Having a single, highly reliable system connector feels like a no-brainer when installation and setup needs to be simple and reliable. Thinking back to the days of plugging in a DVD player to a television with numerous connectors might serve as a reminder that the more connectors there are, the more opportunities there are for errors. By having just one modular connector, the chance for error — and resultant quality issues — is avoided entirely.

In the past, the thought of a custom connector might not have been the chosen route for engineers. It likely would’ve been thought to be too expensive, hard to specify and hard to get a reliable supply, making it a non-favorable option. With the advent of modular configurable connectors, though, those troubles are obsolete.

Superb design for versatility and reliability

A highly reliable and configurable connector makes excellent design sense, and this is especially true with the high vibration and shock environment that industrial machinery, robots and train and aircraft systems often face. Connector failure can be one of the hardest problems to troubleshoot and to repair but having one reliable input/output point can be a game changer in terms of time and cost savings. It also presents a substantial safety advantage, as one connector removal usually puts everything in a known state.

With the CombiTac connector from Staubli, the engineer can select from signal, power or high-voltage contacts, along with coax, fiber-optic, Ethernet, thermocouple, pneumatic and liquid. This is about as versatile as a connector can get and is the reason the engineer can almost always have one system connector.

Figure 1. The versatile CombiTac connector. Source: Staubli

The unique Staubli MULTILAM construction technique yields specially formed and resilient electrical contact elements that greatly enhance connector durability and reliability. There are 0.6 mm, 1.0 mm and 1.5 mm signal connections, all of which are crimped to cable wires at installation. Power connections go from 3 mm to as big as 12 mm in diameter — for up to 300 A and 1,000 V (see Figure 1). Power modules may have crimp or screw terminal connections.

The CombiTac connector from Staubli offers incredible versatility and features a straightforward, 3D, online configuration app. Once the configuration is done and sent in, the company will analyze and quote within 24 hours and may also include optimization suggestions.

With the CombiTac uniq function, all contacts are rated for up to 100,000 mating cycles. In a robot design, the connector will undoubtably last the lifetime of the system. And, if a lower-stakes version will suffice, the CombiTac direqt still achieves 10,000 mating cycles and costs less. This is immeasurably important for mobile robot applications since nothing much matters if the robot cannot reliably and repeatedly plug itself in to recharge its batteries.

CombiTac in the field

Mechatronics refers to the intersection of mechanics, electronics and computing. Mechatronics engineers create simpler, smarter control systems. Any engineer designing such a system would most likely want to use the CombiTac modular connector for its versatility and ruggedness.

These connectors are found in countless applications — automotive, buses, trucking, railway and aviation control applications. They can be used in factory automation and warehouse robotic movers. It is also functional in medical imaging systems and in power generation equipment, welding machines, tool changers, automatic presses and packaging machines (see Figure 2); this list is not exhaustive. Most of these applications require robust and durable connectors for a harsh or vibration prone environment, and the CombiTac connector is perfectly suited to succeed.

Figure 2. CombiTac connector assembles are compact and lightweight. Source: Staubli

Staubli advantage

Sourcing components from a company that’s not well established can lead to headaches down the road. In today’s uncertain markets, winding up trying to build products with parts that can no longer be ordered from a supplier that no longer exists is happening more and more frequently, with no foreseeable solutions on the horizon.

Staubli is a well-recognized company headquartered in Switzerland that began business in 1892. Starting off as a technological pioneer, Staubli has since extended its expertise to connection solutions, and has positioned itself as an industry standard worldwide with decades of successful installations under its belt. Visit Staubli’s website to learn more about the CombiTac connector and other products.