Metalwork is the manufacturing of formed metal workpieces according to specific geometric parameters. Many different manufacturing processes exist today, and engineers will think about the workpiece, how the machine will modify it, and try to ensure that the result is as reliable and reproduceable as possible. Therefore, developing machines for metal works requires experience and knowledge of the conditions they will operate in.

The machine has to be very robust to withstand all the forces which occur during the forming process. Physical parameters might change during the process which has to be considered. The harsh environment and the worker equipped with protection gloves are often a risk for damaging a connector during mating cycles. Electrical connections are critical for any machining equipment, since the connections can have a major impact on the machining result. A broken electrical connector might cause unreliable results because of unsecure transfer of sensor data, modified sensor data or loss of power during a process. Poor handling behavior or unsafe conditions increase the risk of damaging the machine or hurting the user. Over time this might damage equipment, injure operators, and ultimately have a critically negative impact on the manufacturer brand image.

To avoid these serious issues an engineer should spend some time evaluating the best electrical connector solution for metal work equipment. Choosing the right connector will save money and time, and deliver operational quality and reliability.

Physical impact on connectors

Metalwork causes a high physical stress for connectors mounted inside of machining equipment or at the head of a robot.  The physical impact might be one or a combination of these:

Mechanical Shock - Vibration - Wide range of temperature - EMI Shielding - Water and humidity - Aggressive chemicals

Temperature

During mechanical manipulations like drilling or welding, the environmental temperature might go up rapidly, even if cooling fluids are used. After a mechanical process cycle the temperature might go down again. This requires connectors which resist high temperatures and repeated temperature cycles.

Water / Humidity / Chemicals

Cooling fluids can be aggressive and cause corrosion. If they find a way inside the connector they will damage inner components which can cause all sorts of problems, ranging from signal integrity to overvoltage. Corrosion inside of a connector can also have an impact on mechanical robustness or cause problems to unlock to connector. Therefore, the connector, as well as the rest of the wiring solution has to be water tight. The solution should also work properly after several maintenance cycles. This can be addressed by using an overmoulded connector. An overmould eliminates the risk of having fluids entering the connector from the back.

EMI

Modern manufacturing processes capture a lot of data during the process which has to be transferred correctly. This requires a shielded connector to ensure signal integrity. Usually only metal connectors will fulfill this requirement. For better handling a plastic housing might cover the metal surface which combines good EMI behavior with good handling.

Ease of use

For maintenance or change of tooling it is required to unplug a connector. Depending on the change frequency a push-pull connector might be a good solution. If changes occur on a daily basis this would be the preferred option for quick and easy operations. Connectors designed for a high number of mating cycles have different contact platings to ensure low contact resistance, even after more than one thousand mating cycles. The design should ensure that the connector and receptacle is not damaged during handling and mating, which is achieved with scoop-proof designs. Push-pull solution comply with all of these requirements.

To ensure a proper mechanical connection in an environment subject to high vibration, this requires a specially-engineered solution which is often reflected in the connector price. For connections which are not unplugged very often a screw termination or bayonet locking mechanism is better. These connectors allow a very stable connection which can be opened without any special tooling.

SOURIAU RANGES:

Souriau-Sunbank by Eaton offers a wide range of solutions to address market needs for the diverse metalwork applications, ranging from plastic to metal shells, and screw mating to push pull. All connectors address most demanding requirements for IP sealing, vibration and shock resistance. Depending on the chosen connector a solution might be optimized for a higher number of mating cycles like with JBX or UTL. Depending on shielding and weight requirements a plastic connector (UTS) or metal connector (UTO) might be preferred. All solutions for metalwork applications are compliant with RoHS and REACH regulations, and depending on the addressed markets the connectors may also require certifications like UL or IEC. To improve robustness of the solution for most connectors an overmoulded option is available.

Souriau industrial products are compliant with all major IEC and UL standards, guaranteeing the safety of your staff and equipment.

The long lifetime of Souriau's interconnect products for metalwork significantly reduces the frequency of maintenance, and for you, that translates into saving costs and gaining productivity. You can find out more about our metalwork connectors by visiting our application page.

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