Interconnection systems: A modular approach

Dynamic markets worldwide are calling for highly flexible, readily implementable production machines and systems that can be reliably and cost-effectively manufactured in batch production. 

The objective is to manufacture such machinery as late as possible in the production process or even at the end-user’s site. Such an approach requires lower levels of staff and involves greatly reduced costs. At the same time, it has the added benefit that the equipment is tailored to individual customers’ requirements. This is particularly the case in today’s global markets, where different customer preferences results in new structures geared to minimising costs while incurring minimum impact on quality and performance.

Modular systems 

These requirements provide an impetus for the development of modular systems (Fig.1), as demonstrated in a recently published study entitled 'Modular Products' by Roland Berger, an internationally renowned industrial consultant and entrepreneur. For mechanical engineering, in particular, the share of modular-based solutions is expected to grow significantly by 2015.

Implementation of these modular machine concepts requires extensive use of interconnection technology. For example, during the development of mechatronic units, mechanical and electrical interfaces are often required that are only finally connected securely during the assembly process. Other interfaces may be designed for repeated disconnection, connection and reconfiguration as installation or application requirements change over time. Factors that may pose no difficulties for mechanical components might require alternative solutions for power, signal and data interfaces in order to provide uncompromised and unrestricted functionality and compatibility. In addition, the interfaces need to be scalable – i.e. dimensioned for specific machine configurations wherever possible – with the possibility of being securely assembled and removed without the need for specialist personnel.

Modular solutions

Harting’s solution strategy emphasises the comprehensive range of variations within the connector product family (Fig.2). The product portfolio features devices and solutions for all major power, control, signal and data connections, allowing the customer to choose just those technical aspects that are specific to the end application as early as the design phase. Users do not need to worry about non-critical parameters of the interface, and can rescale the interfaces in a machine module with optimal cost-effectiveness and functionality at any stage of the development. The diverse coding variants available make it possible to configure each interface in such a way that the assembly of the machine modules can also be performed without specially trained personnel. 

Interface variations

The variations available within the product range allow a number of special-purpose configurations to be accommodated. These include a high-current interface for up to 40 A which can be used to supply power to complete machine modules or to the controls of larger individual motors or heaters. This means that, if the customer is only interested in the current-carrying capacity (40A) of the power contacts, the contacts can be applied in different combinations of contact inserts and housings.

The same applies to the provision of gigabit Ethernet connections - for Ethernet-based bus systems, for example, or for the high-resolution video systems that are applied in production and manufacturing applications. Here, a wide variety of contacts can be used with different contact inserts and housings. For example, Variant 4 of the Harting PushPull industrial connector family is well suited for providing reliable termination for today’s camera systems in applications such as industrial quality control or security surveillance (Fig.3). 

The comprehensive product range and compatibility of Harting products gives users in the industrial manufacturing sector a wide range of application possibilities while increasing the flexibility and variability of the systems in which they are employed.