Everett Charles Technologies’ (ECT) Compliant Connectors Team has successfully developed a custom solution for a demanding medical application in the area of video imaging and endoscopic data. With their expertise in probes and RF simulation, ECT was able to fully meet the mechanical, electrical and environmental specifications while keeping to the customer’s project schedule.
This customer faced a major challenge related to a connector requirement. The connector had to fit into a tightly confined area—therefore the connector design needed to be very compact. The application was in a very dirty environment. The connector needed to be field cleanable and withstand the environmental conditions.
Tony DeRosa, Product Manager for ECT, explained how they met these challenges.
“…We selected materials that are resistant to the invasive chemical environment. A company spokesman said strong biasing methodology also contributes to uninterrupted performance in harsh environments by providing for self-cleaning operation.”
As an added complication, the connector had to maintain a 100-Ohm impedance for proper signal transmission. Finally a life of ten thousands of insertions was required.
An ECT representative said the electrical ratings were the most difficult aspect of the design process, however they were still able to meet the mechanical and electrical challenges and complete the custom solution on schedule.
“Signal transmission required an impedance of 100 ±10%, matched pair.” wrote DeRosa. “And the connector was required to carry 10 Adc.”
“Our engineers followed transmission line theory principles such as conductor diameter, conductor spacing and ground proximity to meet the 100-Ohm impedance requirement,” a spokesman said. “The key design process involved accurately modeling the connector in electrical-magnetic simulation software (HFSS) so that performance simulation could be performed. Mechanical parameters such were then adjusted to dial in impedance.”
DeRosa added “Meeting 10 A continuous current rating was achieved through spring probe biasing techniques. Biasing is the probe’s internal force that pushes the plunger onto the barrel into contact. Through advanced biasing techniques, ECT was able to ensure the plunger and barrel are in constant contact. This allows for uninterrupted conductivity through the probe.”
ECT’s capabilities of RF signal integrity simulation and validation were key for project success. Accurately predicting electrical performance of the spring probe connector as well as complete circuit performance prior to fabrication was essential to avoid multiple iterations and delays. ECT accurately modeled electrical performance and adjusted design parameters on-the-fly to ensure the prototypes met performance specifications.
DeRosa commented: “In addition to our off-the-shelf ‘catalog connectors’, which can be configured to customer requirements, we offer solutions fully designed to customer specifications, where standard products can’t meet the entire set of requirements. Our in-house expertise in RF simulation is a unique and valuable asset for this. With our RF simulation and validation capabilities we optimize the design prior to production. This way we ensure both: best performance and fast project completion.”
Everett Charles Technologies
ect-cpg.com
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