Nano-circular connectors and round cables are becoming increasingly important in the design of sensors for rugged applications. With the advancement of data-acquisition and information-monitoring technologies, a wide range of devices, such as drones, robotics, automobile safety systems, and medical alert devices, rely on sensors and their interconnections to gather and transmit data.
In military and defense applications, satellite constellations and autonomous defense systems utilize nano-circular connectors and cables to transmit vital information, monitor ground troops, and enable data communication through satellites. These connectors play a significant role in guiding missiles by providing direction and angle data to ailerons or fins, allowing for precise tracking and supersonic speed attacks.
Integrating sensor chips into miniature circuits is a key approach to expanding data digitization. Sensors are strategically positioned in various applications, such as at the end of robotic arms in remote surgery tools or in missile weapons to collect data for tracking and targeting purposes. The challenge lies in designing connectors that can withstand demanding conditions, including constant vibration, wide temperature ranges, and physical shocks.
Nano-circular connectors and cables offer several advantages for adapting sensors to new equipment and machinery. Since many sensors operate on low voltages and minor current levels, they can function with modest power supplies or battery packs. These connectors can be designed to fit within the system, bend and flex in multiple directions, and easily connect to the back housing of a round nano-circular connector shell.
The design of nano-circular connectors involves selecting pin and socket elements based on military standards like MIL-STD-83513 or MIL-STD 32139. These connectors are rigorously tested for reliability and repeated use. Beryllium copper flex pins, nickel- and gold-plated, are commonly used and have undergone extensive testing for field and extreme environmental applications. Insulators are molded from materials similar to micro and nano-D connectors, and the pins and socket elements are arranged in circular patterns with tight spacing.
Connector options include various metal shell designs such as push-pull, quick-disconnect, and twist lock, as well as custom shapes to fit specific applications. Molded polymer outer shells are also available, offering smaller size, lower weight, and increased shock and vibration resistance. Nano-circular connectors can endure over 2,000 connection cycles without wear or performance degradation.
Cable design is crucial for signal speed and integrity. Shielding and drain wire interconnections contribute to system accuracy and eye pattern quality, while reducing jitter and crosstalk. The smaller size and ruggedness of nano-circular connectors make them suitable for portable ground troop electronics, airborne equipment like unmanned aerial systems (UASs) and unmanned aerial vehicles (UAVs), and satellite systems.
When selecting nano-circular connectors and cables, specific requirements should be considered along with standard designs offered by suppliers. Collaboration with connector designers allows for application-specific adjustments to existing MIL-spec quality connectors. Solid modeling and 3D samples facilitate the prototyping process, providing a faster route to fit and confirmation within a week.
Nano-circular connectors are essential for rugged, lightweight, and high-reliability applications. They offer a variety of materials, shielding options, sizes, shell types, and mounting options to meet diverse needs. Miniaturization is critical for robotics, small satellites, and lightweight designs, and nano-circular connectors provide MIL-spec quality and reliability with commercial off-the-shelf (COTS) availability.
(Photo 1: Nano-circular connectors provide rugged, lightweight, and high-reliability solutions. Omnetics offers a wide range of options for these versatile connectors, including materials, shielding, sizes, shell types, and mounting options.)
(Photo 2: Omnetics’ nano-circular connectors ensure MIL-spec quality and reliability in miniaturized designs for robotics, small satellites, and other lightweight applications.)
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