Manufacturing engineers can experience the frustration of a production line being shut down due to a failure of a motor controller, but repairing the controller requires removing dozens of connecting wires. Technicians look for the circuit in the wire harness and hope to find the correct one among hundreds of wires with similar appearance. It takes only a few minutes to complete the work. This situation highlights the challenges of electrical connections in industrial environments. Hardwired systems initially appear to be cost effective, but create hidden inefficiencies, which escalate over the life of the equipment, and the nature of the problem is the rigid nature of the hardwired connection. Fortunately, modular connector solutions (Figure 1) are now available to meet changing requirements while maintaining industrial-grade reliability.
HARTING Han-Modular ® Modular connector system
Figure 1: Han-Moular ® Modular connector system. Image source: HARTING)
The Origin of Standardized Industrial Connection Technology
In 1945, Wilhelm HART realized that postwar industrial developments needed connectivity solutions that were significantly different from existing designs. Starting at a small repair facility in Minden, Germany, HART developed a product later known as the Heavy-Duty Connector (HDC), thus establishing the principles that are still affecting the design of industrial connections today.g.
The construction of rectangular connector designs offers a breakthrough over the circular design that initially dominated military and aerospace applications. Rectangular structure improves space utilization of industrial control panel and realizes higher contact density within standardized footprint. The Han connector line was introduced prior to the industrial boom in the 1960s, demonstrating how robust, standardized connections handle multiple media and withstand harsh plant environments.
This historical accumulation is very important because Han-Mtechnology directly inherited the proven principle. This is not a reinvent of the basic concept, but a combination of proven designs with the latest materials, manufacturing technologies, and integration capabilities.
Design of Deconstructed Modular Connection System
The Han-Mtechnology of HARTING adopts the modular construction mode. Engineers can select individual modules based on specific needs for media such as power, signal, data, air, etc., and combine these building blocks into protective enclosures designed for the specific environment.
The Han-Mmodule can handle specific media within the connector assembly, for example, the power supply module can provide 16 A to 200 A for heavy load applications, the signal module can support low voltage control circuits, and the communication module for Ethernet, fieldbus, or fiber optic connections. Engineers can combine these different types of modules within the same assembly frame, eliminating the need to install connectors individually for each medium. The protective enclosure provides mechanical support and environmental sealing for the module combination, with standardized enclosures ranging from compact Han 6B to Han 48B configurations (Figure 2), suitable for heavy duty/multi-media requirements.
HARTING Han 48B Bulkhead Mounting Housing
Figure 2: Example of Han 48B panel mount housing. Image source: HARTING)
Depending on the severity of the application, a graded seal structure is used for environmental protection. The basic IP65 degree of protection protects against ingress of dust and water, which is common in most production facilities. On the other hand, the Han-Mconnector performs a stronger IP69K specification to withstand the high pressure flushing procedures required for food processing and pharmaceutical production.
Han-Mconnectors incorporate a variety of safety features to eliminate connection errors. The mechanical keying system uses a unique shaped guiding element that allows only properly matched male and female heads to be connected together. This physical design prevents technicians from connecting incompatible connectors, which are common wiring errors in hard-wired connections. Keying systems directly and completely eliminate false connections without relying on wiring labels or circuit diagrams that become blurred over time.
HARTING with DigiKey: Han Configurator Launch
Connector specifications pose challenges to engineering workflows. Engineers must personally cross-reference component specifications from multiple data sheets, confirm environmental ratings, and verify compatibility requirements for each connector type. This process is time consuming and labor-intensive, which will affect the project schedule and lead to selection errors.
To address this issue, DigiKey in conjunction with HART has launched an integrated design tool that automatically verifies and selects components. Engineer using Han Configurator ® Configurator can input system requirements such as medium type, rated current and protection level, and receive real-time feedback information on component compatibility and supply status. The configurator uses rule-based selection logic to prevent incompatible combinations and to provide alternatives when their selection conflicts. The configurator also provides multiple views of the configured components, allowing engineers to verify mechanical suitability and cabling requirements prior to procurement.
The Han Configurator configurator also generates complete documentation, such as a bill of materials with current prices and supply status. Direct integration with DigiKey's procurement system helps eliminate manual creation of parts lists and placement of orders. Engineers can use post-comparison tools to evaluate modular and hard-wired alternatives or preconfigured libraries as a starting point for cross-industry generic applications.