How to Choose Low-Frequency Industrial Connectors?

When it comes to Industrial Connectors, they can be broadly categorized into high-frequency and low-frequency types, with low-frequency Industrial Connectors operating at frequencies below 3MHz. In this blog, we will explore how to select low-frequency Industrial Connectors.

Electrical Parameters

Low-frequency Industrial M12 d Connectors are crucial components for connecting electrical circuits in aerospace and aviation applications. Therefore, it is essential to carefully consider their electrical parameters when selecting the appropriate connectors for your specific needs.

Rated Voltage

The rated voltage, also known as the working voltage, is a critical parameter that depends on the insulation materials and the spacing between the contacts used in the connector. It represents the maximum voltage level at which the connector can safely operate. It's important to note that some components or devices connected through Industrial Connectors may not function properly if operated below their rated voltage.

In practice, the rated voltage should be understood as the manufacturer's recommended maximum working voltage. As a general principle, Industrial Connectors should perform reliably at voltages lower than their rated voltage. It is advisable to choose the rated voltage based on factors such as the connector's dielectric strength and the safety requirements of the specific application.

Manufacturer's Recommendations

It is worth that for connectors with similar withstand voltage (dielectric strength) specifications, you can choose different maximum working voltages based on varying usage conditions and safety requirements. This approach allows for more flexibility and alignment with the actual usage scenario.

Rated Current

The rated current, also referred to as the working current, is another critical parameter to consider when selecting low-frequency Industrial Connectors. Just like with rated voltage, Industrial Connectors can typically function correctly at currents lower than their rated current. However, during the design process of these connectors, thermal considerations are taken into account to meet the rated current requirements.

As electrical current flows through the contact pairs in Industrial Connectors, resistive heating occurs due to the conductor's resistance and the contact resistance. If this heating exceeds a certain limit, it can damage the connector's insulation and cause softening of the contact surface, leading to operational failures.

It's essential to limit the rated current to ensure that the temperature rise within the aviation plug does not exceed the designated threshold. For multi-core electrical connectors, it is particularly important to apply derating. For instance, connectors with 3.5mm contact pairs may have a rated current of 50A, but in cases with five cores, a derating of 33% is applied. This means that the rated current per core is reduced to 38A. As the number of cores increases, the derating effect becomes more significant.

Environmental Factors

One of the key considerations when selecting low-frequency Industrial Connectors is the environmental conditions in which they will be used. Different environments, such as high humidity, extreme temperatures, or exposure to chemicals, may require specific connector characteristics. Ensure that the chosen plugs are designed to withstand the conditions they will be exposed to.

Safety Requirements

Safety is paramount in aviation and aerospace applications. The choice of Industrial Connectors should align with the safety regulations and requirements of your specific application. It's crucial to select connectors that meet or exceed the safety standards and guidelines set by relevant authorities.

Multi-Core Connectors

When dealing with multi-core Industrial Connectors, it's important to account for derating, especially in high-current scenarios. Be aware that as the number of cores increases, the derating effect becomes more pronounced. Proper consideration of derating helps ensure the reliable operation of the Industrial Connectors under high-current conditions.

Conclusion