M12 connectors become more reliable, easier to fit and reduce installer injuries

The M8 and M12 sealed connector systems are the most common method of cable termination for sensors in harsh environment industrial and control applications. 2015 is the 30th anniversary of the introduction of the M12 interconnects, and was initially launched with 3 and 4-pin versions. Originally targeted at the automotive manufacturing market, the screw-type, dust proof, water tight connectors found favour in many other industries, including food and beverage, textile and machine building.

The need for increased productivity and Digital Industry 4.0 has increased the demand for higher data rates. Production lines and manufacturing systems are no longer stand-alone, but are digitally interconnected, “talking” to each other to deliver instantaneous decision critical data.

Coding options for M8 and M12 connectors have expanded from the original A-code (analogue) used for sensors and actuators, to B-code (fieldbus) and now includes D-code (100 MB Ethernet Cat5) and high speed X-code (Gigabit Ethernet Cat6) types. This in turn has led to higher expectations for secure connections even under extremely harsh conditions. In addition to IP67 (Ingress Protection – dust tight and 1m water immersion), M12 connectors are also offered with IP65, IP68 and IP69K (high pressure and high temperature spray) ratings.

Compounding the challenge is the sheer number of connectors that are now being used.  Their locations, often in very restricted places, can make installation difficult. Equipment upgrades to cope with the higher data rates can become very time consuming and complex.  Molex, as a manufacturer of high-quality connectors, has set itself the task of simplifying and speeding up installation while improving communication integrity.

The traditional mainstream M12 connector utilises a screw thread that has three disadvantages. The hand applied torque during installation is a relatively uncontrolled process. Insufficient tightening can result in a poor connection, but too much will result in a compromise of the seal. Secondly, the time to fit a connector is quite long and thirdly is that of potential repetitive motion injury to the installer.

With its patented Brad® Ultra-Lock® connection system, Molex has brought to the market an entire portfolio of M12 connectors with Push-Pull functionality. This breakthrough thread-less design combines innovative engineering and advanced ergonomics, while still meeting the mechanical and electrical requirements of IEC Standard 61076-2-101.

The connector is simply pushed into place and an automatic locking mechanism ensures a secure mate, even under the stress of machine vibration and accidental cable pulls. This quick and easy operation is highly repeatable, regardless of the worker completing the task.  Labour savings of up to 75% are achieved compared to the traditional screw type. The loss of concentration and fatigue involved with such a monotonous, repetitive task is also reduced. This is especially the case when assembly needs to be done in confined spaces and in crowded device junction boxes. At first glance the connector head appears larger, but actually saves room as no additional space needs to be reserved laterally for hand or tool tightening of the screw thread.

An integrated radial seal replaces the commonly used axial type resulting in a guarantee that every connection, even without assembly aids, provides compliance to even the most rigorous IP69K standard.

Molex has also introduced the spark-free Brad Ultra-Lock (M12) EX Connection System, designed for industrial automation use in Class I, Division 2 and Zone 2 hazardous areas.

In cases where a machine possesses a high number of connections, where a worker has to screw/unscrew hundreds of connectors, the push on Ultra-Lock connection system dramatically reduces potential repetitive motion injuries. Globally this is a major concern.  US based industry research estimates the cost of cumulative stress trauma exceeds $20 billion a year in worker’s compensation. It cites manufacturing companies as one of the industries having high incident rates for occupational injuries. The National Institute for Occupational Safety and Health estimates that 20 million workers on assembly lines are at risk of developing injuries such as carpal tunnel syndrome. The National Safety Council reports that repeated trauma disorders have the highest incidence rates of all occupational illnesses, with manufacturing workers constituting 72% of these disorders.

In summary, the Molex Brad Ultra-Lock connector is quickly becoming the preferred solution for M12 connector systems:

• A repeatable fast, secure and sealed connection via the push-to-lock principle
• A 75% reduction in assembly times
• Reduced workload and injury risks to installers

From connectors which can be freely assembled, to over-moulded connectors, shielded connectors, distributors and distribution boxes – the Molex Brad Ultra-Lock spans the entire range of products needed for a machine’s cabling solution.