Transform Your Connections with Han-Modular®
What is Han-Modular®?
With the Han-Modular® series, you can optimally design connectors to supply machinery and equipment. This is made possible by combining individual modules for different transmission media. The connector handles different signal types through the combination of different modules that the designer selects. Modules can also be used to accommodate multimedia types, such as power, signal, and data can be combined into a single connector rather than separate connections.
Explore the Benefits of Modular Connectors
- Space Savings
- Integration of multiple connectors into a single unit allow for significant reduction in space requirements.
- Low-Maintenance
- Using a pre-assembled, pre-tested connector assembly can reduce hard wiring and installation time.
- Flexibility
- With the Han-Modular® series, users can assemble their ‘own’ connectors according to their own individual requirements. Essentially creating a “custom” connector using standard stocked modules.
- Future Proof
- Placeholder modules give you the flexibility to future-proof your modular connector design.
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Frequently Asked Questions
What is a modular connector?
It is one where power, signal, and data can be combined into a single connector rather than separate connections. The connector handles different signal types through the combination of different modules that the designer selects. Modules can also be used to accommodate nonelectrical media such as connections for air lines and fiber optics in the same device as electrical connections.
What kind of machine automation applications would replace hardwired connections with a modular connector?
The typical justifications for modular connectors include reduced installation and maintenance costs. They can be particularly compelling for machines or processes produced for multiple installations. A truism for modular connectors is that the connector pays for itself the first time it is disconnected. Modular connectors also find use when space is tight partly because their rectangular shape typically can handle more contacts than similarly sized circular connectors.
How does the configuration process for a modular connector begin?
he designer begins either with the electrical schematic or with a knowledge of the number and kinds of cables that the connector must accommodate. Both the makeup of the connector and its location typically also depend on where in the enclosure the connector conductors will go. Other factors that affect the connector design include the need for locking and the degree to which there’s a need for water-tight performance.
Is there a maximum or minimum physical size for modular connectors?
There is no maximum size but most modular connectors are normally less than 2 in. wide by 3-6 in. long. It is possible to find larger connectors but usually only for specialized applications such as handling high amperage conductors in locomotives and energy storage and generation. Typical connectors are in the 5 × 3-in. range. The smallest modular connectors are generally about an inch square and generally handle only a few conductors.
Is there a maximum number of conductors that modular connectors can handle?
It is physically possible to accommodate 300 24AWG wires or 216 14-gage wires in a modular connector. But it is exceedingly rare to see this sort of device. Most applications use connectors handling between four and 50 conductors for electrical conductors that are 22-gage or larger.
What kind of connections can modular connectors handle?
It is common for modular connectors to contain small signal wiring and power connections. Fiber optic connections can be built in as well. And frequently, pneumatic lines are combined with electrical connections in modular connectors.
What are the limits on the connection parameters?
Industrial connectors typically don’t carry specs for high-frequency signals but they can handle signal frequencies that characterize mainstream industrial processes. Most connectors are rated for 600 V but special models can handle voltages up to about 5 kV. Similarly, there are connector models that will accommodate conductors carrying hundreds of amps. For air connections, connectors can handle air pressures of 116 psi at most through quarter-inch-diameter hose.
What kind of quality standards apply to modular connectors?
UL and cUL standards apply for safety and environmental ratings. DIN standards govern crimping, spacing, and other internal electrical qualities of the connector. But there are no standards governing the mating interface. HARTING is the inventor of the modular rectangular connector and has set the interface industry standard for modular connectivity.
What determines whether a connector needs a lock?
If the connection must be physically strong, the mating devices may need to be held together with screws. In some applications a quick release is important, and push-button style disconnects will often work well. Still other connectors can be outfitted with one or two levers, typically attached to the housing, for clamp down. The lever position can take into account where there is free space available for hand access.
Can connectors be water tight?
Most connectors are rated IP65, meaning they withstand water jetted at them for at least three minutes at 1,000 kPa. If need be, connectors can be made with ratings of 1P67 of IP68 which means they stand up to immersion of up to 1 m and 2 m respectively for an hour.
Can connector housings be plastic or metal?
Connectors that must have IP65 or IP67 ratings are available in plastic or metal. Connectors requiring an IP68 rating are metal and are fastened together via screw or toggle locking designs. Connectors with pushbutton disconnect also must be metal. Most metal connector housings are powder-coated aluminum. But housings can also be stainless steel for washdown applications or zinc where the housing must not spark when touching other surfaces. Plastic housings are fiberglass-reinforced resins and may be lighter and somewhat less expensive than metal versions of the same connector.
Are there special factors that bear on connectors that combine different signal types?
Typical factors resemble those used to ensure signal fidelity on printed circuit boards. For example, when shielded cable terminates in the connector, the connector should carry the shield through to the mating side. This type of practice is important when power signals are in close proximity to low-voltage signals.
Circular vs. Rectangular
You twist circular connectors into place & lock rectangular connectors with latching mechanisms.
Discover which one you should use!
Frequently Asked Questions
What kinds of connectors can engineers specify for machine designs today?
Design engineers have two choices for industrial electrical connectors: circular and rectangular. Circular connectors have a long history in military applications and in food and beverage processing. Rectangular connectors are used widely in modular machine design, factory automation, robotics, transportation and power generation. Both have benefits - for example, circular connectors are advantageous when a cable is passing through a cable tray. Rectangular connectors offer other benefits, such as easy customization with standard modules and space saving.
Why are circular connectors so common, if they pose drawbacks?
Circular connectors are common because they have been the standard for a long time. This does not mean that they are the best solution for every application as the benefits of rectangular connectors often outweigh the benefits of circular connectors. For example, any side-by-side circular connector arrangement requires additional space for accessibility to twist and lock in the connectors. A rectangular connector arrangement does not require as much space in between connectors.
How are today’s connectors different than those in the past?
In the past connectors simply passed voltages between two points. Today’s connectors must meet the complex needs of modern systems by allowing the incorporation of multiple medias, such as power, signal, coax, Ethernet, fiber optics and pneumatics cabling into a single connector. A rectangular connector can easily combine multiple medias into a single connector using standard modules that can be easily arranged into a custom solution. Systems using circular connectors still require separate connectors for Ethernet, fiber optic, and coax power.
What are the main benefits of rectangular connectors?
When compared to circular connectors rectangular connectors are generally less expensive, have shorter lead times, and are more easily customizable. Rectangular connectors also have a better grounding system providing more protection against overvoltage and have a visual polarization for easy mating. They can also be easily keyed.
Key advantages for using rectangular connectors over circular include:
- Off-the-shelf modules for easy, custom designs for any application
- Superior space efficiency
- More termination options – crimp, solder, screw terminal, others
- More locking options - single or double -lever and push button
- Ability to connect to other devices such as a PCB
- Greater contact density possible
- Greater cabling flexibility – top, dual, side or angled cable entry
- Surface mount, panel mount and cable -to -cable compatibility
- Lower cost
- Better protection against overvoltage
- Easier visual mating
Which connectors are more reliable?
Rectangular connectors are more reliable than circular connectors. While both protect against vibration, the locking elements and seals or rectangular connectors do not allow the penetration of dust and dirt. Rectangular connectors also offer guide pins to protect signal pins and key the connection to prevent mismating a similar connector. In contrast, the threads on circular connectors are more prone to damage. They also require thread or bayonet-style locking and run the risk of cross threading.
What other challenges does the connector market face?
The biggest challenge to the connector market as a whole is direct hardwiring. This has been historically very common in the US compared to the rest of the world. However, despite its wide usage hardwiring has obvious drawbacks. Using a pre-tested connector system reduces installation and maintenance time, lowering operational costs and downtime. Connector systems also offer flexibility during development when configuration changes are common.
Do rectangular connectors provide other electrical benefits?
Rectangular connectors have a solid and reliable protected earth (PE), or ground connection that is first mate (last break). Grounding is a standard feature in rectangular connectors for safety reasons. That means designers can mix male and female contacts on same side. This allows more flexibility in the choice or wire gauge and the handling of shields.
In contrast, a PE connection in circular connectors is not a standard feature. It can be added, but it will be a costly option. Since there is a limited number of pin configurations, only a specific pin can function as ground, and there is only one contact gender per side.
In contrast, a PE connection in circular connectors is not a standard feature. It can be added, but it will be a costly option. Since there is a limited number of pin configurations, only a specific pin can function as ground, and there is only one contact gender per side.
What does the future hold for rectangular connectors?
The latest is a new line of fiberglass reinforced plastic connectors that can utilize existing time- tested rectangular connector inserts and modules. Compared to standard aluminium die-cast connectors, the plastic connectors are low cost, lightweight and can be used in machinery of all types. These new connectors also provide protection in corrosive environments, such as salt water. There are many applications where metal connectors are not needed, but they have been used only because there is no other choice.