Industrial service robotics: smart navigation, safety and control with TE Connectivity’s connector solutions
Safety systems in service robots also need fail-safe connectivity to maintain signal integrity under adverse operating conditions.
interference protection in industrial environments where variable frequency drives, welding equipment, and other high-power systems can generate electrical noise that could otherwise corrupt data transmissions. Mini I/O connectors feature a hermaphroditic contact layout with spring action on plug and receptacle sides that provides consistent performance throughout the connector’s lifecycle of 5,000 to 10,000 mating cycles. This durability can be valuable in robots that dock repeatedly for charging or data transfer, as RJ45 connectors typically fail after hundreds of cycles. The 98N cable pull force rating prevents accidental disconnections during robot movement, while the compact form factor enables multiple network interfaces within limited panel space. The Dynamic Mini connector (Figure 5), with a 1.8 mm pitch, is suitable for extremely high-density connections for serial communication buses that link up distributed sensor nodes and actuator controllers. It uses a 3- point contact system with 0.38 μm gold plating which offers low contact resistance over millions of operational cycles. For internal communication between distributed control modules, TE Connectivity’s Dynamic Mini connector family covers 3 A signal connections up to 100 A power links.
Operating specifications from -55°C to 105°C with vibration and shock resistance provide reliable operation throughout the robot’s operational lifetime. Future-ready connectivity for evolving robotics trends As service robots achieve full autonomy with enhanced capabilities and deeper integration with IIoT systems, connectivity will only become more demanding. For example, integrating 5G communication capabilities into industrial robots will require connector solutions capable of supporting the high-frequency signals and antenna connections for wireless operation. Emerging technologies like Single-Pair Ethernet will enhance robot networking by delivering high- speed communications over simplified cabling. TE Connectivity is positioned to support these emerging standards while maintaining backward compatibility with existing protocols. Edge computing implementations that place artificial intelligence processing directly within robots demand exceptional signal integrity for high-speed processor interconnects. The AMPMODU and MicroCon connectors’ time tested performance at multi- gigabit data rates helps ensure readiness for these computational advances. As robots become more intelligent and autonomous, the reliability and performance of their
low-power sensor circuits to high- current motor drives. Moreover, a 1500 VDC capability aligns with the latest high-voltage battery systems/industrial power supplies, while a 100 kA short-circuit rating offers exceptional safety margins to protect sensitive electronics from system faults. For efficient signal distribution within robotic central control units, TE Connectivity offers its AMPMODU ™ family of connectors (Figure 3). These products feature a 0.025” square post design with dual-beam contacts that provide mechanical robustness for connections subjected to heavy vibration while maintaining the electrical performance required for high-speed digital signals.
Operating temperatures from -65° C to +105°C accommodate thermal extremes in industrial facilities without compromising connection integrity. The AMPMODU connectors are offered in pitch options from 1mm to 3.96 mm. High-speed processor interconnects can benefit from the 1mm centerline option with significant space savings compared to 2.54 mm connectors, while power and low-speed control signals can utilize larger pitches for easier assembly and higher current capacity. This flexibility allows control unit designers to optimize board layouts for both electrical performance and manufacturing efficiency.
Figure 5: The Dynamic Mini connector Source: TE Connectivity
Figure 3: AMPMODU family of connectors Source: TE Connectivity
Delivering high-speed, durable connections
interconnection infrastructure becomes even more critical to overall system functionality.
TE Connectivity’s Industrial Mini I/O connectors (Figure 4) address key limitations of RJ45 connectors with unique designs that achieve considerable size reduction while maintaining mechanical and electrical performance. For example, the Mini I/O uses a ‘fighting snake’ contact design with dual contact points that maintain connectivity and redundancy even when subjected to extreme vibration levels up to 50g encountered in mobile robotic applications. With data rates from 10 Mbps to 10 Gbps, the Mini I/O system can be utilized in both legacy fieldbus protocols and newer Time-sensitive Networking (TSN) implementations. Power over Ethernet (PoE) capability can also simplify wiring architectures to further reduce the weight of robots. Moreover, Mini I/O connectors are designed using 360-degree metal shielding for electromagnetic
Conclusion Industrial service robots are some of the most demanding applications for durable
connector technology, combining requirements for miniaturization, durability, signal integrity, and power handling that push traditional solutions beyond their limits. TE Connectivity’s comprehensive portfolio of specialized connectors including the ERNI MicroCon connectors and Entrelec DBL blocks, etc., provide reliable connections in a broad range of robotic applications for multiple industries. For more information on TE Connectivity’s robotics connectivity
Figure 4: TE Connectivity’s Industrial Mini I/O connectors Source: TE Connectivity
solutions, visit DigiKey’s TE Connectivity Robotics page.
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