Igniting the Spark! Electrification and e-Mobility, our latest eBook, delves into the evolving and impactful interconnect solutions that are meeting the immediate and future challenges of our electrified world. From factories to farms, vehicles to infrastructure, connector companies are leading the charge to make electrification safe, efficient, rugged, and reliable, as demand advances and grows.
OCTOBER 2025
IGNITING THE SPARK Electrification and e-Mobility
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Electrification and e-Mobility IGNITING THE SPARK
John Bishop Managing Director
Igniting the Spark! Electrification and e-Mobility , our latest eBook, delves into the evolving and impactful interconnect solutions that meet the immediate and future challenges of our electrified world. From factories to farms, vehicles to infrastructure, connector companies are leading the charge to make electrification safe, efficient, rugged, and reliable, as demand advances and grows.
Amy Goetzman
Managing Editor
AJ Born
Associate Managing Editor
Raine Arzola
Creative Director
TABLE OF
CONTENTS
OCTOBER 2025
E-MOBILITY & VEHICLE ELECTRONICS
FACTORY & INFRASTRUCTURE
Powering the Future: Connector Selection for Automotive Electrification and e-Mobility 29 I-PEX
Smart Factories 07 Phoenix Contact
Safer Power Distribution in
Lessons from the World’s First DC Factory 10 Schaltbau GmbH
EV Charging? 33
Powering the Future with Smart Manufacturing:
Is Boosting the Current the Solution to Faster
Smiths Interconnect
Vehicle Electrical Architectures 36 Molex
Backbone of Battery Manufacturing 13 PEI-Genesis
The Road to 48V: Navigating the Future of
From Grid to Gigafactory: The Connector
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Solutions to Meet Evolving Demands 17 Bulgin
Zonal Architectures and the Connector Evolution: Enabling the Future of Flexible Vehicle Electronics
Smart Infrastructure: Advancing Connectivity
TTI Inc. Americas
FARMING & FOOD HANDLING
Navigating Complexity: Customized PCB Interconnect & Press-fit Solutions for e-Mobility 44 ept
the Connected Farm 21 EDAC Group
Better Data, Better Harvest: Building
Product Briefs 48
with Circular Connectors 24 binder
Revolutionizing Robotic Food Handling
CONTRIBUTORS
FACTORY & INFRASTRUCTURE
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Distributed power applications are common across many industries, including smart factories. Today’s factories require more connectivity than ever before, so delivering that power both safely and economically is critical in the development and deployment of power distribution networks. In the U.S., the National Fire Protection Agency (NFPA) and the National Electric Code (NEC) establish rules to ensure safe power distribution. NFPA 79 outlines the use of overmolded cordset installations, which allows cordsets to replace more traditional junction boxes and conduit in many scenarios. Part of this code is established to permit the use of cordsets that are exposed run-rated (ER-rated). To achieve the “ The NEC Tap Rule requires overcurrent protection to be present where the conductors receive their supply
SAFER POWER DISTRIBUTION IN SMART FACTORIES
Phoenix Contact USA Dean W. Smith Senior Product Marketing Specialist
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ER rating, cables must pass additional crush and impact tests that certify they are rugged enough to be run without conduit to protect them from damage. With these types of cordsets established under NFPA 79, they can now be used to more quickly and easily distribute power throughout a network via feeder lines and taps. The configuration of those feeder conductors (or trunk line) and branch circuits (or taps) is defined under the NEC Tap Rule. NEC Tap Rule Overall, the NEC Tap Rule requires overcurrent protection to be present where the conductors receive their supply, but several sub-rules define how a trunk line can be tapped to energize a load without the need for overcurrent protection at the tap point itself. This makes it much easier to install passive distributors without additional fuses or breakers to tap power off the trunk line for individual load devices. For typical power distribution networks, where the tap lines are generally under 25 A, two defined sub-rules are the most relevant: the 10-foot (3-meter) and 25-foot (7.5-meter) rules. In both cases, overcurrent protection only needs to be located at the termination point of the tap line, meaning it can be located at the load device. This leaves the travel distance from the tap point to the load device free of the need to implement additional components. Specifically for the 10-foot rule, the amperage of the tap conductors must be no less than 1/10 of the amperage rating for the trunk line conductors. For example, a trunk line with conductors rated up to 40 A must have tap lines with conductors rated for a minimum of 4 A. In this case, many sensor-actuator cordsets will meet the 4 A minimum rating, but more typically, one would see the deployment of 7/8- inch or M12 power form factors rated above 10 A (Figure 1). For longer taps, there is the 25-foot rule. Any tap lines between 10 and 25 feet would now be required to carry conductors rated for at least one-third of the amperage of the trunk line conductors.
Figure 1: Example of trunk-and-drop where the feeder line and tap line are both rated to the same current.
Tap Rule in action As an example, let’s look at a trunk line rated for 30 A per conductor (Figure 2). Here, each of the tap line conductors would need to be rated for at least 10 A. Typical sensor- actuator cordsets would be off the table, and we would be looking more at power cordsets in the 7/8-inch and M12 power form factors that generally run at least 10 A, but can go up to 16 A or more depending on the applied UL test standards.
Figure 2: Example of trunk-and-drop where the feeder line is rated up to 30 A, while the tap line is smaller, with a capacity of at least 10 A.
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To run these cordsets safely, they need to be protected from environmental conditions that could compromise the cable jackets, and ultimately, expose the conductors. Many cordsets will need something to protect them further, leading to them being channeled through raceways or flexible/rigid conduit. This adds significant cost to the materials used and extra time for the installation of the power distribution network. However, an alternative exists. Using ER-rated cordsets can eliminate the extra cost of conduit, making it faster, easier, and more cost-effective to install the power network. As for securing these tap lines, an ER-rated cordset will only need to be secured every 6 feet (2 meters) to ensure it’s not inadvertently becoming entangled or hooked on people or other equipment.
Finally, looking at NFPA 79 and the NEC Tap Rule, when combined with ER-rated cordsets, those cordsets offer a cost-effective, safe, and efficient way to design and deploy distributed power networks. It reduces installation time, material costs, and complexity, especially in systems where tap conductors are under 25 A and run distances for those tap lines are under 25 feet — often seen in many intralogistics and intelligent assembly networks. Today’s factory managers are looking for safe yet affordable ways to distribute the power in their complex networks. Overmolded TC-ER-rated cordsets, used in accordance with the NEC Tap Rule, offer an easy option for plug-and-play replacement in the field. Connect with Phoenix Contact to learn more.
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POWERING THE FUTURE WITH SMART MANUFACTURING: Lessons from the World’s First DC Factory
Guido Bachmann
Schaltbau GmbH Director Engineering R&D Electronics & Software
Modern manufacturing is under real pressure. Rising energy costs, growing energy demand, and more stringent sustainability requirements are expos- ing the limits of factory infrastructure designed decades ago. Most plants still run on alternating current (AC) systems, a choice that made sense in the last cen- tury. But today, direct current (DC) power is making a comeback as a more efficient, flexible, and sustainable alternative for modern production. The NExT Factory, operated by Schaltbau in Germany, stands as the world’s first industrial facility to be fully powered by a DC microgrid. More than just a showcase, it’s a full-scale production environment designed from the ground up to test and prove what a truly modern factory could look like. After two years of operation,
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the lessons are becoming clear, and they extend far beyond theoretical efficiency gains.
And yet, the shift to DC isn’t simply about efficiency; it’s about resilience. Throughout its first years of operation, the NExT Factory has maintained energy continuity even during grid disruptions, including “island mode” operation — when it temporarily disconnects from the main grid and relies solely on internal sources. Central to this capability is its advanced battery storage system, featuring 405 kWh of capacity and 270 kW of output. Notably, the system integrates second-life lithium-ion (NMC) cells, batteries previously used in other applications, now repurposed to extend their lifecycle. With intelligent thermal management and a projected lifespan of 15-20 years, the unit helps flatten peak demand and en - hance energy independence while contributing to circular economy goals.
At the heart of this shift is a straightforward principle: Energy should flow directly and efficiently, with as few conversions as possible. In traditional AC-based systems, power from solar panels or batteries — which naturally generate work on DC — must first be converted, leading to losses and complexity. By using a DC grid internally, the NExT Factory avoids many of these conversions. The result is significant: photovoltaic (PV) systems connected to the factory’s DC grid have demonstrated an 8% boost in efficiency compared to equivalent AC configurations. This is achieved by reducing complexity instead of adding components. But the advantages don’t stop there. Energy storage, an- other critical component in resilient industrial power, also benefits from DC architecture. Battery systems connected via DC experience 3-4% less energy loss, while high-demand robotic systems have seen power consumption drop by as much as 21%. Cable sizes can be reduced thanks to higher operating voltages, cutting copper usage by up to one-third. Taken together, these changes contribute to a potential 37% reduction in overall transmission losses — figures that are not theoretical but documented through real-world operation.
This storage solution is optimized through an inhouse-devel- oped energy management system (EMS) designed specifical - ly for DC environments. Processing over 5,000 data points per second, the EMS uses machine learning and digital twin simulations to anticipate load fluctuations, shift energy usage, and coordinate between generation, consumption, and storage. It’s not a black box; it’s an evolving intelligence layer, fine-tuned to deliver stability, cost savings, and deep system insight. Technically, one of the most compelling breakthroughs has been in voltage management through so-called droop con- trol strategies. These methods are used to distribute power load across multiple sources. While the linear droop curve (LDC) offers a simple proportional approach, Schaltbau has tested and validated a more advanced interleaved droop curve (IDC), which provides non-linear, multi-stage control.
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“ Energy should flow directly and efficiently, with as few conversions as possible
This enables faster, more precise load balancing, espe- cially in high-capacity scenarios. During one test, the system dynamically shed a 200 kW battery load, which is about one third of the installed DC power, without disrupting operations, demonstrating not just efficiency, but agility. The shift toward DC power has already rippled through day-to-day operations. Forklift chargers now run on DC, reducing energy waste in logistics. Plans are underway to integrate vehicle-to-grid (V2G) systems, allowing electric vehicles on-site to function as mobile storage assets, further flattening peaks and enabling real-time flexibility. Still, this transition hasn’t been without friction. Im- plementing a full DC architecture required custom hardware, retraining for staff, and navigating regulatory gray zones that weren’t built with DC in mind. More- over, integrating legacy equipment into a new power architecture created challenges in interoperability and safety compliance. These are not insignificant barriers, but they are solvable. Ultimately, the most important takeaway from the NExT Factory is that sustainable transformation doesn’t re- quire compromise. The facility has shown that emissions reductions and energy independence can be achieved not by bolting green tech onto old systems, but by
rethinking the very infrastructure that powers them. In doing so, it offers a working model — not a concept — of how industrial resilience and environmental responsi- bility can coexist. If more manufacturers adopt these principles, DC grids could become more than an engineering curiosity. They may well be the standard blueprint going forward. Connect with Schaltbau to learn more.
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FROM GRID TO GIGAFACTORY: The Connector Backbone of Battery Manufacturing PEI-Genesis
As the global race toward electri- fication gains momentum, battery gigafactories have become the engine rooms of the energy transi- tion. These vast, highly automated plants are transforming raw ma- terials into the battery cells that power everything from electric vehicles to grid-scale storage. But behind the towering machinery and robotic operations lie the connector systems that keep the entire operation running. Every stage of production, from raw material handling to final testing, relies on connectors to deliver power, transmit data, and enable fast, safe changes on the factory floor. The demands are steep: high voltages and currents, real-time sensor data, continuous uptime, and the flexibility to retool lines quickly for new chemistries or formats. Around the world, new facilities are developed to meet soaring demand. In the UK, AESC is build- ing a £1 billion gigafactory in Sunderland to support the next generation of EVs. Meanwhile, in
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the U.S., Stellantis and Samsung SDI have launched a major site in Indiana with a projected annual ca- pacity of 33 GWh . These examples highlight the global surge in battery manufacturing and while their scale is impressive, it's the infrastructure inside that determines how efficient - ly and safely they operate. Connectors play a vital role in giga- factory environments, from grid-lev- el power delivery and high-speed data transmission to reconfigurable production lines and predictive maintenance. As the battery in- dustry advances, so too must the connectors at its core. Power under pressure Gigafactories demand power sys- tems that go well beyond con- ventional industrial capabilities. Connection systems must reliably handle currents from hundreds to thousands of amperes, often at voltages exceeding 1,000 V, to en- ergize manufacturing tools, charge test stations, and distribute power across formation and aging lines. Across the factory floor, different stages call for different types of high-performance connectors. Rugged circular power connectors are commonly used for grid input and large-scale machinery, offering high current capacity, vibration re- sistance, and environmental sealing. For equipment like formation ovens and drive systems, busbar-style con- nectors with low contact resistance and high thermal conductivity are essential to prevent energy losses and overheating under continuous load. Modular rectangular connectors are often deployed in reconfigurable power cabinets and test rigs, deliv- ering compact high-current connec- tions with integrated safety features such as touch-proof contacts and IP-rated housings. In areas exposed
to moisture, solvents, or conductive dust, sealed connectors rated to IP67 or higher are critical for maintaining uptime and operator safety.
Amphenol Heavymate connectors
Each of these connector types must combine high current ratings with long- term mechanical durability, thermal efficiency, and compliance with global safety standards. Their selection and performance directly impact the energy efficiency and resilience of the entire manufacturing ecosystem. Where power meets data Beyond raw energy transmission, connectors play a crucial role in transmit- ting data across sensor arrays. As each cell undergoes formation and quality control, performance data is collected in real time, including current draw, voltage stability, temperature gradients, and internal resistance. High-density, mixed-signal connectors are used to transmit both power and data through a unified interface, streamlining system architecture while reducing space and weight.
Maintaining signal integrity in these electrically noisy environments is a central challenge. Connector systems must provide robust shielding against electromagnetic interference (EMI), resist degradation from humidity and thermal cycling, and preserve isolation between high-voltage and low-voltage circuits. Coaxial contacts , twisted pair configurations, and inte - grated grounding features are often used to mitigate signal loss and cross- talk, especially in high-channel-count test stations.
SV Microwave coaxial contact
Choosing connectors with proper impedance matching and low contact re- sistance is essential, not just for data accuracy, but for long-term reliability in continuous production cycles. Built to adapt The battery industry moves fast, driven by evolving cell chemistries like lithium iron phosphate (LFP), nickel manganese cobalt (NMC), and solid-state, along
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and guided alignment features reduce mechanical wear and prevent contact damage. Many of today’s connector systems also support predic- tive maintenance strategies. Built-in diagnostics, such as contact resistance monitoring and thermal feedback, allow maintenance teams to detect degradation before it leads to downtime. This shift from reactive to proactive maintenance helps safeguard production targets while extending the operational life of connector systems across the plant. The connector ecosystem Connector systems exist as part of a broader engineer- ing ecosystem. From cable harnesses and wire man- agement to socket interfaces and cleaning equipment in dry rooms, the success of a gigafactory depends on tightly integrated, standards-based connector design. Global connector manufacturers now offer highly customizable solutions tailored to battery production “ Battery gigafactories represent one of the most advanced and critical expressions of industrial automation in the electrification era
with shifting preferences in form factors from pouch to cylindrical or prismatic. To keep pace, gigafactories must be modular by design, allowing new tools, lines, or configurations to be introduced with minimal downtime. This kind of flexibility relies heavily on modular con - nector systems. Quick-release high-voltage connectors, blind-mate docking systems, and magnetic alignment features make it possible to swap out machines or re- configure stations without rewiring or requalification. These systems reduce changeover time while preserving electrical and mechanical integrity. Connectors used in retoolable setups must combine durability with precision, handling repeated mating cycles, vibration, and potential misalignment without performance degradation. Floating panel mounts, lock- ing mechanisms and integrated keying options are often built into the design to support error-free installation and safe high-voltage handling. In a production environment where speed and scal- ability are everything, the right connector architecture makes all the difference. Endurance by design Modular design may allow gigafactories to adapt quick- ly, but adaptability is only valuable if the components themselves can withstand the pace. In high-throughput battery environments where production runs 24/7, connectors are subject to constant mechanical stress, temperature fluctuations, and exposure to dust, hu - midity, and chemicals. Over time, these conditions can compromise connection quality, unless reliability is engineered in from the start. To meet these demands, modern industrial connectors are built for longevity. High-mating-cycle designs, corro- sion-resistant contact finishes, and vibration-proof lock - ing systems all help maintain stable performance under continuous use. In automated zones where connectors are regularly coupled and decoupled, floating bushings,
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The backbone of the battery age Battery gigafactories represent one of the most ad- vanced and critical expressions of industrial automation in the electrification era. Their success hinges not just on chemistry or scale, but on the essential components that enable every stage of manufacturing. Connectors that are robust, precise, and increasingly intelligent are the enablers of power delivery, data capture, tooling flexibility, and operational reliability. As chemistries advance and battery product continues to expand across continents, the design and deploy- ment of connector infrastructure will remain a central engineering concern. Whether powering formation lines in Europe, testing cell stacks in Asia, or supporting au- tomated QC rigs in North America, connectors are the backbone of the battery production industry. Connect with PEI-Genesis to find the right inter - connect solutions for your battery manufacturing operation.
workflows. These include hybrid connectors for power and data, stackable HV modules and quick‑disconnect busbar interfaces. At the same time, sustainability goals are driving innovations in recyclable materials, reduced mixed-material content, and easy disassembly at the end of the equipment’s service life.
To support this complexity, PEI-Genesis brings engineering expertise and rapid custom assembly to the gigafactory environment. Manufacturers can specify and deploy components that meet stringent performance, safety, and sustainability requirements. Value-added services, such as connector modification, kitting, and design consultation, make it easier for engineering teams to integrate robust, application-specific connectivity into fast-moving production lines.
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Advancing Connectivity Solutions to Meet Evolving Demands SMART INFRASTRUCTURE:
Thisen Bird
Associate Product Manager
Bulgin
The installation of smart infrastructure in- volves the costly integration of IoT sensors into existing systems or the upgrading of these systems. Similarly, the IT infrastruc- ture must be capable of high efficiency and effectiveness in processing and storing vast volumes of data. Additionally, both infrastructures must be scalable to accom- modate the growth and development of a smart city, adapt to the evolving demands
Developing Internet of Things (IoT) systems in- volves more than just incorporating sensors and data collection; it requires designing robust, scal- able networks that can operate effectively within practical operational constraints. IoT devices play a pivotal role in shaping the future of our cities and their development must consider the current challenges, the existing connectivity options, and the future smart technologies that will enable current municipal infrastructure to adapt. Smart infrastructure is the term that describes the integration of digital technologies into physical infrastructure, such as road networks, power grids, and buildings, with the intention of improving the everyday lives of those who live in the highly populated areas becoming smart cities. The “smart city” concept focuses on sup- porting urban development and growth with modern technology to address various challenges and create a sustainable, resilient, equitable, and privacy-conscious community for its residents. These cities leverage advanced technologies and data-driven solutions, including IoT devices such as sensors and cameras 1 . Current challenges to implementing Smart Infrastructure Authorities face numerous challenges when implementing the infrastructure to enable the smart city to function as intended. One of the main concerns is cybersecurity, as the infrastructure is vulnerable to cyberattacks, particularly the sensor networks, which are susceptible due to their design. Attacks on infrastructure can lead to device outages, data loss, privacy breaches, and the injection of malicious code, potentially compromising the integrity of smart city systems. To counter this, smart cities implement advanced security measures 2 .
“ One of the main concerns is cybersecurity, as the infrastructure
is vulnerable to cyberattacks, particularly the sensor networks, which are susceptible due to their design
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of the residents, and handle continuous data flow. The infrastructure must also possess sufficient flexibility to support a diverse array of software platforms and future technological implementations. Environmental challenges such as continuous exposure to water and dust necessitate solutions with high ingress protection and UV resistance for optimal longevity. Furthermore, systems must be resistant to vibration and fluctuating temperatures throughout the year. Therefore, connectors used in these environments must be proven, sealed solutions that can perform reliably in all circumstances. Connectivity: Wired and wireless To enable smart infrastructure, both wireless and wired connectivity have their advantages and disadvantages when it comes to communication between devices. Wired networks are ideal for smart city infrastructure applications that require high bandwidth and persistent reliability, such as traffic management systems and surveillance networks. These applications demand con- tinuous, low-latency data transmission. Wired networks provide enhanced stability with minimized exposure to electromagnetic interference and network outages.
Wireless networks are well-suited for dynamic or spa- tially constrained urban environments, including public transportation systems, intelligent lighting systems, environmental sensing infrastructure, and mobile service units. They facilitate rapid deployment and straightforward scalability, enabling cities to add devices efficiently or reposition them in response to evolving urban demands and operational requirements. IoT devices in wired applications require a connector and cable assembly which can handle the transmission of data for real-time monitoring and which is compact enough to prevent a cumbersome system design. Single-pair Ethernet (SPE) uses a single twisted pair of Ethernet wires to deliver Power-over-Data-Line (PoDL), meaning the IoT device can be powered and transmit data through the SPE connector. Utilizing this singular connection for the IoT device enables the miniaturiza- tion of the device, thereby expanding the possibility of integration within the infrastructure to collect data, and improving the efficiency of the infrastructure in that environment.
4000 Series single-pair Ethernet Connector, rated to IP68, suitable for smart city applications.
Future connectivity technologies In addition to SPE, other connectivity technologies are in development that will enable smart infrastructure. One of these, active optical systems, incorporates fiber optics for data transfer over traditional copper, thereby ex-
Example of a traffic management system using an environmentally sealed connector
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References 1 IEEE. (2025). Smart Cities Rely on Smart Infrastructure to Make People’s Lives Better. Retrieved from IEEE Technology for a Sustainable Climate. 2 Bahalul Haque, A. K., Bhushan, B., & Dhiman, G. (2022). Conceptualising smart city applications: Requirements, architecture, security issues, and emerging trends. p. 39(5). 3 Montero, D. S., Altuna, R., Barco, J., Lopez-Cardona, J. D., & Vazquez, C. (2024). Power-over-Fibre Integration in 5G Optical Fronthauling based on Multicore Fibres.
tending cable lengths beyond the limitations of copper cabling. This means that active optical cable assemblies will play a pivotal role in enabling applications such as real-time traffic monitoring. Moreover, fiber optic cables offer greater reliability compared to traditional cables, as they are resistant to electromagnetic interference, ensuring stable and secure connections. This depend- ability is essential for the effective operation of critical smart city infrastructures. Power-over-Fiber (PoF) is a technology that enables power delivery through optical fibers to remote nodes, thereby reducing electromagnetic interference and enhancing energy efficiency. The technology can be integrated into existing telecommunications infrastruc- ture, facilitating the development of smart infrastructure through dynamic reconfiguration and improved user service throughput 3 . Additionally, PoF supports cen- tralized power monitoring and management, which are essential for maintaining service quality and operational efficiency in modern smart networks. Examples of PoF use cases within smart infrastructure include powering streetlights with motion sensors, cameras, and environmental monitors to achieve en- ergy-efficient, responsive lighting and enhanced safety. PoF can also support traffic cameras, vehicle detection, and digital signage on motorways and in urban areas for reliable, interference-free operation and streamlined transport. Supplying PoF for sensors, access systems, and energy monitors in smart buildings and substations will enable centralized management, reduce cabling, and boost operational efficiency. While smart infrastructure presents tremendous oppor- tunities to create more efficient, safe, and sustainable urban environments, significant challenges must be addressed to realize its full potential. Cybersecurity remains a critical concern, as sensor networks and con- nected devices are vulnerable to attacks that can disrupt services, compromise privacy, and spread misinforma- tion. The high costs and complexities of installing and upgrading IoT and IT systems require careful planning, ensuring infrastructure is scalable, flexible, and capa - ble of handling vast amounts of data. Environmental factors such as exposure to dust, water, UV damage, vibration, and temperature fluctuations demand robust, sealed, and proven hardware solutions. Overcoming these challenges with innovative technologies and strategic implementation will be essential to unlocking the transformative benefits of smart infrastructure for future cities. Connect with Bulgin to learn more.
FARMING & FOOD HANDLING
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BETTER DATA, BETTER HARVEST: Building the Connected Farm EDAC Group
operations. These systems, whether hybrid or fully electric, support modularity and responsiveness far beyond the capabilities of traditional mechanical platforms. Mobile and stationary equipment is increasingly powered by renewable energy. Solar-assisted machinery, battery-powered drones, and remote charging stations are enabling operations to expand into areas with limited infrastructure. By leveraging solar panels, battery banks, and DC charging platforms, the farm gains mobility, reduces downtime, and extends operating windows during critical periods of the growing season. This distributed electrification model enables smarter workflows and helps farmers scale their operations with reduced resource consumption. Reliable connectors play a key role in supporting these systems by ensuring stable power and signal transmission across environments exposed to dust, vibration, moisture, and temperature extremes.
Agriculture is evolving. Fields once managed through manual labor and mechanical tools are now guided by data, automation, and electrified systems. The connected farm is no longer a concept of the future, it’s a reality powered by advancements in electrification and mobility that improve operational efficiency, enable better decision-making, and support sustainable growth. At the center of this transformation is the need for accurate, real-time information. Better data leads to better yields. To achieve this, farms are integrating a growing number of intelligent systems that each require consistent power and communication across challenging, distributed environments. Electric drive systems are rapidly being adopted for agricultural machinery. Electric tractors, robotic planters, and other smart machines not only reduce emissions and operating costs, but also enable precision control over planting, spraying, and harvesting
EDAC Group's Waterproof D-Sub connectors are highly reliable, ensuring operation in field conditions. The core of the connected farm is its ability to collect, process, and act on data. Sensors buried in soil or mounted accordingly continuously monitor moisture, nutrient levels, and environmental conditions. UAVs fly over fields, capturing imagery to identify stress zones, optimize inputs, and evaluate crop development. Autonomous vehicles execute precise tasks based on real-time guidance, weather conditions, and historical data. Each of these systems feeds data into edge computing nodes or cloud platforms where it can be used to inform decisions – whether that’s when to irrigate, where to apply fertilizer, or how to adjust for variable field conditions. As systems integrate and expand, the farm evolves into a dynamic feedback loop, where data continuously informs action and refines results. This capability is essential for sustainable
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As energy demands increase, smart power distribution and energy harvesting systems are being integrated into the agricultural landscape to maintain uptime without adding operational complexity. The result is a more resilient, more accessible form of precision farming that scales without depending on fixed infrastructure. “ This distributed electrification model enables smarter workflows and helps farmers scale their operations with reduced resource consumption
agriculture. It allows for targeted inputs rather than uniform application, reducing water use, chemical runoff, and energy waste. It also improves traceability, which is critical for food safety, certification, and operational efficiency. Behind these technologies, rugged interconnect solutions support uninterrupted data flow and power delivery, helping ensure each component performs reliably under field conditions.
Card edge and board-level connectors from EDAC Group support secure power and signal transmission within embedded systems. Farms span large, often disconnected geographies, which present a unique challenge. Electrification and e-Mobility technologies provide flexibility to deploy intelligent systems in areas where traditional infrastructure would be costly or impractical. Portable soil test kits, solar-powered weather stations, livestock monitors, and modular drones operate independently, drawing power from batteries or solar arrays and transmitting data wirelessly to central systems. Charging stations, whether tractor-mounted or pole-mounted, service these remote systems. Mobile battery units and vehicle-based charging ports keep drones, tools, and autonomous vehicles running across long workdays and wide coverage areas.
EDAC Group’s waterproof in-line connectors provide sealed, high-retention connectivity in demanding operating conditions.
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Better harvests begin with informed action. Electrification and connectivity together form the foundation of the connected farm. When UAVs transmit early signs of plant stress and modular implementations respond in real time the system prevents loss before it escalates. When autonomous tractors self-correct based on edge- processed weather data, efficiency is gained without intervention. When off-grid sensor networks detect localized soil dryness and trigger targeted irrigation, water is conserved, and crop yields increase. The value of these actions is not only in the precision, but in the scalability. The connected farm model empowers smaller operations with the same decision-making tools as large-scale commercial farms, closing productivity gaps and increasing resilience across the industry.
Circular connectors from EDAC Group offer sealed, vibration-resistant connections with secure mating mechanisms. The integration of electrification and digital mobility is laying the groundwork for the next generation of agriculture. These technologies enable farms to do more with less – less water, less fuel, less chemicals or fertilizers – all while producing more food, with better quality and traceability. The connected farm’s success depends on system reliability. Power systems, communication lines, and control interfaces must remain robust through changing weather, continuous motion, and exposure to dust, moisture, chemicals, and UV radiation. As agriculture evolves, the performance expectations for every component, used in modules like autonomous platforms and remote data nodes, continue to rise. Electrification and e-Mobility technologies are advancing the agricultural industry, enabling greater connectivity and operational efficiency across the entire value chain. Connect with the EDAC Group to learn more about interconnect solutions that ensure reliable connectivity in the field.
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Revolutionizing Robotic Food Handling with Circular Connectors
binder USA Paul Pulkowski
Food and beverage production is evolving to become faster, cleaner, and more automated than ever. From robotic arms to high-speed conveyor systems, reliable connectivity is the backbone of next-gen equipment. Circular connectors enable high-performance automation in even the most demanding hygienic environments. Designed to withstand frequent washdowns, extreme temperatures, and aggressive cleaning agents, today’s circular connectors ensure uninterrupted signal and power transmission under rigorous operating conditions. As production lines integrate more smart technologies, the right connectivity solutions are essential for maintaining uptime, improving efficiency, and meeting strict industry standards for hygiene, safety, and long- term performance.
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“ Circular connectors play an essential role in enabling flexible, hygienic automation without compromising uptime or safety
M12 stainless steel connectors and M12 FDA compliant products are suitable for the food and beverage industry. Market evolution & industry challenges The food and beverage industry is under increasing pressure to deliver higher output, minimize contamination risks, and reduce reliance on manual labor, all while maintaining compliance with stringent regulatory standards. To meet these demands, manufacturers are rapidly adopting advanced robotics and automation technologies. However, the effectiveness of these systems depends on the reliability of every component involved. From harsh washdown zones to dynamic motion applications, connectors and cabling must be engineered to withstand the unique stresses of hygienic production environments. Only with purpose-built, high-performance components can automation deliver the speed, precision, and cleanliness the modern market requires. Key connectivity challenges: • Materials must meet strict hygiene regulations (FDA, Ecolab). • Harsh environment durability is essential to endure frequent washdowns and chemical exposure. • Design must accommodate rapid changeovers with easy handling, quick disconnect systems.
M12-A FDA compliant and Ecolab approved
Circular connectors excel in robotic food handling Circular connectors play an essential role in enabling flexible, hygienic automation without compromising uptime or safety. Application areas for circular connectors include:
ROBOTIC FOOD HANDLING
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• Robotic arms facilitate flexible, repeatable move - ments with washdown-capable connectors for grippers and wrist joints. • Packaging & sorting transmit power and signal to decentralized I/O systems for high-speed con- veyors. • End-of-arm tooling allow rapid changeovers or removal for sanitation with quick-release designs. • Pick-and-place units support lightweight, high-pre- cision designs with compact form factors. • Tray loaders & palletizers minimize downtime from vibration and impacts with rugged interfaces
Why connectivity matters in robotic food handling In highly automated systems, every connection counts. Circular connectors ensure uninterrupted communication and power transmission between control units, robotic end-effectors, sensors, and actuators. This matters even in extreme food-processing conditions. Exposure to moisture, aggressive cleaning agents, temperature fluctuations, and mechanical vibrations can compromise performance if components are not properly engineered. Robust circular connectors, designed with hygienic housing and IP-rated sealing, safeguard data and power integrity in these environments. By maintaining consistent performance under stress, they enable robotic systems to operate with precision, reduce unplanned downtime, and uphold the strict hygiene and safety standards essential in modern food production. Connect with binder to learn more.
M12-A cordsets designed in sensor application.
e-MOBILITY & VEHICLE ELECTRONICS
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The transition to electric and autono- mous vehicles is fundamentally reshap- ing the automotive industry. At the heart of this transformation is innovative design. Engineers orchestrate a network of powerful new electrical interconnects to ensure the seamless transmission of power and data, making these compo- nents not merely passive elements, but critical enablers of functionality, safety, efficiency, and reliability. Connector technology facilitates the electrification of modern vehicles. The current design phase has progressed far beyond theoretical concepts; the practical implications, design consider- ations, and performance requirements that make modern vehicles possible have been engineered into a new gen- eration of components. Efficiency: Minimizing energy losses and maximizing performance In electric vehicles (EVs), efficient power transfer is paramount. A design en- gineer’s goal is to specify connectors that can handle high current loads with minimal resistance and voltage drop, especially in high-power circuits such as onboard chargers, traction inverters, and battery interconnects. Look for connectors that utilize highly conductive materials, such as copper alloys, and contact designs optimized for low resistance. Consider terminal interface geometry and surface finish - es that help minimize heat generation during high-cycle mating. For thermally constrained designs, select components with built-in heat dissipation features or options for integration with heat sinks. Compact form factors should not come at the cost of electrical per- formance. Understand how current de-rating and ambient temperature affect the selection of connectors. Eval - uate datasheets carefully for insertion loss, current density per contact, and derating curves to ensure the connec- tor can meet system-level thermal and efficiency goals.
Connector Selection for Automotive Electrification and e-Mobility POWERING THE FUTURE:
I-PEX
“ Look for connectors that utilize highly conductive materials, such as copper alloys, and contact designs optimized for low resistance
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In modular battery designs or distributed inverters, low-insertion-force connectors that maintain stable contact under vibration are especially valuable. These allow multiple power stages to be serviced or replaced without compromising system performance.
High-speed connectors with robust grounding schemes are essential for zonal architectures, edge computing modules, and sensor fusion systems. When routing high-speed signals near noisy power systems or motor drives, consider shielded connectors with low-profile, 360° EMI protection. Miniaturization is essential in applications such as cameras, radar modules, and interior human-machine interfaces (HMIs). Low-profile connectors with right-an - gle options and flexible mounting orientations help with tight packaging. Keep clearance, mating cycles, and PCB retention strength in mind when making a selection.
I-PEX AP-10
Connectivity: Enabling high-speed data transmission Design engineers working on software-defined vehicles, ADAS, and infotainment modules face increasing chal- lenges related to bandwidth and signal integrity. Con- nector choice must align with evolving requirements for automotive Ethernet, LVDS, PCIe, and other high-speed digital interfaces. Focus on connectors that maintain impedance control and provide shielding to mitigate electromagnetic inter- ference (EMI). Pay attention to differential pair layouts and connector geometry to avoid reflection and cross - talk. Simulation data for S-parameters (insertion loss, return loss, etc.) and eye diagrams can help validate signal integrity early in the design cycle.
I-PEX CABLINE-CA II & CABLINE-UM
Safety: Withstanding harsh and high-stress conditions Automotive environments are punishing, and connector selections must account for wide temperature ranges, vibration, shock, ingress, and electrical overstress. Be- gin with application-level stress testing and evaluate IP
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ratings, temperature cycle performance, and vibration resistance. For high-voltage systems, ensure that connectors meet the insulation, creepage, and clearance distance require- ments as defined by standards such as ISO 6469 or UL 2251. Consider housing materials rated to at least 125 °C or higher for underhood applications. Contact plating (e.g., tin-silver, gold flash) should be selected based on mating cycles, fretting resistance, and current level. In safety-critical functions (braking, steering, occupant sensing), redundancy is key. Use connectors that sup- port dual contacts, fail-safe latching, and provide both visual and audible feedback for proper mating. Incorpo- rate position assurance and secondary locking features to mitigate assembly errors. Request validation test reports from suppliers, including data on AEC-Q200, USCAR-2/37/42, and other relevant test protocols, to assess long-term reliability.
Serviceability is another essential consideration. Use connectors with visual mating indicators and high extraction force tolerances for components that may need periodic replacement. Including QR-coded labels or laser-marked identifiers on housings can simplify part identification and accelerate diagnostics. From a DFM (design for manufacturing) perspective, involve connector suppliers early to ensure footprint compatibility, packaging constraints, and insertion/ex- traction force profiles align with production equipment.
I-PEX MHF I LK and MHF-TI
Sustainability: Designing for lifecycle and environmental compliance
Sustainability is increasingly shaping engineering deci- sions. Choose lightweight connectors to support vehicle weight reduction goals. This directly impacts range and emissions, particularly in hybrid powertrains and heavy-duty electric vehicles. Select materials that meet RoHS, REACH, and ELV direc- tives. If applicable, request documentation for lifecycle assessment (LCA) and environmental product declara- tions (EPDs) from suppliers. Consider connector designs that facilitate disassembly and material separation for recycling at the end of their life. Snap-fit enclosures, mechanical coding, and modular housing strategies can simplify teardown and reduce environmental impact. Designing for durability also reduces total lifecycle emissions. Prioritize connectors with high mating cycle ratings, corrosion resistance, and self-cleaning contact interfaces to extend field life and reduce warranty claims.
I-PEX ISH and IARPB
Accessibility: Design for assembly, modularity, and maintenance Ease of assembly is crucial for both manufacturing and field service. Engineers should consider features such as polarization, tactile locking feedback, and blind-mate designs that reduce labor time and minimize human error on production lines. When designing modules or subassemblies, select mod- ular connector systems that can be installed in advance and snapped into place during final integration. Pin and socket layouts should be optimized for wire routing and strain relief within the assembly to ensure optimal performance.
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• Charging interfaces: Ensure compliance with SAE, ISO, and regional standards while also considering thermal management and mechanical durability. Future outlook: Innovation opportunities for engineering teams As vehicle designs evolve, so do the challenges and op- portunities for connector design. Areas for exploration and collaboration include: • Integration of smart features: Embedded tem- perature sensors or memory chips in connectors can enable condition monitoring and predictive maintenance. • Design automation: ECAD/MCAD connector librar- ies and simulation tools accelerate placement, validation, and harness routing. • Additive manufacturing and prototyping: 3D-print- ed custom interconnects or enclosures are valuable for early validation and testing. • Flexible and optical interconnects: Developments in fiber-optic and high-speed flexible printed circuits (FPCs) for electric vehicle (EV) and infotainment architectures can improve design. For design engineers shaping the next generation of electric and connected vehicles, connector selection is not a secondary decision — it is foundational. The performance, reliability, and manufacturability of nearly every subsystem depend on choosing the right inter- connect solutions. By balancing electrical, mechanical, thermal, and en- vironmental requirements early in the design cycle, engineers can make direct contributions to vehicle safety, efficiency, serviceability, and sustainability. Whether specifying a high-voltage busbar or a minia- ture high-speed signal connector, the decisions made at the design table have a ripple effect across the entire vehicle lifecycle. Connect with I-PEX to learn more.
I-PEX EVAFLEX 5-SE-G VT
Applications across the vehicle: Key considerations for design engineers Design engineers encounter unique connector require- ments depending on the system. • Battery and power systems: Focus on current rating, thermal rise, creepage distances, and short-circuit survivability. • Data communication: Prioritize impedance control, EMI shielding, and support for next-gen protocols like 10BASE-T1S. • Sensing and control: Use miniature connectors with reliable latching and mechanical strain relief; validate IP rating for exterior sensors. • Infotainment and connectivity: Minimize connec- tor profile height while maintaining shielding for wireless modules. • Interior comfort: Select flexible interconnects that are compatible with dynamic motion (e.g., seats, doors) and can withstand cyclic stress.
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