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michelletan

About michelletan

Product Manager for Industrial Field Connector and Field Device Connector

Plastic VS Aluminium – Heavycon Edition

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Heavy-duty connectors are typically made of aluminium as it is supposed to be tough and durable. However, being an innovative company and discontented with the current industrial norm, Phoenix Contact had come up with HEAVYCON EVO in plastic.

The plastic used in HEAVYCON EVO housing is not just any normal plastic, it is made of polyamide, reinforced with glass.

So, how strong is strong? Several tests were done to the plastic HEAVYCON including basic IP and NEMA tests in accordance with DIN EN 60529, NEMA 250. This ensures that the contact inserts within the plastic housing are protected against the ingress of dust and heavy jet water. The other tests include:

Vibration test in accordance to IEC 60068-2-6

Harmonic, sinusoidal vibration is applied to HEAVYCON plastic housing to simulate rotating, pulsating or oscillating forces. HEAVYCON plastic housing fulfils these requirements, making it ideal for heavy machinery application.

Temperature shock test in accordance to IEC 60512-11-4

We simulate significant temperature changes by switching HEAVYCON plastic housing between 2 chambers of extreme temperatures within seconds. The result is affirmative – HEAVYCON plastic housing is suitable to be used in applications with ambient temperature between -40 to 125 degree Celsius.

IK shock test in accordance to IEC 62262

Shock is introduced by dropping a hammer of 1.7 kg mass from a height of 0.3m. HEAVYCON plastic housing is able to meet the mechanical requirements similar to the HEAVYCON aluminium housing.

Roll over test in accordance to DIN IEC 62196-1

This is a special test carried out on the plastic housing where a forklift truck weighing several tons rolls over it. HEAVYCON plastic housing is able to withstand high amounts of stress from heavy, moving loads without any adverse effects on its function. In fact, in Singapore, we proved it again by driving a car over the connector.

Dynamic load test

Besides the strength of the plastic housing, we have to ensure the latching mechanism is heavy-duty enough as well. In this test, we applied a force of 200N to the cable at an angle of 90 degree. This is to test the HEAVYCON EVO bayonet as well as the locking latch between the housing and panel mounting to make sure that they do not malfunction under extreme static load.

Through the tests we have done, we can conclude that plastic can be as strong as metal too, in this case aluminium. To find out more about the durability of our HEAVYCON EVO in plastic, please leave a comment below.

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10 Things You Need to Know about Fibre Optic LC Connectors

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Fibre optic cables carry information using light and it is only slightly thicker than human hair. It transmits data faster and further than a copper cable, but you probably already know this. Instead of going into details about fibre optic cables, we are going to show you 10 things you probably do not know about the fibre optic LC connector.

  1. LC stands for Lucent Connector, sometimes also known as “little connector”
  2. It is one of the smallest fibre optic connectors in the market. It is half the size of a Square Connector (SC) which is the most commonly used fibre optic connector in the market.
  1. Although both LC and SC are classified as push-pull connectors, LC uses latch locking while SC uses locking tabs.
  2. The introduction of LC wasn’t a bed of roses. Due to the high licensing fee, it was not well-received when it was first launched.

Source: http://www.publicdomainpictures.net/view-image.php?image=188267&picture=broken-piggy-bank

  1. However, due to the factor of its small form, LC had slowly gained its popularity in applications that requires high density connections.
  2. LC is usually used in high density patch panel. High density patch panel provides the flexibility for future expansion.
  3. LC is the preferred connector for single mode fibre optic cables. Single mode is able to transmit a higher bandwidth over a longer distance. However, it’s more expensive as compared to multimode fibre optic cables.
  4. Phoenix Contact new modular patch panels enable users to connect up to 72 LC duplex connectors to optimise the use of space within control cabinets.
  5. Phoenix Contact compact splice box FDX 20 allows users to connect up to 12 LC duplex connectors. It is also one of the smallest splice boxes in the market.

  1. Besides LC connectors, Phoenix Contact offers a full array of fibre optic products and accessories including patch cords, reusable connectors and tools.

To know more about our range of fibre optic products, feel free to fill up the form below!

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5 Ways to Terminate Cables into an Electrical Panel

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There are several criteria when it comes to choosing the right cable entry method into an electrical panel, such as ingress protection (IP) rating, ease of connection/ disconnection, cost of the connector etc. In this post, we have sorted out 6 different cable entry methods that Phoenix Contact has to offer.

  1. Cable Gland

The most common way to terminate cables into an electrical panel would be to use a cable gland. It is easy to use and comes in many variants such as different sizes, materials and with additional certifications such as ATEX. Cable glands are probably one of the most affordable cable entry methods mentioned in this article.

However, cable glands have its limitations too. It is difficult and time consuming to do multiple connections/disconnections with cable glands as the cables are terminated directly into the components within the electrical panel. In addition, the pre-cut holes on the gland plate are irreversible. It provides limited flexibility for mistakes and modifications.

  1. Heavy-duty Connector

As the name suggests, it is rugged and enables fast and easy connection/disconnection to the electrical panel. Cables are prewired into the connector base, which is mounted onto the panel while the field cables are prewired into the connector hood. The hood is then plugged into the base on the electrical panel for a complete connection up to IP 69K.

Heavy-duty connector is especially useful for portable applications and testing facilities as it allows quick connection and disconnection. Although heavy-duty connectors are more expensive than cable glands, it minimises time and labour needed for onsite installation and commissioning up to 80%. It also reduces errors that could occur during onsite installation.

Heavy-duty connectors are typically made from Aluminium. However, Heavycon EVO from Phoenix Contact also comes in plastic (polyamide with reinforced fibre glass) to support applications that do not require metal housings and provides cost savings of up to 30%. Besides that, the dual entry cable gland enhances the flexibility for onsite installation. Phoenix Contact’s well known Push-in Technology is also used in Heavycon to further reduce the installation time.

  1. Cable entry system

Cable entry system (CES) is similar to cable glands. However, it helps to arrange the cables neatly and systematically into the electrical panel. By better managing the cables, the gland plate can be better utilised. It works in a modular form where the cable sleeves can be flexibly combined depending on the wiring. The slotted sleeves also allow the use of sensor actuator cabling while cone sleeves come in handy when the cable diameter is not predefined.

The cut-out of CES is the same as that of heavy-duty connectors. Thus, they are interchangeable. However, CES is not a pluggable connector. Thus, it is not suitable for applications that require frequent connecting/disconnecting.

  1. CES Multigate

Similar to CES, multigate offers great cable management. However, unlike CES, multigate has prefixed cable entry. Each cable entry is a cone-shape membrane that is able to accommodate a range of cable diameters. This is especially suitable for panels with defined cable specifications. As the cables are well arranged, it is easier to isolate faulty lines, if any.

  1. Service interface

Service interfaces make maintenance, servicing, and diagnostics easier than ever. The front plate comes in different configurations of D-SUB, RJ45 and USB, offering numerous combinations.  The mounting frame offers up to IP 65 protection with locking mechanism for extra security. This reduces the need to open up the panel during programming or configuration.

There are many factors to consider when it comes to choosing the most suitable cable entry method to your electrical panels. Let us help you with the selection by filling up the form below!

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HEAVYCON Modular for IIOT

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IIOT

More often than not, when people talk about Industrial Internet of Things (IIOT) or Industry 4.0, they neglect the ‘links’ between the sensors and components.

Yes, I’m talking about the connectors (the ones that connects sensors and components, what else?).

A huge part of IIOT includes data collection and analysis.

This means that a lot of sensors and cables will be used to detect, capture and transmit data. It can be really time consuming and a chore to wire these amount of cables directly into the panel on-site during installation and maintenance.

If you’re reading this, consider yourself lucky.

I’m going to show you how Phoenix Contact’s Heavycon can make connection easy, fast and smart. (Don’t be fooled by its name. It’s not heavy in weight rather, it’s heavy duty – able to withstand demanding environments).

So what’s a Heavycon?

HEAVYCON

HEAVYCON

Phoenix Contact’s Heavycon is a plug-and-play solution.

It allows the cables to be pre-wired into the connector within the panel and in the field. This makes on-site installation and maintenance fuss-free and efficient.

Simply plug and play! It eliminates the tedious process of direct wiring on-site.

It also removes the need to open up the panel during installation and maintenance which in turn reduces the risk of people meddling with the crucial components within the panel.

Pictured: Definitely not HEAVYCON. Because we don’t want people messing around with what’s already a mess.

Termination of wire is also made easy with Push-in Connection Technology. No special tool is required. Simply insert the wire with ferule into the designated slot. To remove, push the orange button and pull the cable out.

Contact inserts with push-in connection

Contact inserts with push-in connection

Heavycon also comes in modular form!

Heavycon Modular allows you to connect signal, data and power in one single connector.

Push-in connection technology is available in module form too. We also have a wide range of network modules such as RJ45, D-sub, Gigabit Ethernet Cat 6 connectors and even fibre optics and power module up to 200A.

Modular contact inserts

Modular contact inserts

The unique snap-in frame makes inserting and removing of modules a piece of cake. This provides the flexibility of changing the configuration effortlessly according to your set up.

Push-in modular contact insert

Push-in modular contact insert

Need more flexibility? Heavycon EVO enables you to change the direction of cable entry on-site depending on your desired arrangement.

HEAVYCON EVO

HEAVYCON EVO

Furthermore, Heavycon is resistant against dirt, water, vibrations and high mechanical strain and has protection up to IP69K.

Thus, it is able to withstand harsh conditions and is suitable for outdoor applications.

HEAVYCON getting sprayed by pressure jets

Looks worse than any rain I’ve ever seen

If you want to see how we torture the Heavycon, you can watch the video below:

With that said, it’s about time to start adopting smart connectivity as we hop onto the IIOT bandwagon.

More videos about the Heavycon:

Register your interest below and request for a product sample today!

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Data Connector – RJ45

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As more factories go into automation, more networks and fieldbuses are used for communicating between machines and people.

RJ45 is one of the most commonly used connector.

What is this RJ45?

It is a type of standard connector for network cables, especially Ethernet.

RJ45 CableSome of the common issues faced with RJ45 connector include intermittent data. Most RJ45 connectors in the market come with a plastic clip.

RJ45 Connector clip

The plastic clip helps to form a secure connection between the connector and the socket. It also ensures that the connector stays seated on the socket.

You would need to exert some pressure on the plastic clip in order to unplug the connector. However, the plastic clip is usually fragile.

It breaks easily when bend backwards or when the connector is dropped on the floor. Without the plastic clip, the transmission of data is not guaranteed. The RJ45 would then be used with the nearest trash bin – if you know what I mean.

E-Waste in bin

Often times, even when the plastic clip is intact, intermittent data could occur due to vibration from the surrounding machines.

Other issues surrounding the RJ45

Moreover, the process of crimping a RJ45 can be tedious. In order for the connector to function properly, the cable (with as many as 8 cores) has to be crimped into specific standards, namely T568S and T568B, with a special crimping tool.

T568A and T568B wiring

Crimping is a manual process and depends very much on the workmanship of the person who is doing the job.

If it is not done properly, the crimp contact will not sit properly within the connector and the data transmission will be affected.

Crimping is an irreversible process. If the connector is crimped wrongly, it cannot be un-crimped (word of caution).

It has to be scrapped and the damaged cable has to be cut which causes wastage.

CAT 6 Twisted Pairs

Problems, problems and more problems. So what’s the solution?

At Phoenix Contact we build innovations based on issues that every day people, like you and me, have.

Phoenix Contact Industrial RJ45 is equipped with 2 springs at the top of the connector to ensure that the connector is sitting snuggly within the socket, even during high vibration applications (yes, even the extreme ones).

 

Phoenix Contact's RJ45 Connector

Phoenix Contact plastic RJ45 connector is made of special plastic. It could not only bend 180 degree without breaking but it could also resist the impact of dropping on the ground.

QUICKON RJ45 Connector

Phoenix contact QUICKON RJ45 connector allows you to terminate cable without the need to strip the cable and the use of expensive crimping tool.

The connector is colour-coded so there is no need to memorise the standards.

IDC Conenction

In addition, the connector is able to reconnect up to 10 times. Meaning to say, there is no need to scrap the connector if it’s connected wrongly. Just follow the simple steps below to terminate the cable.

RJ45 Quickon assembly step-by-step

Or alternatively, if reading is a chore, you can watch this video right here:

https://www.youtube.com/watch?v=Pm2wNf9DUCk

See how easy that was? At this rate you’ll be producing thousands of RJ45 within seconds.

 

So if you’re looking for a reliable and problem-free RJ45 cable, look no further.

Request a product demo today!

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Manufacturing Expo 2017

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We would like to invite you to join us in at Manufacturing Expo 2017 located in Thailand, Bangkok, BITEC, from 21 to 24 June 2017. Manufacturing Expo is one of the biggest manufacturing exhibitions in South East Asia. It comprises of 7 sub-shows. We will be located at Automotive Manufacturing, under Singapore Pavilion (3D15)..

One of the most thriving industries in Thailand, Automotive adopts industry 4.0 to boost the production efficiency. Moving with the industry trend, Phoenix Contact would like to take this opportunity to showcase our capability on smart connectivity for smart factories as well as Phoenix Contact very own Industrial Internet of Things (IIOT) solution.

Being an innovative company, we strive to increase productivity and efficiency with cutting edge connection technologies. Quick connection technologies were incorporated into our connectors as well.

For example,

Push-in

Push-In Connector

Insulation Displacement Connection (IDC)

Insulation Displacement Connection (IDC)

Piercecon for high density (up to 17 positions)

Piercecon Connection

Besides signal, M12 connector is also used in transmitting data such as Ethernet and Profinet as well as power (AC/DC). Phoenix Contact is able to provide a complete solution from device connectors to field cablings.

Signal, Data, Power

Industry 4.0 requires the transmission of more signal, data and power than ever. Phoenix Contact circular hybrid connector provides an All-in-One solution.

HEAVYCON Modular

Using Heavycon Modular, signal, data and power can be mix and match easily in one connector. It also provides the flexibility for future expansion and modification

HEAVYCON Surface Mount

Besides copper based data connectors, we also have a complete solution for fibre optics according to your requirements.

Fibre Optic Data Connectors

Interested to know more about the applications of the products mentioned above? Come join us at Manufacturing Expo. Our sales team will be happy to assist you. Express your interest by helping us to fill up the survey form to receive a mystery gift.

Drive the Automotive Industry with Phoenix Contact’s Data Connectors

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Automative Assembly Line
The Automotive industry is one of the highest revenue-generating industries in the world. In 2016, about 95 million cars were manufactured. Thailand is the biggest country for the automotive industry in South East Asia and the 12th largest in the world as of 2015.

About 2 million vehicles are manufactured annually in Thailand.

Automotive manufacturers are adopting automation for a more cost-efficient way to make vehicles. By replacing human with robotic technology, the company would be able to save on wages and related costs such as insurance, medical leave, employee’s benefits as well as taxes. This shifts the labour intensive production to a data-driven production.

Phoenix Contact solution to secure data transmission

Push-pull Advance Connector

Push-pull Advance Connector

Phoenix Contact’s Push-Pull Advance data connector is 360 degree shielded and is able to transmit data up to 1 Gbit/s. Field assembly without special tool is possible with QUICKON connection technology. It also has production indicator for traceability.

Push-Pull Advance data connector is equipped with a locking system to increase the security of the connector. To lock/unlock, use a screw driver to shift the orange catch to the respective indication.

Push-pull advance connector handling

Keen to find out more? We will be having a booth (3D15) at Manufacturing Expo in Bangkok, Thailand, where we will be showcasing more products on smart connectivity.

Venue: BITEC
Date: 21- 24 June 2017

* Manufacturing Expo is Thailand largest manufacturing exhibition. It consists of 7 sub-shows
InterPlas Thailand, for plastics parts production
InterMold Thailand, for mold and die manufacturing
Automotive Manufacturing, for Automotive Parts Manufacturing
Assembly and Automation Technology, for Automation and Assembly Technology
Surface & Coatings, for Surface Treatment, Paints, & Coatings
NEPCON Thailand, Assembly, Measurement and Testing Technologies for Electronics Manufacturing
Mfair, Business Matching Platform for Manufactures’ Network in Asia

We hope to see you there!

HEAVYCON Complete

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heavycon connectors

Heavycon Complete

HEAVYCON Complete

In the blog post written earlier in June this year, we talked about the new addition to the HEAVYCON Complete family – HEAVYCON modular. Today, we would like to go in depth and tell you more about HEAVYCON Complete.

First, let me give you a brief introduction on heavy duty connector. It consists of a pair of contact inserts and the housing which is made up of a base and a hood.  In Phoenix Contact, HEAVYCON comes in 3 different models to suit your different requirements.

HEAVYCON EVO

heavycon evo

Heavycon Evo

Uniquely Phoenix Contact!  HEAVYCON EVO is specially designed for users who are unable to determine direction of the cable entry. By simply twisting the special bayonet gland, the direction of the cable entry can be changed as desire. Furthermore, the special bayonet gland comes in 4 different sizes ranging from M20 to M40 that fit all the HEAVYCON EVO housings. This basically means that you can save up to 70% of the logistic cost when you’re using various sizes of the housings.

HEAVYCON Standard

heavycon standard connectors

Heavycon Standard

HEAVYCON Standard comes in 2 parts- a panel mounting base and a hood. Like HEAVYCON EVO, HEAVYCON Standard can be plugged and unplugged easily without the use of additional tools. A huge array of different combination is available depending on your needs, be it single latch, double latches or box mounting (where no panel cut out is required). All our metal housings are made of AlSi12 aluminium which is seawater resistant. Thus, suitable for marine application

 

HEAVYCON Advance

heavycon advance connector

HEAVYCON Advance

Instead of panel mounting base like HEAVYCON EVO and Standard, HEAVYCON Advance uses panel mounting flange which reduces the height of the connector. Need higher IP rating? HEAVYCON Advance is IP69K rated which means that it is dust tight and is able to withstand powerful high temperature water jet.

 

 

HEAVYCON Connection Technologies

Push-in connection

Push-in Connection

Spring-cage connection

Spring-cage Connection

Crimped connection

Crimped Connection

Screw-in connection

Screw-in Connection

QUICKON connection

QUICKON Connection

From the most widely used, screw connection and crimp connection to push-in connection technology that’s uniquely Phoenix Contact. Our HEAVYCON connectors come with a wide array of connection technology that will suit individual needs.

Rugged and All-weather

Last but not least, HEAVYCON plastic connectors are tested in accordance with numerous national and international standards. They are definitely as rugged as the metal connectors.

IP Protection test DIN EN 60529

IP Protection Test
DIN EN 60529

HEAVYCON vibration test

Vibration Test

HEAVYCON Temperature Shock Test

Temperature Shock Test
IEC 60512-11-4, test 11d

HEAVYCON IK08 Shock Resistance Test

IK08 Shock Resistance Test
DIN EN 50102

HEAVYCON Rollover Test

Rollover Test
DIN IEC 62196-1

HEAVYCON Dynamic Lateral Load Test

Dynamic Lateral Load Test
DIN EN 60512-5

HEAVYCON Modular- Everything in One Housing

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In production processes, assemblies and machines are interconnected using industrial plug-in connectors. These connectors have to be reliable and flexible enough to accommodate to future modifications and expansions. Phoenix Contact sees this and introduces the newly enhanced HEAVYCON Modular into HEAVYCON Complete family.

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