The exponential growth of transferred data is indisputable as industries move into an era where even the smallest devices are expected to communicate and receive data in real-time. The Internet of Things (IoT), Manufacturing 4.0, and the increasing number of cyber-physical systems, both in-place and mobile, add to the huge amounts of data communicated daily. Much of this data moves wirelessly from point to point, but the most important data still travels along cables where external interference and risk of data loss is minimized.
Wireless communication data transfer rates vary widely depending on the location of the sending and receiving points, the environment, and the amount of electrical interference that the signal has to overcome. For wired communication, data speed is impacted by how well the connector and the cable work together in the specified environment.
The need for increased performance to USB 3.1 gen 1 (5 Gb/s) or gen 2 SuperSpeed(10 Gb/s) has been driving more demand for pre-wired cable assemblies because of a difficulty in finding and manufacturing the fastest interconnect solution for a given application. This approach often saves time, frustration, and money. But that isn’t always an option.
Connector Selection
Selecting connectors for data speed begins like any other connector selection. You need to know your electrical and data requirements and the application inside and out before selecting the best material for the required functionality.
Material |
Application |
Plastic |
Normally used in high voltage applications to protect the user from electric shock. Because of its properties, it is not appropriate for vacuum applications. |
Aluminum |
Lightweight but still rugged, use aluminum connectors when you want to reduce the weight of your device. Excellent for indoor laboratory applications, even when hermetic sealing is necessary for a vacuum. Not appropriate for caustic environments or prolonged exposure |
Nickel plated brass |
Great for any outdoor application where the connector might be exposed to rain, salt water, dirt, etc. Nickel-plated brass can be used with long term exposure, including with weather sensors. |
Stainless Steel |
Best choice for corrosive environments where the connector would come into contact with chemicals. Also important in cleanroom environments to stand up to harsh sterilization methods. Stainless is generally more expensive than brass or aluminum, but certain applications require a connector that can withstand extreme conditions. |
If your application is in an outdoor or hazardous environment, you will have to make decisions on the sealing levels and techniques. Most of these decisions should not impact data speed, but some of the materials that are needed to meet the demands of harsher environments can increase cost and reduce the options available for a given data protocol. You will also need to make sure that your O-ring and insulation materials are appropriate for the temperature ranges the device will operate in. If the sealing or materials aren’t right for your application’s environment, your data speed could suffer, and your connector may not last as long as you would like. If you connect and disconnect often, make sure your connector is designed for the right number of mating cycles. Commercial-grade connectors are more fragile and prone to vibration issues, so signal speed may degrade over time.
Cable Selection
Cable selection and its ability to interface easily and efficiently with the associated connector can impact data speeds. Designing a connectivity solution for a specific data protocol requires optimizing the design of both the connector and the cable. The first condition for a functional solution is to have a connector that is capable of handling a specific protocol. Each protocol requires specific design rules for the connector, and all of these specific rules are combined for multi-protocol connectors. Software simulation is the perfect tool for this design process since it allows the designer to check the compatibility of the designed connector/cable assembly with the targeted protocol. The effects of design modifications can be evaluated immediately, giving you the confidence that the connector/cable solution will perform properly in the field.
We have been working with companies looking for faster data transfer speeds in specific protocols, and have engineered dozens of cable/connector combinations to achieve the speed that they are looking for. We’ve seen instances where a connector or cable will pass a test, but when you put the two together, either the data doesn’t reach the expected speed or errors are introduced. So here are a few tips to help you avoid too much trial and error:
Be in the correct lane. Design specifically for the protocol you want to run (Ethernet, Firewire, Thunderbolt, USB 3.0, etc.). Generic design elements may be a bad compromise.
Play the match game. Make sure that the cable and connector you are using have the correct impedance for the protocol you are using. Impedance mismatches will lead to losses and reflections that will lower your signal to noise ratio.
Shields up! Many protocols specify individually shielded data pairs in the cable. Internal shielding can be especially important in multiprotocol systems to help reduce crosstalk and interference.
Take the test. Be sure and test all aspects of your design or get the information from the manufacturer. System level testing is critical to determine if you have any unexpected issues between your hardware and your cabling. When in doubt, consult closely with your connector manufacturer on cable selection. Many have in-house cable assembly services and the expertise to find the best solution quickly.
Fiber Optics
Of course, no discussion of data speed using connectors and cables would be complete without a discussion of fiber optics. Engineers will often choose this option if they need to move a lot of data (4K video for instance) or send data over long distances (such as a sensor application that sends real-time data several miles away). Copper cables are the enemy of distance and speed, so the additional hardware needed for fiber optics can be worth it if you really want to go fast and far. Getting the hardware right and matching it with your protocol is the best way to ensure that your data has a quick and low-error trip to its next destination.