This week’s Product Roundup highlights main suppliers’ high-voltage and high-current connector merchandise for industrial, mil/aero, automotive, transportation, datacom/telecom, and shopper electronics purposes.
Excessive-Voltage and Excessive-Present Connector Merchandise
Amphenol Pcd’s Rhino Collection Connectors mix the advantages of field-proven MIL-DTL-38999 Collection III round connectors with low-resistance hyperbolic RADSOK® energy contacts to ship high-reliability efficiency in harsh-environment army, automotive, aerospace, and industrial purposes with high-power, high-voltage, and high-vibration necessities, together with electrical drive automobiles, business and army plane, and automation, mining, and offshore gear. Options embrace an industry-standard MIL-DTL-38999 footprint, IP68 sealing, a tri-start thread coupling mechanism, an anti-decoupling ratchet mechanism, superior EMC efficiency, low contact resistance, excessive contact endurance, IP2X finger safety, six commonplace keying choices to stop mismating, and RoHS-compliant black zinc nickel plating. The collection is accessible in six shell sizes (13, 15, 17, 21, 23, and 25) and three shell types (jam-nut, wall-mount, and plug) and options 38999 Collection III or Bulldog breakaway connector interfaces, crimp, screw, or flathead terminations, and straight or right-angled backshells for pressure aid and 360° EMC/RFI screening. Out there shell supplies embrace aluminum, marine aluminum bronze and chrome steel for high-corrosion environments, and titanium for weight-restricted purposes, and plating choices embrace RoHS-compliant zinc cobalt and zinc nickel, in addition to cadmium and electroless nickel. The collection is compliant with the newest army and industrial specs and security necessities and is rated for as much as 1,000A, 630V, working temperatures extending from -55°C to +125°C, and greater than 500 mating cycles.
Avnet shares off-the-shelf Mega-Match Overmolded Cable Assemblies from Molex, which mix rugged sign connections with a user-friendly interface and built-in pressure aid, can be found in a number of circuit sizes and cable lengths, and meet IPC specs, which nearly eliminates design and tooling time and price. Very best to be used in wide selection of commercial, business car, shopper, and datacom purposes, the collection options high-current terminals that ship extra energy per linear and sq. millimeter than most mid-range energy merchandise — as much as 23A, absolutely polarized housings that forestall mismating, constructive housing latches that present audible mating affirmation and guarantee safe retention, and absolutely remoted terminals that shield towards dealing with and mating injury. One answer within the collection, the Mega-Match Six-Place Receptacle Meeting, contains a Zero.5m UL 2464 cable and matte-tin-plated copper alloy crimp contacts, is rated for 300VAC and working temperatures extending from -20 to 80C, and is RoHS compliant. Perfect purposes for the collection embrace heavy gear and equipment, automation gear, lighting techniques, energy converters, unsealed digital management modules, workplace gear, fan tray assemblies, gaming and merchandising machines, washers and dryers, heaters and air conditioners, hubs and servers, energy provides, and private computer systems.
Smiths Interconnect’s HeavyPower Transformer Collection high-density, modular connectors for on-board energy purposes within the rail market permit for a number of customer-defined configurations, allow straightforward meeting with no particular tooling, and additional improve flexibility with the power to combine native cabling and elements. The collection’ detachable and interchangeable modules additionally simplify new and retrofit installations, mitigate upkeep necessities, decrease the entire value of possession, and supply area and weight financial savings in comparison with junction packing containers. Out there in one- to four-pole variations able to supporting as much as 300A per pole and three,600V, the collection options rugged passivated aluminum shells with straight and proper angle termination types, high-protection polyamide insulators that guarantee right creepage and clearance distances, 4 coding keys that allow side-by-side set up, built-in anti-swing equipment that negate the necessity for additional fixing units on the gangway, locking screws, shielded or unshielded cable harnesses, and cable glands for pressure aid. Additionally they function nickel-plated-copper Tortac® high-power hyperboloid contacts, which ship excessive reliability, excessive density, low insertion and extraction forces, low contact resistance, lengthy lifecycles, and immunity to shock and vibration, and are able to accepting cable cross-sections spanning 25–70mm2. The connectors are rated for 12kV withstanding voltage, IP66 or IP67 safety per NF EN 60529, working temperatures extending from -55°C to 125°C, and greater than 500 mating cycles, are examined to at least one million swaying cycles to simulate gangway environments. They’re additionally corrosion resistant, withstanding as much as 96 hours of salt spray when unmated and greater than 500 hours when mated, are to are compliant with the primary railway requirements, together with NF F 61-Zero30 (contact retention and acid and fluid resistance), EN 61373 (vibration), EN 45545 (hearth and smoke), and EN 50124 air pollution diploma Four (insulator design), which permits them to be put in on practice roofs, beneath practice automobiles, on bogies, and between automobiles as jumpers.
Newark, An Avnet Firmshares ITT Cannon’s APD Four-Approach Excessive-Voltage Collection connectors. Best to be used in harsh-environment automotive, transportation, off-road, specialty car, and industrial purposes that require strong IP69 sealing, excessive vibration resistance, and resistance to engine transmission and brake fluid, these versatile, plastic, direct in-line and bulkhead round connectors are VDE licensed for high-voltage operation as much as 500VDC/AC and supply a low complete value of possession because of straightforward meeting and useful element value. These ISO15170 connectors (initially DIN72585) have a 2.5mm contact system, 4 machined and stamped copper alloy sign contacts with tin, silver, or gold plating and crimp terminations, three shell types: cable connecting plug and flange or jam-nut receptacles, and two mechanical codings. They’re rated for 20–11AWG, 30A at 40°C, 500VDC/AC, working temperatures extending from -40°C to +125°C, and 50 mating cycles.
AVX Company’s STRIPT™ 9177-500 Collection single IDC contacts present rugged, cost-effective, and UL-approved options for the fast, straightforward, and dependable board termination of large-gauge (12–18AWG), high-voltage and high-current strong and stranded wires (as much as 600V and 15A) in harsh-environment purposes extending throughout the economic, transportation, and various power markets. Ultimate to be used in photo voltaic and wind power installations, outside and transportation lighting, business constructing wiring and electrical methods, and industrial motor controls, drives, and pumps, the collection contains a confirmed, gas-tight, and redundant pure-tin-over-nickel-plated phosphor bronze contact system constructed to face up to excessive temperatures, shock, and vibration and suitable with potting and overmolding encapsulation processes for extra environmental safety. The contacts are dimensionally matched to 12, 14, 16, or 18AWG to realize impregnable, fatigue-resistant, and UL-certified cold-welded connections between high-voltage and high-current wires and PCBs in harsh environments and successfully bridge the hole between extraordinarily low-cost, however exceedingly unreliable hand soldered connections and dependable, however a lot bigger and costlier two-piece insulated connector options. The only, insulator-less IDC contacts are rated for 12–18AWG strong or stranded wires, 15A, 600VAC, temperatures spanning -40°C to +125°C, and three termination-cycle sturdiness.
Materion’s new high-conductivity QMet™ Strip Alloys for high-current purposes starting from shopper electronics to electrical automobiles supply a singular mixture of excessive power, wonderful formability, rugged resistance to emphasize rest, and excessive conductivity designed to help and advance each present and rising applied sciences. Particularly very best for creating compact elements that may deal with excessive energy in small type elements subjected to excessive working temperatures, the brand new QMet 200 alloy — a copper/chromium/nickel/silicon (CuCrNiSi) alloy — provides one of the best formability in its class and helps versatile order portions with quick turnaround occasions to assist enhance clients’ responsiveness in industries with demanding construct schedules. As well as, the brand new QMet 300 — a copper/chromium/silver (CuCrAg) alloy — gives higher conductivity than all different alloys of comparable power with sharp formability and stress rest resistance corresponding to that of beryllium copper (BeCu). QMet 300 permits design engineers to create high-current and high-heat-transfer elements to be used in smaller areas than ever earlier than and may accommodate small batch order and brief lead occasions, offering fast entry to this important materials. Able to offering efficiency advantages that even maxed-out commodity alloys can’t, the brand new QMet alloys are additionally RoHS compliant and are perfect for use in purposes together with automotive wire harness terminals, high-voltage connectors, EV charging contacts, equipment and pc energy contacts, photovoltaic (PV) system connectors, heat-spreading elements in shopper electronics, and backplane, midplane, and card-edge connectors.
Interstate Connecting Elements (ICC)a division of Heilind Mil-Aero, shares Class L MIL-DTL-22992 Connectors from Amphenol Aerospace. These giant, heavy-duty, round connectors are solely out there within the particular shell fashion, shell measurement, and get in touch with configurations prescribed by MIL-DTL-22992 as a way to guarantee the right interconnection of electrical circuits for max security and reliability in army and industrial purposes. For example, wall-mount and cable-connecting receptacles are solely provided with socket contacts and all the time lead from the facility supply and plugs with coupling rings solely have pin contacts and all the time result in the gear finish. As well as, the direct relationship of shell measurement to current-carrying functionality reduces the potential for insufficient wiring for heavy electrical masses: shell measurement 28 options measurement 6 contacts rated for 40A, shell measurement 32 options measurement Four contacts rated for 60A, shell measurement 44 options measurement 1/Zero contacts rated for 100A, and shell measurement 52 options measurement Four/Zero contacts rated for 200A. The collection is suitable with direct present (DC) and single- or three-phase 60/400Hz alternating present (AC) and offers excessive environmental resistance to warmth, moisture, vibration, influence, and immersion. It has a rugged development comprised of high-strength aluminum and design options together with a programmed coupling sequence that ensures that grounding and impartial contacts interact earlier than energy contacts for foolproof mating, arc-quenching recessed socket contacts, easy-clean double-stub coupling threads for quicker connections with no cross threading, left-hand accent threads to attenuate cable twisting, wire breakage, and unintentional connector disassembly, a singular mixture of grommets and seals that gives waterproof safety whether or not mated or unmated and capped or uncapped, and straight-line accent attachments that get rid of the potential of cable twisting or misalignment. Present scores span 40–200A, conductor sizes span 6–Four/Zero, and contacts are usually crimped to the cable earlier than connector meeting, so no insertion instruments are required; nevertheless, bushings can be found to adapt smaller diameter wires to bigger contacts.
Fischer Connectors’ Fischer Core Collection Brass gives a variety of high-performance push-pull connectors and cable assemblies with advantages together with compact, rugged type elements, high-reliability efficiency, 10,000-cycle sturdiness, and excessive versatility. Designed to be used in all kinds of demanding medical, army, automotive, marine, and instrumentation purposes, the collection reveals excessive temperature and chemical resistance, is suitable with most sterilization processes, and options IP68/69 or airtight sealing, mechanical keying, color-coding, and a patented push-pull locking mechanism for fast and straightforward operation. It additionally provides multi-polar, energy, coax, fluid, and hybrid connector configurations and is absolutely configurable, permitting clients to pick any measurement and configuration that fits their wants. Normal choices for the collection’ high-voltage multipole energy connectors embrace three to seven contacts, insulated one-piece clamps fitted for optimum high-voltage scores, 50kV check voltage scores, and 60A present scores. Excessive-voltage coax and combined high-voltage options are additionally out there, and the vary may be pre-cabled in an ISO 9001 and ISO 13485 facility upon request.
Energy & Sign Group provides Aptiv’s (previously Delphi’s) portfolio of high-voltage and high-current connector applied sciences for EV and HEV purposes, together with the APEX® HV280 Two-Approach Connection System, which is right to be used in powertrain, air con, and battery charging techniques and with high-voltage peripheral gear. The APEX HV280 options the ErgoMate™ Axial Mating Help System on the harness connector, twin IP67/IPX9K sealing for mated and unmated environmental safety, IP2XB finger-proof safety, an built-in high-voltage interlock loop (HVIL) shunted inside the harness connector, two high-voltage energy circuits with 2.8mm terminals, two keys/indexes, two-stage disconnect to make sure protected unmating, and bundle shielding with an exterior braid. It has a 46mm x 53mm flange, panel mounts to units with an interfacial seal, accepts energy cables measuring 2.5–4mm2 in diameter, and is rated for 35A at 70°C, 1,000V, and working temperatures extending from -40°C to +125°C.
JAE’s DW Collection high-current connectors are perfect for use in electrical energy models, energy conditioners, semiconductor manufacturing gear, and battery storage techniques, just like the lithium ion batteries used for energy provide and storage in inexperienced power purposes together with solar energy era methods. The UL-approved collection has sign contacts designed to verify the situation of battery cells and determine variations in electrical accumulation, which may scale back manufacturing work time, and is obtainable in 4 variations (DW1, DW2, DW3, and DW4): three rack-and-panel configurations with two energy contacts and 20 or 24 sign contacts and a single-pin board-to-cable configuration particularly designed for small-scale storage purposes. DW Collection connectors are rated for 600V (energy) and 100V (sign) and can be found with present scores starting from 100–500A (energy) and 2A (sign). Working temperatures prolong from -40°C to +115°C, relying on the variation, and every is rated for 100-cycle sturdiness, save for the DW1 variation, which is rated for 20-cycle sturdiness.
Amphenol ICC’s BarKlip® BK100 I/O connector supplies a handy technique of distributing as much as 100A per contact between busbars, cables, and circuit boards in purposes together with AC/DC pluggable energy provides, networking gear, switches, servers, storage, and hyperscale computing architectures utilized in IoT-enabled various power purposes. It options 12 absolutely unbiased, cantilevered, and silver-plated copper alloy conducting beams, which give a real compliant spring that adjusts to variations in busbar alignment and floor end, and an ultrasonically welded connection between the wire and call, which will increase the effectivity and reliability of present transition. The cable connects with a system rack bar and a 6.00mm-thick copper bar to realize a direct pluggable connection to an uninsulated busbar and generates very low power loss with a most resistance of solely Zero.2mΩ per port. It additionally has a large working temperature vary extending from -40°C to 125°C, is blind-mating suitable, meets JEDEC JS709 low-halogen necessities, accepts 10–Four AWG wire, and helps a number of totally different mixtures of equal cross-section space (e.g., as much as 4 8AWG wires) for a variety of energy distribution necessities.
Phoenix Contact’s new M12 energy connectors and cable assemblies supply breakthrough high-voltage and high-current efficiency in comparison with present M12 connector options. Rated for 16A and 630VAC/DC, the brand new M12 energy line delivers most energy in a small quantity of area, enabling compact and versatile field-installable power connections. Benefits embrace high-power transmission, area financial savings, 5 totally different codings that shield towards mismating (S, T, Okay, L, and M), and optionally available 360° shielding. The vary can also be standardized in accordance with IEC 61076-2-111 and permitted in accordance with UL 2237.
Mill-Max prolonged its 08XX Collection Ruggedized, Excessive-Present Spring Pins with three large-scale counterparts to its miniature spring pins. Designed to be used in cable, entrance panel, board stacking, and docking station purposes that require larger spacing than miniature spring pins’ typical 2.54mm centerline spacing with a view to meet electrical and mechanical specs, the brand new large-scale, high-current spring pins function ruggedized constructions produced from brass alloy that’s high-speed machined to precision tolerances and gold-plated for wonderful mechanical, thermal, and conductive properties. The rugged, large-scale spring pins have thick wall constructions, strong plungers, and gold-plated chrome steel springs that ship ultra-high reliability, efficient corrosion safety and put on resistance, and spectacular 1,000,000-cycle sturdiness. They’re rated at 9A, supply 1.143mm working journey and a couple of.286mm most journey, and exhibit greater spring forces than smaller, miniature spring-pin connectors. As well as, every gives distinctive terminations. The 0856-Zero-15-20-82-14-11-Zero has a solder tail for PCB mount meeting, the 0854-Zero-15-20-82-14-11-Zero has a solder cup, and the 0855-Zero-15-20-82-14-11-Zero has a crimp barrel, and each of the latter two can settle for wire diameters as much as 16AWG.
Nicomatic’s CMM Micro light-weight, rugged, rectangular connectors permit for greater than 20 million normal configurations of board-to-board, board-to-wire, and wire-to-wire cable assemblies with 1–three rows, as much as 120 gold-plated sign, high-frequency coaxial, and high-power contacts in combined layouts, and with numerous mounting hardware. The extraordinarily modular collection has a 2mm pitch grid format that delivers as much as 60% area financial savings and 50% weight financial savings in comparison with comparable rectangular connectors and a UL94 V-Zero PPS insulator that’s oxygen-free and immune to solvents, radiation, and humidity absorption. It additionally meets or exceeds the electrical and environmental efficiency necessities for MIL-DTL-55302F and BS-9525-F0033, is RoHS compliant and suitable with infrared, wave, and vapor part soldering, and is very immune to shock and vibration, designed to face up to temperature biking between -60°C and +260°C, and rated for as much as 2,500 mating cycles. Connector housing markings allow full traceability, and lead-times prolong from one week with low minimal order portions. Very best purposes for the collection span the civil avionics, protection and safety, power, medical, area, telecom/datacom, and transportation markets.
Schleuniger’s MegaStrip 9650 Automated Minimize and Strip Machine offers high-precision processing options starting from easy stripping to multi-stage operations for single-core wires, multi-conductor cables, and shielded cables as much as 35mm (1.38”) in outer diameter, together with quite a lot of high-voltage and high-current cables. It has a modular design that gives optimized options based mostly on application-specific necessities and environmental circumstances, allows fast and straightforward upgrades, and is suitable with a variety of equipment able to delivering a good broader vary of capabilities. The machine is obtainable in two primary variations: The MegaStrip 9650 M, which options Schleuniger’s patented multiple-blade place cutterhead for multi-step operations, and the MR mannequin, which provides a high-precision rotary incision unit with an automated centering system for high-quality shielded cable slicing. Each fashions come normal with the corporate’s SmartBlade™ system, which allows super-fast, solely seconds-long blade changeovers, function servo-driven transport models that ship unparalleled velocity and striping energy, are suitable with as much as two totally different inkjet marking methods, and have a 10” shade touchscreen consumer interface with intuitive icons and navigation and in depth libraries of predefined cable varieties, processes, and operations that simplify machine programming.