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Challenges in designing a solution for harsh environments
One of the most challenging aspects to address is the cost of a connector, as the overall expense can be a decisive factor in the development process. To manage this effec - tively, establishing strong relationships within the supply chain is crucial. These relationships help ensure access to the most competitive prices, thereby reducing the overall product cost. Additionally, the design of the product is a major contributor to cost, potentially accounting for up to 80% of the product [2]. Consequently, utilizing standard components and op- timizing the product design, such as removing complicated features, can effectively reduce overall costs more than any other measure. Enabling customers to repair damaged products or reinstall systems poses significant challenges. Addressing this issue involves designing connectors that facilitate straightforward disassembly. Solutions include the utilization of extraction tools for removing contacts from the housing, as well as the adoption of reusable sealing mechanisms. There are also situations where repairs must be carried out onsite; in some cases, this may occur underwater. Such scenarios present considerable difficulties in designing connectors that can be repaired while submerged, without compromising their integrity. Technologies such as wet-mate connectors offer viable solutions. Product compliance remains an ongoing challenge. Chang- ing regulations have led to the adoption of more environ- mentally friendly materials. Ensuring adherence to RoHS and REACH directives necessitates continuous review to confirm that all materials used within the product port - folio remain compliant. To address this, new designs are developed with compliance considerations at the forefront, aiming to create future-proof products capable of meeting current and future regulatory requirements, including re- gional approvals in Europe and North America.
Standard Vitalis Buccaneer, Bulgin’s signature power connector has been re-engineered using bio-based plastics, with up to 86% bio-based content by weight. A shift in focus is evident with the emergence of nano con- nectors that maintain existing speeds and power levels. This advancement allows engineers to minimize the footprint of their systems into which these connectors will be integrated. Such developments are fostering devices and systems that are more portable and efficient, with a lower environmental impact. By reducing the overall size of the connector and utilizing bio-based materials, the PCF of nano connectors can be significantly lowered compared to previous designs. Shifting to a solution which aims to enable AI in harsh envi- ronments is active optical technology. Active optical cables (AOCs) are a modern data transmission solution that utilize optical fiber technology to create slimmer, more user-friend - ly cables. Their design ensures reliable operation over long distances, even with suboptimal connections, making them ideal for data centers, high-performance computing, and devices requiring high data transfer rates [1]. Standardiz- ing this into a connector with a peripheral, such as a USB, opens the potential of AOC in existing systems that use a USB interface. Coupled with an environmentally sealed housing creates a solution that enables outdoor usage. Thus, it removes the distance limitation of USB and brings the capability of AI to systems that are deployed in outdoor environments.
“ Product compliance remains an ongoing challenge
AO Series USB, Bulgin’s active optical cables, use integrated circuits to boost signals, converting electrical inputs into optical transmission through fibre between connectors.
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