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We now live in an age with systems that rely on constant access to large quantities of real-time data. Through inline measurement, these large quantities of data allow industrial processes to operate more efficiently, while advanced metering systems mean that homes and offices can consume less energy. There is also the potential benefit for regular data updates from equipment to be shared remotely, enabling the latest smart functionality and over the air (OTA) updates to be applied, even after the initial installation.

The data acquisition hardware and instrumentation needed for these applications call for the use of high-performance components. These components must have characteristics that will allow equipment to deliver the highest levels of data integrity – without the risk of failure.

Application examples

There are many applications that rely on real-time data acquisition, below are just a few of the many areas where the use of sophisticated data acquisition techniques is helping to change our society.

Metering

A combination legislation and wanting to combat climate change and reducing the size of energy bills is driving the roll-out of next-generation metering technology. Utility companies need metering hardware that goes beyond just locally situated analysis. They are looking to implement smart measurement solutions in which field-based IIoT devices are supported by high-speed communication infrastructure for cloud connectivity.

Smart factories

At production plants and processing sites, robotics and automated systems are now widely implemented as these facilities move into the Industry 4.0 era. This leads to increased throughput and lower manufacturing costs. Also, information from robots, AGVs, PLCs, IIoT nodes, and other monitoring equipment on numerous different parameters can be transported back to the cloud through low-latency industrial networks. Once there, it may be acted upon or stored for later examination and used for Condition based Monitoring (CbM) as part of a Predictive Maintenance schedule to reduce potential downtime of manufacturing equipment.

Remote Monitoring

Many industrial applications can be carried out in remote places with harsh environments. Utilising remote monitoring equipment, continuous data feeds from oil-drilling platforms, for example, can allow them to be run around the clock with either no, or minimal, human intervention being required.

Component selection

It is clear that data acquisition equipment needs to be accurate but it must also be highly durable due to the possible harsh application environments where they are placed. Additionally, given that it will generally be left unattended for long periods of time, and can often be fitted in positions that are difficult to reach (making repair and maintenance work costly to carry out), this equipment must also be highly reliable. Durability and long-term reliability are needed at a system level, and also at the component level too. Therefore, specifying suitable connectors from a reputable brand such as Harwin is critical.

Several key criteria as follows must be considered when specifying connectors for high-reliability data acquisition tasks.

• Compactness – In each of the examples given above, systems are likely to be subject to acute space constraints. For this reason, more streamlined interconnect solutions are recommended.
• Multi-functionality – The use of connectors capable of delivering power and data will be preferable, as this allows further space-saving. Reducing the amount of board real estate utilised also means less wiring is needed (curbing the bill-of-materials costs too).   
• The ability to maintain prolonged operation – Due to the application settings in which these connectors are placed, they may be subjected to shocks, vibration forces, and extreme temperature fluctuations. These can each have an impact on operational lifespan if connector components that have inadequate resilience are chosen. Also, strong mating cycle durability will be advantageous in applications where cabling must be regularly detached and reattached.

Gecko-MT connectors

The 1.25mm-pitch Gecko-MT series from Harwin is the most compact and lightweight combined power/data connectors in its class. These connectors are highly optimised for use in industrial automation systems and instrumentation, there are board-to-board, cable-to-board, and cable-to-cable options available.
The Gecko-MT connectors incorporate an array of 8x 2A-rated contacts for data transmission, accompanied by power contacts (either 2 or 4) capable of delivering 10A currents. They feature a proprietary four-finger contact design which assures interconnect integrity – even when exposed to heavy shocks (up to 50G) or continuous vibrations (up to 20G).
The data and power contacts the Gecko-MT uses are manufactured from Beryllium-Copper alloy, giving enhanced electrical performance alongside long-term durability. This allows to connectors to offer 1000 mating cycle durability. The Stainless-Steel jackscrews strengthen mating retention, and parts have an operational temperature range of 65°C to 150°C.

Click below to see an introduction of the benefits of mixing power and signal connections in one connector

Datamate Mix-Tek connectors

For applications that have greater power carrying requirements, Harwin offers the Datamate Mix-Tek series of connectors. These can be specified in configurations with single row power or 6GHz coax contacts alongside double row signal contacts.
The same 4-finger contact arrangement with Beryllium-Copper construction has been employed to mitigate the effects of shock and vibration. The Datamate Mix-Tek signal contacts can handle 3A currents, while different current levels can be supported by the power contacts – going from 5A up to 40A. 20AWG wiring can be used for 5A system designs, but for higher current levels (20A or above) 12AWG wiring should be used. The Datamate Mix-Tek connectors can handle temperatures from -55°C to +125°C and are specified for 500 mating cycles.
For additional security and robustness additional Jackscrews are optional, with both standard and reverse-fixing versions being provided. Fast-mating 101Lok locking mechanisms can also be specified.

EMI Shielding Cans and Clips

As well as having compact and robust interconnects, data acquisition equipment must be protected from electromagnetic interference (EMI) – otherwise, the quality and integrity of the data being captured will be compromised. For this reason, Harwin supplies Nickel-Silver shielding cans in various shapes and sizes. Attached via surface-mount clips, these are easy to fit and replace, with configurations adaptable to new design layouts. Plus, through the shield can kits that are also available, engineers can quickly create custom shields for use in prototyping.

Click below to see how easy the EMI Shielding Cans are to remove and replace

Anglia are offering customers FREE samples of the Gecko-MT, Datamate Mix-Tek and EMI Shielding Can products from Harwin, please fill in the form below to register your interest now.