89 data transmission, EMC and other key concepts in hot demand among connector producers, particularly in comparison to five or six years ago amid the low speeds, signal bandwidths, and EMI for connectors working to USB 2.0 and RS-232 standards. In the interest of good service, connector companies are accruing an understanding of the ecosystems of different devices in need of connectivity in the markets they serve, through which they are able to adapt existing solutions or innovate new ones – going beyond connectors themselves to a range of related systems, as we will explore below. Rugged and secure As autonomous systems proceed to drive, fly and sail at faster speeds and in harsher conditions, so connector r&d teams are searching for new means of ruggedising the delicate signal and power links holding vehicle subsystems together, while saving on weight and cost where possible. For particularly shock- and vibrationprone environments, chrome-plated brass remains a leading choice for ruggedised shell materials, while aluminium shells are also used as a more weight-optimised alternative (often nickel-plated for added robustness), particularly in aerospace, and some exploration of composite material shells is under way. Additionally, certain plastics, such as PEEK and LCP, serve as highly temperature-resistant contact block materials, with various other plastics playing a key role in balancing ruggedness against cost (which can increase greatly when using metals). In the pursuit of effective plating methods, some manufacturers are stepping away from using hexavalent chrome plating for connector shell production and switching to trivalent chrome plating, which is more robust and consistent, as well as less energy intensive and environmentally polluting, while still being compliant with EU regulations on chrome bath processes. An arguably greater quantity of r&d has gone into new locking mechanisms, with new launches over the past year including a new bayonet-style system using a ratchet to secure a locking pin from the male end into the female end. This type of approach serves as a compromise between legacy screw-type latches (which are satisfyingly tactile, but laborious to mate and unmate) and pushpull connectors that are insufficiently secure for certain harsh environments. One such approach integrates a bright orange O-ring, which is visible to the handler until the connector is fully turned and locked, providing visual assurance that the system is secured. A key application has been in locking a COTS, high-speed, high-frequency, ruggedised USB-C connector, ensuring its data transmissions persist amid high vehicle velocities and vibrations. That said, push-pull latching connectors remain widely popular simply due to the ease of engagement and disengagement, and in specific applications where vehicle downtime must be minimised, such as in search and rescue, or wildfire monitoring (and mitigation, now that UAVs capable Connectors | Focus Uncrewed Systems Technology | February/March 2025 A wide variety of housings and shielding options are key to the different shock, vibration, EMI and other hazards connectors must endure (Image courtesy of Omnetics)
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