Ruggedness

Reliability and durability specifics for rugged connectivity

Heavy-use or safety-critical applications must be designed to withstand specific levels of mechanical stress and environmental conditions without degrading power, signal, or data transmission.

To endure the toughest conditions, our connectors, cables and electronic solutions are built and assembled with robust materials and a rugged design.

 

  • Mechanical endurance to resist abrasion, wear, and intensive use – up to 10,000 mating cycles without any loss of signals or power
  • Design and assembly robustness – resistance to vibration and shock, safe and extremely robust locking (push-pull, breakaway, screw) and keying (with easy error-proof blind mating as well as color coding identification), mating rotation resistance up to 20 Nm torque, ultra-resistant resin sealing (body and contact block), cable tensile strength up to 400 N (central strength member)
  • Material mix (housing, plating, insulating, sealing, overmolding, jacketing) for increased hardness, flex endurance and resistance to environmental conditions such as high temperatures, radiation, corrosion and salt fog, chemicals (sterilization, disinfection and decontamination proof)
  • 360° shielding ensuring EMI/RFI protection for faultless data transmission (data integrity and security)

 

‘Ruggedization’ methods and processes pertain to the entire designing, engineering and manufacturing chain of our connectors, cable assembly and electronic solutions. From choosing high-quality materials for housing, coating, plating, insulating and sealing, to overmolding or jacketing cables to protect the insulation and conductor core against environmental aggression and chemical deterioration, etc.

Our solutions

What we mean when we say ‘our solutions are rugged’

Vibration and shock resistance

Extreme temperature resistance

Corrosion and chemical resistance

Radiation resistance

Vibration and shock resistance

Tested in compliance with the Military Standard 202 Method 214 and Condition I, our connectivity solutions resist random vibration of up to 37.80 Grms for our most rugged series.  Mounted onto a vibration equipment, the locking and contacts specifications (or functionalities) of a connector pair are thoroughly verified.

 

Electrical signals are monitored to ensure that no micro-cuts smaller than one micro-second occur.

Monitoring electrical signals is also performed to ensure that our connectivity solutions can withstand shocks of up to 300 g amplitude (half sine pulse of 3 ms, no discontinuity > 1 μs).

 

As for drop resistance tests, they measure the mechanical deformation that could impact the connection’s functioning and performance following drops or bump shocks from different heights.

Extreme temperature resistance

Our most rugged series offers standardized products that operate within the temperature range of -55 °C to +135 °C, tested in compliance with the Military Standard 810 Methods 501.6 and 502.6. Cabled connectors overmolded with TPU material withstand temperatures ranging from -40 °C to +125 °C. As for soft caps, they resist a maximum temperature of +85 °C.

 

Tailored solutions are designed to reach much higher or lower temperatures for dedicated applications.

The highly configurable Fischer Core Series includes high-performance chromium-plated brass connectors, in IP68/IP69-sealed and hermetic versions, which resist extreme temperatures ranging from -100 °C to +200 °C. The premium materials used in these connectors also allow them to withstand most sterilization methods selected for medical applications.

Corrosion and chemical resistance

Protection against corrosion mechanisms – pitting, intergranular or crevice – is achieved with the right choice of materials and type of coating. The most common coating on metallic parts is nickel chromium or thin gold-based layers applied with a galvanic or sputtering deposition process. Common materials and coatings used in circular connectors are:

  • Brass with nickel or chromium coating
  • Aluminum with nickel or chromium coating or anodized (aluminum oxide Al2O3)
  • Stainless steel, which is one of the best materials for corrosion resistance, since corrosion protection is embedded within the material itself

 

Tested in compliance with standards IEC 60068-2-11 Test Ka, MIL-STD-202 Method 101, and EIA-364-26, our products go through long-standing exposure to a 5% salt solution at a temperature of 35 °C without any impact on their mechanical or electrical functionalities.

Thanks to their special surface finish, most of our connectors can withstand the exposure to salt fog during 1,000 hours.

 

In hospital sterile environments, dentistry and laboratory settings, as well as in food and pharmaceutical processing, devices and equipment must be cleaned, disinfected and sterilized on a regular basis. Our products’ components – shells, contact blocks, O-rings and seals, cable jackets, etc. – are made of ultra-resistant materials to withstand the conditions incurred by sterilization methods with chemicals such as Steris LCS, Sterrad and EtO. They also endure exposure to chemicals in oil, gas and petrochemical environments such as aliphatic hydrocarbons, oils or fuels, greases, detergents, dilute acids and bases, and most aqueous salt solutions.

Radiation resistance

In addition to protection requirements in high temperatures, sealing and shielding, high radiation resistance is required for long-lasting tasks in nuclear or contaminated environments such as handling heavy radioactive loads, performing inspections, and repairing equipment – sometimes performed remotely by robot workers due to inaccessibility or the danger of radiation exposure.

 

Our radiation-resistant connectivity solutions made of stainless steel are easy to handle with gloves and remotely, are compatible with nuclear decontamination fluids, and offer a premium material mix and insulation and sealing performance.

Radiation-resistance connectors and cables are also required when healthcare professionals sterilize by gamma irradiation (typically Cobalt 60), at ambient temperatures, their medical devices and equipment, whose materials can otherwise not withstand the high temperature of steam autoclaving.

Resistance of our materials

Check out which material is the most suitable for your application

Tests & proofs

Innovative, reliable solutions designed to last

 

Rugged connectors and cables undergo stringent and thorough testing according to international industry and military standards such as IEC, EIA, MIL-STD-202 and MIL-STD-810. Only a selection of mechanical and environmental tests is shown in these eight videos: endurance, oscillation, vibration, immersion, sealing, cleaning, corrosion and temperature.

 

These tests and proofs have been conducted in our laboratory and in the field on the Fischer LP360™ connector with 7 contacts from the Fischer Freedom™ Series.

Related news and information

Tech insights

Reliability and durability specifics for rugged connectivity: four types of resistance

Tech insights

10,000 mating cycles: creating the perfect connection… every time

Tech insights

8 steps for properly specifying rugged connectors

See how we harnessed our technologies to solve our customers' challenges.