—to your machines and to
the people that interact with them.
Although all connector designs could be copied,
you may find the most commonly used designs
more at risk. M12, M8, 7/8 in., M12 splitters, M12
junction boxes, and circular pin-style connectors
are the most popular type of industrial
connectors frequently copied, as are telecom
(RJ style), fiber and other power products.
Here are a few tips to avoid purchasing
these fakes.
1. Know your suppliers
Perhaps the simplest solution to
avoiding counterfeit connectors is to
buy only from authorized distributors.
Brian Krause, global marketing and
communications, Molex Inc., advises
users to only purchase connector
products through companies
authorized by the manufacturer.
“Check with the manufacturer for a
complete list of companies authorized
to sell their products,” Krause said. “In
most cases the manufacturer’s website
will highlight those companies and
provide current contact information.”
Also, Krause added, “for most
companies, power and data are
resources to be monitored and
protected. Avoid purchasing or
putting into service any connector
components of dubious origin.”
2. Check the certifications
Krause and Dave Gallagher, product
manager at L-Com, both stress the
importance of product certifications.
Checking UL, ETL, NEC and other numbers
on a product is one way to confirm
authenticity.
The same goes for cordsets. Turck insists
that cordsets must meet IP ratings. In
applications with moisture and ingress
protection, if the connector will not hold
up to requirements demanded of the
application, there will be problems.
L-com
connectors with
50 microinches
of gold do not
degrade.

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Four tips to avoid counterfeit connectors
CONTINUED
3. The cost is clear
If a price seems too good to be true, it probably is.
L-Com’s Gallagher said that a great price usually
means something is missing.
And on the opposite end
of the spectrum, a highly
expensive component does
not necessarily mean it’s
going to be a better product,
either, he added.
4. Solid gold vs. minimal
plating
If you’ve already purchased
a component that might
be counterfeit because Gold flash on RJ45 contact has
degraded, eroding connectivity.
the first three flags above Photo courtesy of L-Com.
weren’t raised, there are a
few things you can look for
to see if the product is safe.
Krause cautions that gold plating can be false. He
suggested you verify gold plating thickness, which
would be among the first ways that counterfeiters
cut corners. Gallagher added that some
counterfeiters might send in a legitimate sample,
then when a purchase is made, you get a different
product. Krause added, “If in doubt, always consult addition, Turck recommends
a reputable manufacturer to verify authenticity.”
Likewise, Turck said cordsets and cables need to
be similarly inspected. With cables, function is a
sure sign the cable is legitimate. For example, is
the material really as advertised (i.e. PVC, TPU/
PUR) and does it look and feel as described? If it
Mill-Max can manufacture
CUSTOM CONNECTOR ASSEMBLIES
to your exacting-specifications.
With over 200 high-speed turning machines on our
premises in Oyster Bay, NY, Mill-Max is readily equipped
to provide custom pins, terminals and receptacles to
your exacting specifications.
Choose a link below to have Mill-Max assist you today
with your application specific requirement.
TECHNICAL ASSISTANCE
Get information on our products or ask a
technical question.
ENGINEERING NOTEBOOKS
View in-depth analysis of our key products
does not work as advertised and technologies.
in flexing or corrosive
applications, or if jacketing SEARCH OUR DATABASE
cracks, you more than likely Search our database for a similar pin or receptacle
have a fake on your hands. In and click the “Customize this Part” button on the
product detail page.
checking the stainless-steel
REQUEST A CUSTOM PART
housings and coupling nuts
To modify an existing part number, log in or create
on a cordset. If it is not 316 an account, fill in the form and submit your request
stainless steel, as is required to our applications engineering team. We assure
in some applications, the you a fast response. Let Mill-Max assist you today
steel (such as 303 or 304) with your application specific requirement.
will corrode.
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The 6 biggest dangers of counterfeit
connectors
Purchasing counterfeit connectors can be extremely dangerous, to
both the people using them and the machines they are connected
to. If you don’t know what to look for, you may consider buying a
fake connector. Here are the six biggest risks you are taking with
your system when purchasing fake designs.

1. Safety is utmost. The most 2. Environmental issues are paramount.

urgent issue with counterfeit
connectors is that they place
customers at risk, said Brian Krause,
vice president, global marketing and
communications, Molex Inc. “Over
time, counterfeit connectors inter-
mated to equipment in the field can
lead to degradation of materials and
possibly cause shorts or, worst case,
thermal incidents.”
Turck adds that not having the
correct UL listings is a risk for
personal safety, as compromising
UL setup in factory automation
installations compromises the
people working in those situations.
And finally, said Dave Gallagher,
product manager at L-Com,
substituting materials can lead to
potential failure in critical systems.
Authentic connectors are designed with the
environment in mind, ensuring that they will not
contaminate or pose hazards to their location
of use. For example, said Gallagher, improper
materials may not be safe in the intended
environment (such as cable burn ratings). If used
in a highly flammable environment without the
proper burn ratings, a spark could cause a fire.
This would not happen with legitimate designs.
In addition, counterfeit connectors could use A legitimate copper cable,
materials that are unsafe for the environment bottom, is compared to an
or the people that use them. Unless you use aluminum fake, top. Photo
courtesy of Turck.
verified components, you may not know what
is inside them. For example, as pictured, cables
could be advertised as copper but are really just
aluminum that was colored to look like copper,
said Turck.
3. Damage to equipment and more. The use
of counterfeit parts can potentially damage
equipment, said Molex’s Krause. He added that

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The 6 biggest dangers of counterfeit connectors
CONTINUED

there is no way to tell how a device or system will perform when
it has been inter-mated with counterfeit connectors. They may fail
to deliver in terms of performance, insertion/withdrawal forces, or
number of mating cycles. For example, said Turck, if a counterfeit
component has the wrong gauge size, and has overstated voltage
or current ratings, it can cause fires, electrocution, and even fatigue
on the connector/cable.
4. Performance slows. Machine functionality is a major problem
with counterfeit connectors. For example, said L-Com’s Gallagher.
“If your computer transmits at 50% less speed…does it still work?
Yes it does…just slower,” he said. So you’re sacrificing performance.
Timothy Senkbeil, connector product line manager at Belden
added, “Poor connector quality can degrade or interrupt the signal
transmissions that are so vital for industrial processes.”
5. Money talks. Clearly, there are huge financial risks with
counterfeit connectors. In addition to lost revenue and risks
to reputation for legitimate connector manufacturers, trying to
troubleshoot and repair a fake connector that only functions
intermittently can mean a lot to your bottom line. “Buying a $0.50
cable instead of the $4 cable might sound like a big savings until
you find out that cable caused a $5000 truck roll to a remote site,”
L-Com’s Gallagher noted.
6. Legal issues may arise. Finally, said Molex’s Krause, “The use of
counterfeit parts can result in legal issues related to warranties or
service contracts.” And, said Gallagher, if a product does not meet
local code rules and the seller knowing sold it with intent, there
could be even more legal consequences.
Remember, you should always avoid buying counterfeit connectors
in the first place. But if you’re tempted by the low costs presented
by what are most likely fakes, read the six dangers above again. It’s
not a risk you should be willing to take with your equipment, the
people that uses it, or even your company.

FR-4 CONNECTORS
I d e a l f o r P r o t o t y p e s a n d L o w - Vo l u m e P r o d u c t i o n
With respect to prototype and low volume connector Mill-Max has the unique ability
requirements, it is often difficult to avoid costly Non- to create these connectors as
Recurring Engineering (NRE) charges up-front. However, many of our standard machined
Mill-Max Mfg. Corp. can provide custom, low-quantity components incorporate a press-fit
connectors while avoiding tooling costs thanks to our feature, making them suitable for
in-house, FR-4 Epoxy milling capabilities. As well as assembly into FR-4 material. This
injection-molded connectors for high-runs, Mill-Max utilizes makes batch production simple
glass filled epoxy material to provide custom-designed and quick, as we often have the
connectors tailored to meet your needs at low volume. machined components on the shelf.
LEARN MORE FROM THE
ENGINEERING NOTEBOOKS ON
MILL-MAX.COM

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 ULGIN
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Making connections in harsh places

While most of us live and work in relatively protected and safe indoor
environments, much of the world’s most critical electronic systems
and equipment operate in harsh conditions. Whether it’s water, dust,
extreme weather, explosive atmospheres or pressure, a range of harsh
environments can create challenging conditions where these systems
and their connectors operate.

ONE OF the most common points for
damage in any electrical system is where
cables get plugged in—the connector.
Connectors are at the junction of system
and cable, needing to have the flexibility
to mate and disconnect easily yet securely,
all while keeping the elements out. As
the guardians of the entry points to both
system and cabling, their integrity in harsh
environments is critical.
Because they’re at the entry point to the
system, connectors face the same hazards
of any electronic system, including water,
dust/dirt, extreme temperatures, potentially
explosive “ATEX” environments, pressure/
weight, shock/vibration and salinity.
specialized equipment. A similar
definition can be applied for
electronics: a harsh environment is
one that would ordinarily cause serious
damage to an electrical system. Wet
or dirty environments with water, high
humidity/water vapor, dust or dirt can
wreak havoc on electrical equipment,
causing short circuits or malfunctioning
equipment. If salinity is a factor, such as
in a seaside environment, corrosion can also be
a serious issue.
Electrical systems are also often sensitive
to temperature extremes, which can cause
components to fail or malfunction. For data
connections, electromagnetic interference
(EMI) can be an issue as it can disrupt wired
communication.
Physical force is another hazard
which can come in the form of
mechanical shock and vibration, or
pressure. To withstand shock and
vibration, a robust mating method
needs to be in place. Connectors in
undersea, aerospace or pressurized

What defines a harsh environment?

A harsh environment for humans can
Commercial and agricultural vehicles
be defined as an environment in which are constantly exposed to dirt, water,
prolonged exposure to the elements extreme temperature changes and
would pose a danger to survival without physical duress.

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Making connections in harsh places
CONTINUED
environments also need additional
ruggedization.
For connectors used in explosive
environments, an additional requirement
is that they do not have any way to set off
a spark, either mechanically or electrically,
and cause a hazardous explosion.
Rugged applications
The range of rugged applications is
extremely varied, and crosses many industry
lines. Ruggedized systems and connectors
are used in industrial, marine, oil and gas,
transportation and infrastructure, telecom,
and more.
Industrial. In industrial environments,
technology such as automation, machinery
and measurement come together to create
today’s hyper-efficient manufacturing
systems. Industrial environments are often
exposed to a variety of harsh elements
including water, vibration, chemicals and
temperature extremes. The move to greater
automation and “Lights-out” manufacturing
means environmental challenges will only
increase as equipment now increasingly
has the freedom to operate in inhospitable
conditions.
Industrial equipment such as food slicers,
saws, sand blasters, food processors and
coating machines can generate significant
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The oil and gas industry depends on
reliable rugged connectors in underwater
ROVs, which provide drilling and
construction support as well as exploration.
shock and vibration, as well as create
dust or airborne contaminants. Sealed,
rugged metal or plastic housing
connectors with IP66, IP67, IP68 and
IP69K ratings can withstand these
harsh conditions and keep power,
signal and data connections secure.
Because of noisy EMI conditions
in industrial environments and
the dependence on sensors and sufficient for many surface applications
communication, EMI is also a concern for while IP68 or IP69K will be necessary
data connections. In these cases electrically when connectors may be submerged.
shielded connectors are ideal. For undersea applications such as diving
electronics, depth loggers or undersea
Marine. Marine applications are faced with remotely operated vehicles, it is important
challenging environmental conditions, both to source independently tested systems
on the surface and underwater. Surface purpose-designed for subsea pressures.
marine applications such as boating
equipment, ship-deck systems, or marina Oil & gas. The oil and gas industry faces
facilities face threats from corrosion due many of the same environmental hazards
to high salinity, as well as water ingress, of industrial and marine environments, but
making robust, sealed components must also deal with explosive atmospheres
essential. which require the use of ATEX /IEC Ex rated
equipment. For offshore platforms, both
IP rated components should be chosen marine hazards and explosive atmospheres
depending on the level of water and dust exist. In addition, the oil and gas industry
protection needed, with IP66 and IP67 makes extensive use of underwater ROVs
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Making connections in harsh places
CONTINUED
for drilling and construction support as well
as exploration.
These underwater remotely operated
vehicles are essentially remote-controlled
robots. They require power, data, and often
fiber-optic lines, have to operate in rough
subsea conditions, and are often asked
to go to depths beyond the possibilities
of human divers. Bulgin’s ROV tether
connector, for example, is designed to keep
these robotic helpers working reliably in
uncertain waters. Made from 316 marine-
grade stainless steel, it is a Pressure
Balanced Oil Filled (PBOF) cabling solution
that uses oil as a compensating fluid for
water pressure, allowing ROVs to submerge
to depths of 7,000 m.
Other applications. From transportation and
infrastructure to automotive and agriculture,
a wide variety of electronic systems operate
in the outdoors. They require connectors
that can withstand extreme temperature
changes, water and dust ingress, physical
duress, and more.
No one-size-fits-all solution
One of the first challenges for the
manufacturers who design connectors for
rugged environments is the term “harsh” or
“rugged.” These terms might lead customers
to the assumption that there is a “holy
grail” of rugged connectors that will be a
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ARTICLE COURTESY OF B
one-size-fits-all solution for
all applications. The truth
of the matter is that this is
impossible, simply because
all applications have their
own subtle differences
and requirements, and all
customers have different
budgets.
The best approach will be
for the designer to work as
closely as possible with the The Buccaneer Data range provides
client to find customized rugged data connections in a variety of
sealed circular connectors, including
solutions. Design engineers USB (including mini-USB and micro-USB),
will first gather as much information as Ethernet and SMB.
possible to accurately scope out the project
and ensure that the solution will be both
wanted and fit for purpose. The engineers
will then work against time, budget and IP66 (protection against powerful water
scope drift to ensure that the solution is jets), and IP67 (immersion up to 1 m), are
adequately tested and delivered by the suitable for many above-water applications
project deadline. where systems may be rained on, or
otherwise repeatedly exposed to water.
Key features Connectors which may be continuously
IP rating. IP ratings define the level of submerged should be at least IP68
protection from dust and water ingress of (immersion to 1 m or more) or greater. For
the component. The first digit indicates the undersea applications, purpose-designed
level of dust protection and goes from 0 to equipment with independently tested
6, while the second digit indicates liquid depth ranges is vital to ensure complete
ingress protection. For harsh environments, underwater protection.
sealed connectors should always be
dust-tight, with water ingress protection IP68 and IP69K (protection against close-
depending on the application. range high pressure and high temperature
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Making connections in harsh places
CONTINUED
Bulgin’s Buccaneer circular connectors
provides reliable and robust connections
in challenging environments.
spray-downs) are extremely effective for medical
and food processing environments as this
allows the equipment to be regularly washed
and sanitized without harming the electrical
components.
Locking/coupling mechanisms. With many
connectors being exposed to environments with
shock and vibration present, a robust coupling
mechanism is a must. There are many different
types of connector couplings, including ring,
twist locking, threaded, bayonet, push-pull and
quick-disconnect couplings, all with different
attributes for various types of applications.
Some, like the bayonet connector provide
better security against shock and vibration while
others, like push-pull and quick disconnect,
provide greater ease of use when
connectors may need to be disconnected
often.
Housing and insulation. The material
that makes up a connector helps it
resist environmental challenges. For
applications with extreme temperatures
as well as plenty of moisture and dust, a
corrosion resistant metal housing may be
appropriate. If lightweight and flexibility
is key, temperature-resistant plastic
composites will be more attractive.
Connector design. The connector’s
shape, mating mechanism and pin
positioning also play a part in its
ruggedness. Circular connectors have
the benefit of easy engagement/
disengagement, as well as the capacity
to fit a wide variety of contacts with the
connector body. Circular connectors also
are easy to seal and less likely to wear
out. An intelligent “scoop proof” design
can be used to avoid pin damage while
trying to mate the connector.
Making the right connections
Our world is becoming increasingly
connected. From outdoor cellular base
stations to connected factories, to
IoT sensors on oil and gas platforms,
electronics are being placed in every
environment imaginable. The electronic
14
ULGIN
ARTICLE COURTESY OF B
systems have to be guarded against all
the forces of nature.
As the point of entry to the system,
connectors must be robustly designed
to seal off and protect against all
environmental challenges present—from
shock and vibration to dust and water, or
EMI. Thankfully today’s connectors have
evolved to provide strong ruggedization
for just about any application in many
markets, such as Bulgin’s Buccaneer
range of power, signal and data
connectors. Through choosing the right
IP rating, locking mechanism, housing
material and connector design, almost
every rugged electrical system today
can be made to work
reliably with the right
connector.
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manufacturing company capable of producing over 100 million
interconnect components a week, making us the largest manufacturer
of precision machined interconnect components in North America.

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