Bulgin Basic Considerations forIOT Connectors Operating in Harsh Environments

Basic Considerations for IoT Connectors
Operating in Harsh Environments

Industrial applications, like smart factory,
mandate that connectors and related
data communication accessories have a
rugged design by default.
The notion of the Internet of Things (IoT) smart factory, it’s critical that connectors can
is partly based on a network of automated withstand the combination of temperature,
machines, devices, and sensors that aim to pressure, dust, and corrosion.
create a digital nervous system by monitoring
and analyzing the performance of electronic That is pushing the connector industry to
systems on a factory floor, inside a vehicle, enhance the underlying designs to efficiently
or out in the field. Here, while IoT serves serve the IoT applications in challenging
a broad array of applications, industrial environments. This whitepaper will highlight
environments—commonly classified under the data connectors, switches, and cable
the complementary banner of Industrial assemblies—serving smart factory and other
IoT (IIoT)—are especially challenging for IIoT segments—and their specific features
connectivity devices like connectors and as well as technology merits in effectively
related assemblies such as switches, catering to these segments. It will highlight
enclosures, and fuse holders. these products’ robust and rugged nature and
their ability to serve in extreme environments
As automation increases and manufacturing with efficiency, reliability, and safety.
processes add connectivity, there is immense
pressure to develop reliable and robust But first let’s see why it gets challenging for
interconnected production and motion control connectors to serve IoT applications in rugged
systems. There are electrical stresses as well and harsh operating environments.
as chemical contaminants, such as salt water
and corrosives. Therefore, when designing
systems for harsh IoT environments such as
www.bulgin.com/us/ 2
Figure 1:
The IoT systems are pushing

connector designs toward
catering to extreme types of
environments.
Connectors in Harsh IoT Environments

The IoT applications serving harsh Then there are radio base stations, serving many
environments in indoor and outdoor settings IoT applications, including telematics and fleet
require some degree of ingress protection. management, where connectors must address
So, connectors and related cable accessories dust and moisture ingress as well as vibration,
for data communications must have a rugged shock, and vermin. In such applications, the
design by default. right cables and connectors are vital in ensuring
secure and waterproof electrical connections.
For a start, the deployment of sensors is a key
premise in IoT applications. And incorporating Next, in the smart-factory realm, automated
sensors into IoT networks requires that processes are transforming the industrial
connectors ensure optimum signal integrity for landscape, which mandates a new generation
data communications. Moreover, most data- of connectors and switches aligned with
communication applications are now employing process control, material handling, and
fiber-optic connectivity. So, the combination manufacturing operations. Therefore,
of rugged sensors and optical networks will be connectivity solutions with metal or plastic
critical in industrial IoT applications like smart housings, as well as vandal-proof pushbutton
factory. switches, can better serve automated machines
and systems while conforming with ratings
Additionally, from smart lighting to surveillance like IP66, IP67, IP68, and IP69K. These ratings
cameras to vending kiosks, IoT applications particularly matter in production lines prone to
continuously evolve and call for connectors dust and liquid build-up.
and switches built for maximum reliability
and performance in both indoor and outdoor The following section will give an account
environments. Kiosks, for instance, encounter of connectors and assemblies that provide
environmental conditions such as foreign environmental and thermal resistance for IoT
objects, humidity, and temperature swings. applications against extreme conditions like
heat, vibration, and shock.
Specialized Designs for
Figure 2:
The waterproof M5 sensor
Rugged Environments
connectors are available in
straight and angled forms with
PVC or PUR over-molded cable
options and various panel-mount
receptacles.
The IIoT applications like smart factory are seen and transfer data. Here, the growing complexity
as the harbinger of the next industrial revolution, of IoT devices is translating into a new era of
often called Industry 4.0. Smart factory, a connector strength and intelligence.
popular manifestation of IIoT, aims to unify every
element of the manufacturing process into a In standard series ethernet, for instance, sealed
single entity. That’s why industrial automation and waterproof circular RJ45 connectors
applications require fast, secure, and reliable serve high-speed data communications in
connections with high environmental protection harsh outdoor environments. Then there is the
in smart-factory settings. circular fiber connector range that facilitates
connectivity in fiber to the x (FTTX), radio base
The M-Series Buccaneer circular automation stations, server rooms, vending kiosks, and
connectors are specifically designed to offer other connectivity-centric applications.
flexible connectivity solutions for a variety of
industrial automation applications. Circular When it comes to speed, 4000 series
connectors, while being small and slim, are also c-type connectors go as high as 20 Gbps.
stronger and easier to seal. These USB c-type 3.2 gen 2x2 devices are
backward compatible with USB 2.0 devices,
These automation interconnect devices come so engineers don’t have to flip the connector
with metal and plastic variants and facilitate several times looking for the correct
secure data connections in harsh environments. orientation (Figure 3). Besides connectors,
The waterproof M5 sensor connectors, the most nylon and metal heavy-duty toggle switches
compact connector type in the M-Series range, serve a wide range of actuator and circuit
are made available in straight and angled forms options such as single-pole single-throw
with PVC or PUR over-molded cable options and (SPST), single-pole double-throw (SPDT),
a variety of panel-mount receptacles (Figure 2). double-pole single-throw (DPST), and
double-pole double-throw (DPDT).
It’s also important to note that networking
systems, whether wired or wireless, are cabled
into local area networks like ethernet to collect
Connectors for the IoT Era
Figure 3:
The 4000 series c-type connectors

are reversible, so engineers don’t
have to worry about the correct
orientation. Elements like water, vibration, chemicals, Take, for instance, security and surveillance
and extreme temperatures call for cameras, one of the most popular IoT use
connectivity solutions with metal or plastic cases, which operate 24/7 in some of the
housings to facilitate highly reliable and most challenging outdoor environments.
safe data connections in the harshest of IoT Likewise, indoor and outdoor lighting systems
environments. That, in turn, demands special confront the challenging ambient and
care in designing standardized, rugged, environmental conditions.
lightweight, and sealed connectivity solutions.
Additionally, field-installable connectors and The rugged anti-vandal switches are crucial in
over-molded cable assemblies are expected smart lighting and kiosk applications where high
to be customized for specific IoT design and resistance to wear and tear, corrosion, and harsh
development needs. settings is a must (Figure 4). Manufactured
from stainless steel, vandal-resistant security
switches are available in front- and rear-panel-
mounted versions in three profiles: prominent,
domed, and low.
Figure 4: For IoT applications like surveillance cameras; polyester materials. These compact and
industrial meters; and heat, ventilation, shock-safe fuse holders come in a variety
The vandal-resistant switches
meet the ergonomic, electrical, and air conditioning (HVAC), it’s also worth of mounting options, including panel mount,
and environmental demands of
mentioning fuse holders manufactured PCB, and base mount.
switch-panel designs.
from high-grade flame-retardant nylon and
Looking Forward
Connectors, which form the backbone of At the same time, these connectors must be
the IoT networks, must be robust enough able to easily interface with RJ45, USB, and
to effectively operate in harsh and rugged even fiber-optic communication systems. And
environments. That’s why connector designs they should be compact enough to easily
are being pushed to new frontiers to meet fit into commercial and industrial spaces. A
the evolving needs of IoT networks. For connector design transformation is underway,
instance, they are now designed to provide and this whitepaper has attempted to provide
sealing against the ingress of water and other a glimpse of such connectors ready to serve
contaminants. the IoT era.
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Basic Considerations for IoT Connectors

Operating in Harsh Environments

The IoT systems are pushing

Connectors in Harsh IoT Environments

The waterproof M5 sensor

The 4000 series c-type connectors

tel: +1-833-428-5446 (1-833-4-bulgin)

UK, Middle East & Africa

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