Overcoming Harsh Environment Challenges with Amphenol’s Ruggedized USB Type-C

Primary concerns center around maintaining the ruggedness and sealing needed to ensure proper operation without the ingress of water or dust from the external environment.  Heat and humidity extremes can be a common concern in these environments, and devices need to be sturdy enough for 24/7/365 use by multiple operators. Adding multiple connectors can sometimes be difficult where space is limited and sealing multiple ingress points adds greater complexity to the design.

Cable clutter is another problem, particularly in mobile deployments or in other situations where there is a lot of activity around the equipment, such as fitness centers, public safety, military, and manufacturing settings.  More cables can increase maintenance and downtime costs because of the additional points for potential failure on sealed devices that need to be immune to dust, moisture, and environmental contaminants.  Devices with several cables will also have higher operator training costs due to the increased complexity of the system. 

Fortunately, the latest USB standard offers a solution to the problem of cable clutter.  USB Type-C cables can replace several interfaces on products and enable streamlined and reliable installations with fewer points of failure and smaller I/O interface panels. 

USB Type-C reflects an effort by the USB Implementers Forum (IF) to expand the “universal” nature of the “Universal Serial Bus” architecture and includes several new and unexpected features.  The most noticeable new feature is the interface is now reversible and the connector contains more individual connections.  The previous USB 3 connectors had a total of 9 pins where the USB Type-C has expanded this to include 24 pins.

Figure 1: USB 3 (top left) vs. USB Type-C (top right, bottom)

The additional pins enable the connector to be reversible while enabling support of USB 2.0, USB 3.1, and power over the same cable, with a few pins to spare.  Instead of leaving the ‘extra’ pins disconnected, the USB-IF designed additional functions to support these extra connections.  When a cable is connected, a voltage is detected on one of the control channel (CC) pins, this lets the port controller know the cable orientation so the basic USB power and USB 2.1 communications are brought online.  The controllers then negotiate advanced power and data transfer functions enabled by the new features introduced with the USB Type-C. 

The first new feature is USB Power Delivery, which now supports Alternate Modes up to 20V / 5A with bi-directional function.  This maintains the ability of USB hosts such as computers and laptops to power attached peripherals while adding higher power modes that can support monitors and other more demanding loads.  Alternate modes of operation let attached devices provide power back to the host, which allows powered USB Type C hubs and peripherals to replace external power supplies for laptops, tablets, phones, and other devices.  Alternate-mode communications can also be negotiated on the high speed signal pairs.  These can be used for USB 3, HDMI, DisplayPort, and other high speed interfaces that used to require a special port and cable to operate.  Because there are two high speed interface pairs, two separate high speed interfaces can be supported over a single USB Type-C port.  Even the cable and connectors have significant mechanical upgrades to increase their reliability.  The USB-IF acknowledged that the smaller Mini-USB and Micro-USB did not have sufficient mechanical robustness for larger devices and designed the USB Type-C connector with Through-PCB attachment points that provide similar mechanical strength to the standard Type-A connector.   

The result is a single mechanically robust port that can support USB 2.1, USB 3.1, Alternate Mode Power Delivery, and Alternate Mode Communications.  The design of products using the USB Type C connector can thus be greatly simplified because all external connections for power, display, and USB expansion can be handled with a single cable – for most devices this would be the only cable needed.  In harsh environments, this means less cable clutter, fewer potential points of failure, easier maintenance and support, and reduced training costs.  Even with these benefits, some devices will need even more environmental and physical protection to meet the unique needs of their usage environment.

Fortunately, Amphenol has recently released their second generation of Harsh Environment Connectors and provides a panel-mount USB Type-C connector with even greater mechanical strength and environmental sealing that exceeds the IEC60529-IP67 specification.  Amphenol’s MUSBR USB Type-C connectors offer a nickel-plated die-cast zinc housing with threaded panel mount connection points and a conductive silicon-rubber gasket, gold- and nickel-plated contacts for superior corrosion resistance in the presence of environmental contaminants, and 100% through-hole connections for enhanced mechanical robustness.

Right angle and vertical PCB mounting options are available, and the design is rounded out with a UL 94V-0 rated thermoplastic connector core, a stainless steel rear cover, and an operating temperature spec that exceeds most industrial specifications. 

The availability of a ruggedized USB Type-C connector designed for harsh environments allows significant product advancement and simplification in several different severe-use applications.  Industrial and factory automation installations can benefit from a design that reduces cabling requirements and provides a single interface to handle power delivery, USB communications, display, and other applications.  While the high-speed signal pairs are designed for applications like SuperSpeed USB or DisplayPort, a proprietary use could leverage these extra connections for control bus signaling or other specialized applications.  Military and Aviation installations always require connectors designed for repeated use in the most demanding environments, but advancements in electronic warfare systems and interactive infotainment systems require high bandwidth connections for reliable data transfer.  With Amphenol’s ruggedized USB Type-C connector, the need for reliability and operation in harsh environments no longer requires the technology running these systems to lag behind the latest innovations.  Cable clutter in these applications is another primary concern mitigated by the use of Amphenol’s USB Type-C solutions and the single connection point with a reversible connector can help ensure that complexity is minimized and still offer reliable operation in these scenarios.  Law enforcement, Public safety, and Fire Fighting applications share many of the same harsh-use and environmental requirements as military and aviation, and the same benefits allow simplified usage and reduces training costs associated with deploying new technology into the field.  Body cameras, for example, may need a cabled connection for bulk data transfer or charging, using a harsh-environment USB Type-C connector can simplify its use while providing high speed data transfer. 

Other applications that could benefit from a ruggedized USB Type-C connector include medical devices, professional audio/video production, and surveillance and gym equipment.  Whether deployed in a healthcare facility or designed for home-use, medical devices increasingly need to be portable and easy to use while providing protection against cleaning sprays and other contaminants.  Amphenol’s harsh environment USB Type-C connectors offer an ideal solution by providing a single-cable operation with a rugged construction ensuring reliable operation in emergency situations.  The increased demand for high bandwidth video and digital bussed audio creates intriguing possibilities for the USB Type-C in professional audio and video production.  Many modern audio systems are moving to Ethernet-based bussing instead of using multiple discreet analog channels, and mobile devices are being used more and more because they allow the artist to control their own monitoring equipment.  Unfortunately, common Ethernet cables are usually not designed with the ruggedness needed to provide reliable and repeated plug and un-plug events in these environments.  Alternate-mode communications over USB Type-C can enable the Ethernet connection to run over a much more reliable interface, and the USB Power delivery can keep mobile devices charged and ready to use. Surveillance equipment is also increasingly Ethernet-based, and the continuous shift to higher-resolution video is creating the need for higher and higher-bandwidth interfaces in these applications.  Traditional equipment also requires separate power and video connections to ensure reliable operation in outdoor installations or in other uncontrolled environments.  The use of a ruggedized USB Type-C connector designed for harsh environments can greatly simplify installation and provide power and communications over the same interface.  Finally, gym equipment is constantly exposed to sweat, cleaning chemicals, and other environmental contaminants, and the connectors are frequently subjected to extreme mechanical stress.  The desire for mobile device charging connectors and increasing infotainment deployments in fitness centers creates a compelling concern as more advanced interfaces are needed to meet user expectations and maintain customer loyalty.  Consumer-grade connectors fail rapidly in these environments and a better solution is needed.  Amphenol’s harsh-environment USB Type-C connectors present an ideal solution that provides high mechanical strength and advanced connectivity that can meet users’ current demands while supporting expansion to tomorrow’s enhanced needs. 

For legacy applications, or situations where support for other connection types are necessary, Amphenol also offers a full line of harsh environment interface connectors that is now in its second generation.  The advanced second generation connectors leverage conductive silicon rubber panel gaskets to ensure good EMI protection, and feature gaskets and seals within the connector to ensure protection beyond the IP67 rating, even over repeated thermal cycling.  For less demanding applications, the lower cost first generation leverages more economical epoxy-based sealing that still fully meets the requirements of IP67. 

Additional harsh environment connectors are also available, and include Generation 2 Cat5e right angle interposer connectors, right angle 4-port RJ45s, plug boots, hoods, and latching dust covers.  Type A USB 3.1 connectors are also on the way.

For other applications, or when slight variations to the commercially available connectors are required, Amphenol is proud to be responsive to their customers specialized connector needs.  When a simplified connection method is desired, or when the harsh environment panel connector is not located near circuit assemblies, Amphenol can create interposer card solutions that provide any number of internal connections, whether they be a mirror of the external connector, another compatible interface connector type, or even connect to a flex connector for vibration isolation or wiring terminals or solder points for cable termination.  Other custom solutions include dust covers for unpopulated ports, and IP67 boot style hoods for the MRJ, MRJR, and USB Type A product lines. 

Whatever your need for harsh environment connectors, Amphenol provides a complete line of ruggedized solutions that will ensure reliable operation in the most challenging environments.