IX connector vervangt RJ45 - FHI, federatie van technologiebranches

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The IX Industrial connector replaces the RJ45 interface in modern equipment. The new IX Industrial interface is now available from Helukabel.

View the IX Industrial brochure here

Read the article below for more information:

The ix Industrial interface offers new possibilities

Hardly any other connector is as widely used as the RJ45. It has been around since the 1970s and subsequently technologically superior variations were developed for use in industrial applications. It is difficult to imagine today's industrial world without the RJ45, not only because of the compelling price-performance ratio, but also because they are almost synonymous with Ethernet connections. However, this may change as the ix industrial interface has recently become a promising alternative with a significantly smaller design and more robust construction (Fig. 1). It opens up new possibilities in device production and offers benefits to end users.

RJ connectors were introduced in the 1970s by Bell Laboratories in the US and standardized a few years later by the FCC (Federal Communications Commission). One of the best known versions is the RJ45 connector – used for decades for telecommunications and data transmission in offices – which connects PCs to a network via patch cables ranging from category 5 to category 7. Over the years, the more advanced, industry - developed approved RJ45 connectors. These are compatible with larger cables and wires, can be mounted without crimping tools and are shielded to meet industry EMC requirements. A popular example is the RJ45 connector used in Siemens DRIVE-CLiQ systems, which has two integrated power contacts that allow data and power transfer over a single cable; Up to eight data cables (four pairs) and two power cables can be connected.

The RJ45 is a barrier to miniaturization

Although the functions mentioned above are suitable for the RJ45, it does have significant disadvantages. First, the connector is not robust enough for many applications; industrial versions have only one locking hook, which unlike the plastic office version is made of metal and thus offers at least some durability. A much more serious disadvantage, however, is the size of the plugs and connection points.

As miniaturization continues, devices become smaller and smaller, as do the circuit boards on which the terminals are mounted. As a result, the connector dimensions from 7mm to 11mm become relatively large, and the product designer must ensure that there is enough space. The limits of miniaturization, especially for compact mobile devices, displays, small programmable controllers, cameras and sensors, are then determined by the size of the RJ45 connector. A smaller Ethernet connector would therefore be desirable.

Robust and requires 70 percent less space

A modern alternative that could replace the industrial version of the RJ45 has recently been developed: the ix industrial interface with 10 contacts, Cat 6A classification and data transfer speeds up to 10 Gbit. It complies with IEC/PAS 61076-3-124 and can potentially replace the standard industrial RJ45 due to several advantages.

Some advantages of the ix Industrial interface are a more compact connection surface and high mechanical robustness. Designed with industrial settings in mind, it has two sturdy locking mechanisms with metal hooks to ensure resistance to vibration and contact durability. This ix connector is suitable for ambient temperatures from -40°C to +85°C and the shielding provides EMC robustness. The space-saving aspect of the ix connector is really impressive: it requires only 30 percent of the space of an RJ45 connector (Fig. 2), requiring less space on the circuit board, which is essential for downsizing the device .

Figuur 2: met de nieuwe ix industrial connector kan een pakkingsdichtheid van 5 keer groter dan een conventionele RJ45 worden bereikt

Figure 2: With the new ix Industrial connector, a packing density of 5 times greater than a conventional RJ45 can be achieved.

Assembly solutions with the new Ethernet interface
New connector technology often requires cable manufacturers to modify existing products or develop new cable technologies. HELUKABEL, one of the leading manufacturers and suppliers of cables, wires and accessories, is early optimistic about the potential of the new Industrial Ethernet interface and its ability to provide plug-and-play mounting solutions with ix Industrial connectors (fig. 3). The industrial focus currently is on automation technology, video and camera technology, visualization in mechanical engineering (e.g. sensing, quality assurance, etc.) and companies that produce measurement systems, all of which require patch cables to transmit power and data. In addition, cables with “mixed” connections, i.e. ix coding, can have an RJ45 connector at one end and another connector can then also be assembled at the other end. All cables have been tested by HELUKABEL and the stored items can usually be shipped within 24 hours.

Figure 3: Two data connectors in two sizes: RJ45 with 8 pins
and ix Industrial with 8 plus 2 pins.

Currently, HELUKABEL can provide the HELUKAT 600IND (P/N: 802184) supply, a shielded and foiled twisted-pair (S/FTP), PUR-jacketed, Category 7 industrial Ethernet cable for use in patch cable assemblies. The ix connectors are currently available A-coded for standard Ethernet (4 or 8 pins, plus two power cables rated 3A for 50 or 60V DC), or B-coded for specific installation applications; both versions are straight (fig. 4). Two plug versions with 90° angles and a C-coded plug for standard Ethernet will be launched in 2020. The significant space savings compared to their RJ45 counterparts provides additional miniaturization opportunities for device manufacturers, especially as horizontal, vertical or upright versions of the associated housing are also available (Fig. 3). Durability, compactness, high data transmission speeds and a double locking mechanism clearly speak for the new ix Industrial interface. Now just wait and see how the market reacts?