https://community.element14.com/learn/learning-center/your place for all things related to learning about electronic engineering. en-USTelligent Community 12https://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/power-and-protection-for-modern-bms-how-bourns-components-enhance-battery-safety-and-efficiencyTue, 16 Jun 2026 08:00:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:91ebf75f-be82-4452-87c8-49ef36483db9e14sbhargavBattery Management Systems (BMS) serve as the critical layer in modern energy storage applications, from electric vehicles (EVs) to grid-scale installations. A BMS continuously monitors essential parameters such as cell voltage, current flow, and temperature across individual cells and battery packs to ensure optimal performance and longevity. Beyond monitoring, these systems actively prevent catastrophic failures by implementing protection and isolation mechanisms that guard against overcharging, over-discharge, thermal runaway, and short-circuit conditions. This Tech Spotlight explores how Bourns’ Power and Protection product families, including the Riedon portfolio, solve key BMS challenges. Modern BMS Architectures And Their Challenges A modern BMS is the vital control layer in any energy storage system. Its core functions include: State-of-Charge (SoC) and State-of-Health (SoH) estimation: Calculates SoC, SoH, and other parameters using algorithms like Kalman filters or machine learning models. Cell balancing: Equalizes the charge across cells to maximize capacity and lifespan. Overcharge/discharge protection: Prevents overcharging, deep discharging, and thermal runaway. Communication with vehicle ECUs and telematics: Interfaces with vehicle control units (VCUs) via Controller Area Network (CAN) bus or similar protocols. However, as battery systems scale in voltage and capacity, BMS designers face multiple integration challenges: High-voltage isolation: Communication and power transfer between battery modules and the main controller require galvanic isolation to prevent cross-faults, with isolation ratings typically ranging from 3 kV to 6 kV for automotive and industrial applications. Transient overvoltage events: Fast switching during charge/discharge cycles can introduce dangerous voltage spikes. Thermal management: Becomes increasingly complex as power dissipation increases, necessitating components that maintain performance across wide temperature ranges. Accurate current sensing: Essential for precise state-of-charge (SoC) and state-of-health (SoH) estimation. These demands make isolation transformers, precision resistors, and multi-layer protection components indispensable to reliable BMS operation. Fig 1. Block diagram of BMS system (image source: Bourns)0 Bourn’s Power Division: High-Voltage Isolation For BMS Communication And DC/DC Conversion Isolation barriers serve to protect equipment and humans from harmful voltage surges. They also enable communication between a transmitter and a receiver. Bourns’ HCT and HVMA transformers deliver stable power and data communication across high-voltage EV battery systems with purpose-built DC/DC conversion and safety isolation. Push-Pull Isolation Transformers (HCT Series): Isolation transformers are essential in BMS for separating HV battery domains from low-voltage control circuits, ensuring safety while enabling efficient isolated power delivery. Bourns’ HCT series features compact, surface-mount toroidal ferrite-core transformers designed for efficient isolated DC-DC conversion in push-pull topologies. The toroidal geometry minimizes leakage inductance and EMI, while low DCR ( 8 mm, 3 kV hi-pot capability, RoHS compliance, and AEC-Q200 options, the series suits demanding automotive and industrial isolation needs. Figure 2 illustrates how leakage inductance, distributed capacitance, and magnetizing inductance affect waveform integrity in a push-pull transformer. By optimizing these parameters, the Bourns HCT Series ensures clean energy transfer, reduced overshoot, and improved regulation—critical for accurate BMS sensing and reliable isolated power delivery. Fig 2. Pulse Behavior in Push-Pull Isolation Transformers Showing Overshoot and Ringing Effects (image source: Bourns) HVMA Series: Flyback and Gate-Drive Isolation: Flyback and gate-drive transformers enable isolated auxiliary power and precise switching control in BMS inverters, motor drives, and HV domain interfaces. The HVMA series delivers AEC-Q200 automotive-grade isolation for flyback and gate-drive power stages, built to IEC 61558-2 and IEC 60664-1 requirements. Flyback models HVMA01F35A-ST10S (1W) and HVMA03F40C-ST10S (3W) offer 900 Vdc working voltage, 4000 VAC hi-pot, 1:1:1 ratio, controlled inductance values, and leakage below 1 µH. The gate-drive model (2W) provides 800 Vdc working voltage, 2750 V hi-pot, 8 mm creepage, low DCR, and a precise 5:1:4 turns ratio. These transformers reliably support gate-drive power, inverters, BMS, motor drives, and industrial power delivery. Bourns’ Protection Division: Multi-Layer Defence for Battery Safety Modern BMS systems protect themselves with multiple security layers where different components work together to address threats throughout the entire system. Bourns' Protection Division offers a comprehensive range of passive components engineered specifically for the harsh electrical environment of battery systems. A few key components form this layered defence. Precision current sense resistors for accurate BMS monitoring: Accurate current sensing is fundamental to BMS safety, as it enables precise SOC/SOH calculations and fast fault detection during charge-discharge cycles. The CSM2F and CSS metal-foil shunt resistors deliver ultra-low TCR (<50 ppm/°C), tight tolerances (±0.5%), and power ratings up to 50 W, enabling highly accurate pack and cell current measurements. Their stability under vibration makes them ideal for automotive-grade ADC interfacing and fast fault detection. Fig 3. TCR curve illustrating the ±50 PPM/°C temperature coefficient of resistance for CSM2F-8518 shunt resistor material ( image source ) Thick-Film power resistors: High-power resistors are essential in BMS for snubbing, current limiting, and dissipating transient energy to protect switching stages and measurement paths. Thick-film power resistors (PWR/PF series) offer compact DPAK, D2PAK, and TO-220 packages for space-constrained PCBs, delivering rated powers of 20–50 W at 25 °C case temperature when mounted on heatsinks. With resistance ranges from 0.02 Ω to 1 MΩ, tolerances of ±1% or ±5%, and temperature coefficients of ±100/±200/±600 ppm/°C, these are ideal for snubber, current-limiting, and load-dump energy dissipation in BMS power paths. Wire-wound power resistors: Wire-wound resistors help ensure BMS robustness by offering stable current sensing, pulse handling, and controlled failure modes during high-energy fault events. The FW, WS, and surface-mount PWR wire-wound series deliver precise sensing and robust pulse performance from 0.5–10 W. Fusible versions support safe failure modes, while non-inductive windings reduce noise in charge/discharge monitoring. Their wide resistance range and operating capability of –55 °C to +275 °C ensure long-term reliability in automotive-grade environments. Surge and overvoltage protectors: Battery systems face diverse transient threats, from lightning-induced surges in stationary storage to load dump events in automotive applications. IsoMOV ™ hybrid protectors combine GDT and MOV technologies to provide low-leakage, high-energy surge suppression for EV/HEV inverters and BMS interfaces. For multichannel analog front-end protection, PTVS diodes offer fast clamping and surge capability up to 3 kA. ZV50S multilayer varistors extend compact high-speed protection up to 4500 A, while SMA6J TVS diodes offer 600 W peak power and sub-picosecond response for sensitive sensing and communication lines. The different overvoltage protection technologies can also be combined to ensure a comprehensive protection scheme. A high-energy MOV can be placed near a main power line for high energy transient dissipation while a TVS diode is placed on a signal line to ensure the voltage is clamped quickly to protect sensitive equipment effectively. Fig 4. The construction of the IsoMOV ™ protector (Image source: Bourns) Fuses & Resettable PTCs for overcurrent protection: Fuses and resettable PTCs are indispensable for BMS because they isolate severe faults, prevent thermal runaway escalation, and protect low-voltage control electronics. POWrFuse ™ PF-63R50H provides 10–40 A overcurrent protection with 20–30 kA interrupt ratings for HV battery packs and BDUs. MF-USHT resettable PTCs add AEC-Q200-compliant, space-saving protection up to 125 °C for BMS sensing, control, and thermal management subsystems. Rectifier Diodes for efficient power conversion: Rectifier and Schottky diodes enable efficient, low-loss power conversion in BMS pre-charge, sensing, and protection circuits while maintaining reliable isolation at high voltages. AEC-Q101-qualified rectifier and Schottky diodes ensure efficient, low-loss power conversion. High-voltage series (up to 2000 V) support isolation in HV paths, while surge-rated and low-VF options improve efficiency and resilience in charge/discharge and protection circuitry. Series Power Rating (W) Resistance Range (Ω) TCR (ppm/°C) BMS Application W/WS/FW 1-7 0.01-15k ±200-300 Overload in chargers, surge withstand PF/PWR (Thick Film) 20-50 0.02-1M ±50-250 Snubbers in BESS, low-inductance drives BR/BRT/BRS (Riedon) 50-500 0.1-5k <±260 Energy dissipation in inverters, BESS UWP (Riedon) 20-100 0.5-1k <±260 Pulse handling in battery chargers Table 1. Comparison of Riedon BR/BRS resistors for high-power BMS dissipation circuit Precision Current Sensing With Riedon ™ By Bourns Riedon ™ high-power thick film resistors (PF2203 and PFS35 series): They provide compact, low-inductance current-sensing solutions for high-power BMS. With 35 W ratings, resistance values ranging from 0.01 Ω to 51 kΩ, and tight tolerances (±1%/±5%), these ensure accurate measurements across –55 °C to +175 °C and offer strong pulse-handling capability for charge/discharge and capacitor-discharge events in BESS-integrated systems. Riedon ™ power resistors: With low resistances of 0.003–0.1 Ω across 1–10 W, these resistors enable precise sensing and stable overcurrent protection in EV/HEV BMS. Their excellent pulse performance also suits industrial power supplies, inverters, smart meters, solar inverters, telecom 5G units, and capacitor recharge/discharge circuits. Riedon ™ Industrial Shunt Resistors (RS/RSH/RSI/RSJ/RSK/RSN/RSW Series): They use Manganin ™ elements to achieve 0.0083–100 mΩ resistance, ±0.1–0.25% tolerances, and ±15 ppm/°C TCR with current ratings up to 6000 A. RoHS-compliant and robust from –40 °C to +100 °C, they enable reliable measurements in BMS charge/discharge monitoring and ensure reliable overcurrent protection and thermal stability in space-constrained BMS setups. Their panel- and busbar-mount designs ensure accurate charge/discharge monitoring and are ideal for AC-DC converters, renewable energy systems, heavy industry, battery chargers, and mining applications. Integrating Bourns Power And Protection In A Complete BMS Architecture An optimized BMS architecture built on Bourns technologies offers end-to-end protection and isolation. A typical integration flow includes: BMS Stage Bourns Component Function Input / HV Bus IsoMOV ™ , PF-63R50H Fuse, PTVS Diode Surge suppression and DC bus overcurrent protection Power Conversion HCT / HVMA Transformers Isolated DC/DC conversion and communication Gate Drive & Control HVMA03F4A-LP8S Transformer, SMA6J TVS Safe switching and gate isolation Measurement & Balancing CSM2F / CSS / Riedon RS Series Shunts Accurate current and power monitoring Low-Voltage / Communication Rails MF-USHT PPTC, ZV50S MLV Resettable overcurrent and transient protection Rectification & Output Stage Bourns Rectifier Diodes Efficient current path management Fig 4. The construction of the IsoMOV ™ protector (Image source: Bourns) Conclusion The future of energy storage and electric mobility depends on smarter, safer, and more efficient Battery Management Systems. To support this, a comprehensive component ecosystem that balances isolation performance, sensing precision, and protection robustness is needed. Bourns has developed an integrated portfolio spanning three key divisions: Power, Protection, and Riedon precision sensing. These divisions collectively enable engineers to build resilient, efficient BMS architectures capable of meeting the demanding requirements of next-generation battery systems. ABOUT THE SPONSOR Bourns, Inc., is a leading manufacturer and supplier of position and speed sensors, circuit protection solutions, magnetic components, microelectronic modules, panel controls and resistive products. Headquartered in Riverside, California, USA, Bourns serves a broad range of markets, including automotive, industrial, consumer, communications, non-critical life support medical (low/medium risk), audio and various other market segments. Learn more here .bmselectric vehiclesbournshttps://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/struggling-with-tight-spaces-why-miniaturisation-demands-a-new-approach-to-cable-design-with-ecogenThu, 11 Jun 2026 08:00:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:40b07a7c-0100-4e14-8ff9-2dd4dcc33130e14sbhargavThe rapid development of technology has not only revolutionized sectors such as advanced robotics, industrial inspection, and medical diagnostics. It has also paved the way for the miniaturization of associated equipment. Today, numerous devices, including inspection equipment, medical diagnostic tools, and robotic arms, have become smaller in size, more aesthetically appealing, and simultaneously increased in functionality. Such miniaturization demands cabling solutions that are not only compact and lightweight but can also maintain signal integrity, mechanical flexibility, and comply with environmental and regulatory standards. Traditional cabling solutions struggle to meet the preceding requirements due to their bulky insulation, insufficient bend radius, or inadequate EMI shielding. This necessitates an innovative cabling solution that provides easy installation and uncompromising performance in dynamic applications, such as robotic arms and endoscopy devices. This article discusses the cabling challenges in space-constrained environments and how Alpha Wire addresses these challenges with its EcoCable Mini®, Micro Coaxial Cables, and EcoWire® hook-up wires. Key Demands of Compact Cable Technologies Advanced wiring solutions are key requirements for many demanding, space-constrained environments, delivering breakthrough performance. Here are a few examples of applications where these specialized cables not only connect components but also provide uncompromising performance. Medical Diagnostics : Medical technology requires advanced wiring solutions as modern medical devices become increasingly miniaturized, more mobile, and integrated with advanced features. As devices like wearable monitors, handheld diagnostic tools, and minimally invasive surgical equipment shrink in dimension, the internal wiring must maintain high electrical performance within extremely tight spaces. These cables transmit sensitive bio-signals reliably while being exceptionally lightweight and flexible, allowing for greater patient comfort and enhanced device mobility. However, designing wiring for medical applications brings forth unique challenges. Cables must be made from biocompatible materials to ensure patient safety and must withstand frequent sterilization and cleaning cycles without degradation or material breakdown. Compact devices create tight bends and demand ultra-thin insulation. This increases the risk of flex fatigue and signal loss, especially in applications that require repeated movement or bending. Medical environments often require low-outgassing and halogen-free materials to prevent toxic emissions, meeting strict regulatory and safety standards. Beyond mechanical constraints, advanced wiring must also provide robust shielding against electromagnetic interference (EMI) and ensure the accurate transfer of diagnostic images and biosensor data. Industrial Robotics : Industrial robots operate in compact spaces with high-speed movements, often involving repeated bending, twisting, and vibration. This requires a wiring solution that provides reliable and precise performance. In robotics, every joint, actuator, and sensor requires cables with high service life that can perform without fatigue or signal loss. For example, multi-axis robotic arms require cables capable of withstanding ±180° torsion every 3 feet while enduring millions of flex cycles. The most critical challenge with the traditional cables is achieving a lifespan of over one million flex cycles without conductor fatigue or insulation cracking. Cables must accommodate extremely tight, constant dynamic bend radii. Additionally, modern robots have become more compact and multi-functional. Hence, space constraints demand cables with smaller diameters, tighter bend radii, and ease of routing through narrow channels without compromising power or data transmission. Other challenges include electromagnetic interference affecting signal integrity, heat buildup during high-speed operations, and the need for chemical and abrasion-resistant materials in harsh industrial environments. Technical Criteria For Dynamic Cable Selection In High-Flex Environments Selection of cables for dynamic applications, such as robots, drag chains, or automation equipment, should focus on mechanical stress, signal integrity, thermal loads, and environmental factors. The following factors should be considered when selecting cables for dynamic applications: Conductor Selection : In dynamic applications like articulated robots or gantry systems, stranded tinned copper conductors are preferred due to their flexibility and resistance to corrosion and fatigue. The American Wire Gauge (AWG) size must be compatible with the device's electrical load and connector requirements. For example, a 7/32 stranding for 24 AWG performs better than solid wires, resisting breaks from repeated torsion up to ±180°/m in welding bots. Insulation and Shielding : The choice of insulating and jacketing materials is critical for signal integrity. Polyolefin-based insulations, such as polyethylene and polypropylene, offer superior dielectric properties compared to PVC, while also providing high strength and low density. This means less total material and a slimmer, lighter, and more flexible cable. In environments prone to EMI, such as those with motors, shielded cables are essential to minimize noise and signal degradation. For example, a double-layer cable with foil tape and 95% braid can reduce surface transfer impedance by 1/5, while preserving impedance (100-120 Ω) in high-speed data links. Figure 1: EcoCable Mini® cable with mPPE jacket offers the advantage of up to 92% lower outgassing than PVC control cable(Source: Belden ) Environmental Resilience: Cables exposed to heat, moisture, chemicals, or UV light must utilize materials such as Teflon or PVC jackets with flame-retardant properties to meet safety standards, including UL or RoHS. Polyurethane (PUR) or Thermoplastic Elastomer (TPE) for the outer jacket offers superior resistance to abrasion, oils, chemicals, and temperature fluctuations commonly found on the factory floor, thereby preventing premature wear and tear. Bending Radius : It is the minimum radius formed by the cable's centerline when it is bent. For cables in a dynamic environment, the recommended minimum bending radius is typically a multiple of the cable's outer diameter (OD), often ranging from 4 times to 12 times the OD. Bend radius requirements vary depending on the type of cable. For example, flexible cables can tolerate smaller bend radii, whereas high-voltage wires or fiber optic cables require larger bend radii for safety and optimal performance. Figure 2: Illustration of bending radius of a wire Installation Practices : When installing cable chains in dynamic environments, the travel distance of the cable chain should be as short as possible to maintain efficiency and reduce wear. For high-speed setups (high levels of acceleration up to 50 m/s²), pick chains that are both lightweight and rigid enough to prevent twisting and handle the motion demands. When installing cables of different diameters, separators should be used to keep them apart and avoid tangling or interference with signal and power transmission. Additionally, proper strain relief and routing should be ensured to allow the cables to flex naturally without sharp bends or excessive tension. Alpha Wire’s Eco-Friendly, Space-Saving Cable Solutions Alpha Wire has engineered its EcoGen family of cables and wires to meet the challenges of space constraints and weight reduction in medical, industrial, and robotic applications. With the EcoGen family featuring EcoCable Mini ®, Micro Coaxial Cables, EcoWire® Hook-Up Wires, and EcoFlex® Series , it provides easy routing, durability, excellent signal integrity, and environmentally friendly footprints compared to traditional counterparts. EcoCable Mini ®: This is the newest addition to Alpha Wire's EcoGen® family of environmentally friendly, high-performance cables. Developed specifically for applications requiring a smaller, lighter, 300 V cable, it offers significant space-saving advantages over standard PVC cable. This makes it an ideal choice for intricate, compact designs in a variety of equipment. The key features are: Smaller and Lighter: Engineered with mPPE insulation and jacketing, making it up to 32% smaller and 44% lighter than traditional 300 V PVC cables. This allows for easier routing and installation in tight or densely packed areas. Environmental Benefits : This cable is free of halogens, phthalates, and heavy metals. It also produces up to 92% lower outgassing than standard PVC cable, which is crucial for sensitive environments, such as those in medical devices and semiconductor manufacturing. High-Performance Materials : The mPPE insulation and jacket combine durability with performance. The stranded tinned copper conductors provide fine flexibility for complex routing. Versatile Configurations : Offers over 250 standard configurations and four shielding options, including unshielded, foil-shielded, Supra-Shield foil + braid, and Supra-Shield foil + braid with enhanced shielding, to optimize signal integrity and noise rejection. Standard Compliance : The EcoCable Mini® is suitable for NFPA 79 applications and meets the requirements of RoHS, REACH, and WEEE. EcoFlex ® Series : These cables become the preferred choice when a pre-jacketed, multiconductor flexible cable is needed in a tight space. The key features are: Flexible and Compact: Using the same mPPE insulation as EcoWire®, EcoFlex® cables provide a flexible, multiconductor solution in a smaller and lighter overall package. Durable: EcoFlex PUR® cables also feature a rigid polyurethane (PUR) jacket for high durability, with an 8+ million-cycle flex life. Multiple Configurations are available, including both shielded and unshielded versions, as well as various conductor counts, allowing for tailored applications. EcoWire ® Hook-up Wire: EcoWire ® is a single-conductor option ideal for point-to-point wiring in densely packed electronics. The key features are: Small and Lightweight: The modified polyphenylene ether (mPPE) insulation is up to 45% smaller in diameter and 40% lighter than standard PVC wire . Environmentally Friendly: EcoWire® is halogen-free ensuring compliance with environmental regulations. Excellent Electrical Properties: The mPPE insulation offers high dielectric strength and is resistant to a wide range of temperatures. Micro Coaxial Cables : Micro coaxial cables are the best choice for transmitting sensitive signals in the most compact configurations. Space-Saving Design: These cables are available in extremely small sizes ranging from 50 AWG down to 32 AWG, with reduced outer diameters for easy routing in confined enclosures. Signal Integrity: The controlled impedance design, combined with a PFA dielectric, provides signal integrity and limits interference over short runs. High Performance: The high-strength, silver-plated or tinned-copper alloy construction extends its temperature rating up to 200°C. A tabulated comparison of the above series of cables is listed: Feature EcoCable Mini ® (Control Cable) EcoFlex ® (Continuous Flex) EcoWire ® (Hook-Up Wire) Micro Coaxial Cables Best For Compact, lightweight multiconductor control applications (300 V) Continuous flexing and high-torsion movement (robotics/drag chains). General point-to-point internal wiring in dense panels. High-performance signal transmission in extremely compact, high-temp spaces. Primary Advantage Up to 32% smaller control cable footprint. 8 million+ flex cycles with a rugged PUR jacket. Up to 45% smaller, 40% lighter, halogen-free. Highest signal integrity in the smallest size. Conductor Sizes Up to 20 AWG Up to 16 AWG 28 AWG to 10 AWG 50 AWG to 32 AWG Insulation Polyphenylene ether (mPPE) Polyphenylene ether (mPPE) Polyphenylene ether (mPPE) Perfluoroalkoxyalkan (PFA). Jacket Polyphenylene ether (mPPE) PUR (Polyurethane) None Perfluoroalkoxyalkan (PFA). Bend Radius 10 × OD (Static) 6 × OD (Static) 5 × OD (Static) 10 × OD (Static) Temperature Up to 80° C Up to 80° C Up to 105° C Up to 200° C Table 1: Comparison of Alpha Wire EcoGen® family of cables Summary Selecting the right cable ensures reliability, efficiency, and safety of the system in space-constrained environments. Components such as medical probes and robotic arms demand compact cable solutions that must deliver superior flexibility, signal integrity, and durability without adding unnecessary bulk. Alpha Wire’s EcoGen product family, including EcoCable® Mini, Micro Coaxial Cables, EcoWire® hook-up wires, and EcoFlex® series, offers sustainable, high-performance, and space-saving wiring systems designed for today’s most demanding applications. By combining reduced size with eco-friendly materials and versatile configurations, Alpha Wire provides unmatched performance and customization with EcoGen® solutions tailored for engineers and designers tackling tight installations. ABOUT THE SPONSOR Founded in New York City in 1922 as a supplier of wire strengtheners to the millinery industry (women’s hats), Alpha Wire grew to become a valued supplier to the expanding radio industry throughout the 1930s by producing wire and insulators for antennas. The company’s purpose-driven, hazard-matched connectivity solutions along with its leadership in flexible automation cabling, consultative approach and responsive support of customers’ unique needs, availability of small put-ups, short minimum runs, and highly engineered custom cable solutions have enabled Alpha to serve many of the world’s leading companies. For more information, click here. Featured Products Micro Coaxial Cable Buy Now EcoWire ® hook-up wire Buy Now EcoFlex ® Series Buy Now EcoCable Mini® Buy NowMicro Coaxial cableAlphaWire-e14Ecogenecowireecocableecoflexalpha wirehttps://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/industrial-waterproof-usb-connectivity-ip67-type-a-typeb-solutions-from-l-comTue, 19 May 2026 16:08:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:99b70761-9c29-4891-98ce-6636494054dde14sbhargavUniversal Serial Bus (USB) is one of the leading serial communication standards in modern electronics. It is present in domestic applications, factory floors, vehicles, and outdoor infrastructures. However, not all environments are as clean as your home or car, especially those found in factories or outdoors. In these environments, water, dust particles, and oil ingress are the main culprits of intermittent faults and premature USB failures. Standard USB connectors are not designed for use in wash-down environments, exposure to rain, or in areas with airborne particulates. The absence of a sealing cover, lightweight backshell, and exposed contacts can lead to corrosion, compromising signal integrity and leading to premature failure. L-com overcomes these challenges with its IP-rated, waterproof USB cables, designed to withstand the dust and moisture often found in manufacturing and other difficult environments. This article explains the key elements of waterproof USB cabling, best installation practices, and USB cabling solutions available from L-Com for deployment in harsh environments. Engineering the seal: What makes a USB cable truly “waterproof”? A waterproof USB connector requires more than a simple rubber boot or splash-resistant coating to achieve genuine environmental protection. Several critical mechanical design choices and factors determine a USB connector's waterproof rating: IP Rating: Waterproof USB cables are specified using an Ingress Protection (IP) rating. IP ratings are defined by the IEC 60529 standards and are represented by two-digit codes. The first digit refers to the ingress of a solid foreign object. The second digit indicates the level of protection against liquid intrusion. Common waterproof ratings for USB cables include: IP67: Fully dust-proof and survives being submerged in 1 meter of water for 30 minutes. IP68: Fully dust-proof and can remain underwater deeper than 1 meter for the duration specified by the manufacturer. Figure 1: IP67 vs IP68 waterproof rating comparison for USB connectors Threaded couplings and O-ring seals provide the primary environmental seal: These create a positive, repeatable seal at the mating surface helping to achieve the IP67 rating in real-world deployments. The threaded coupling draws the two connector halves together while the elastomer O‑ring compresses to exclude water and particles at the interface. Rugged backshell: Molded backshells resist impact, flex, and cable side‑loads, which are common on machinery and vehicles. They also help control strain where the cable meets the connector , reducing micro‑fractures and shielding damage. Gold ‑ plated contacts and shielding: A typical 30 µin gold contact plating supports reliable mating cycles under varying vibration, humidity, and temperature conditions. Additionally, a combination of foil and braid shielding effectively resists EMI/RFI , ensuring signal integrity remains within USB specifications. Panel ‑ mount options: Bulkhead jacks with flying leads facilitate bringing a sealed USB feed‑through to the outside of an enclosure without compromising the cabinet’s ingress protection. Port covers and caps: An open, exposed receptacle breaks the sealing chain and compromises it. Port covers and caps preserve the seal when ports are unused. Best practices for selecting and deploying waterproof USB: selection, installation, and lifecycle Achieving reliable waterproof USB connectivity extends beyond simply selecting an IP-rated cable. It requires careful component selection , proper installation techniques, and proactive lifecycle management to ensure long-term performance in harsh environments while minimizing the total cost of ownership. Right connector family and data rate: Selecting the correct USB connector and version is crucial for data and power transfer. For example, USB-A connectors are suitable for most computers or external hard drives. USB-B connectors are used for printers and other large peripherals. Similarly, USB-C, which has the capability of faster data transfer rates, has become a standard connector for many newer devices. In addition to different shapes and sizes, USB connectors also differ in their data transfer capabilities. USB 3.0, 3.1, and 3.2 connectors are designed for high-speed data transfer, making them ideal for transferring large files or streaming HD video, compared to slower USB 2.0 versions. Practical cable lengths and thickness considerations: USB cable length is limited by signal timing and voltage drop (e.g., 5 m for USB 2.0, 3 m for USB 3.x, and 0.8 m for USB4). Longer runs increase resistance and delay, reducing signal and voltage. Similarly, gauge (AWG) is chosen to keep the voltage drop under 5% and deliver the required current. A thicker (lower AWG) cable can carry more current and is suitable for longer or higher power cables (e.g., 20–22 AWG for 3–5 m, 3 A USB-C cables compared to 28 AWG for short, 0.5 m data-only cables). Maintain the integrity of the entire mating chain: IP67 protection only holds when all interfaces are properly sealed. If the enclosure features a waterproof bulkhead receptacle, the mating field cable must also be the matching IP-rated plug with a dust cap on any unused female side to maintain the system’s rating integrity. Installation & lifecycle best practices: To ensure the long-term reliability of waterproof USB or similar sealed connectors, cables should be routed with drip loops and kept away from areas where water can pool, as IP67 ratings guarantee only temporary immersion. Proper cable management, strain-relief boots, clamps, and rugged backshells protect against vibration and side loads. During installation or servicing, connectors should be tightened only until the O-ring is uniformly compressed to prevent damage to the threads. The unused ports must be capped immediately with tethered or lanyard caps. L‑com waterproof USB solutions: The building blocks you can mix and match Waterproof USB cables and cable assemblies from L-com provide exceptional reliability for computing applications in harsh environments. These IP67-rated USB cable assemblies and components feature robust construction that shields against dust and water ingress, making them ideal for manufacturing environments where computers must interface with robots, CNC machines, and automated equipment in the presence of particulate contamination and moisture exposure. These waterproof USB cables enable reliable computer connections in process industries, including food, pharmaceutical, and chemical processing, where exposure to liquids and chemicals is a constant concern. L-com's waterproof USB solutions also excel in demanding environments such as construction sites, mining operations, and military applications. L-com’s product range covers USB 2.0 and USB 3.0 standards and includes a wide variety of connector types such as Type-A, Type-B, A/B, B/A, Type-C, and Mini-B 5-position, along with specialized options like USB/FireWire combinations, shielded cables, extension cables, and field-installable connectors. To maintain complete system integrity, L-com also offers replacement gaskets, nuts, and IP67-rated port protection accessories, such as the WPCVR-USB-1394 Port Protection Cover . These components allow engineers to create a fully sealed, end-to-end USB path from panel feedthroughs to device connections, reducing maintenance costs in critical applications. Product Family / Component Connector Types Key Features and Use Cases Typical Lengths Waterproof Cable Assemblies (General) Broad IP67-rated USB family: Type-A, Type-B, A/B, B/A, Mini-B, Type-C, USB 3.0 Utilizes rugged housings, threaded couplings, and O-rings for sealing. Designed for harsh environments; maintain IP67 seal when mated Various (0.3 m – 5.0 m) Type-A Extension Cable Panel-Mount A-Female ↔ Standard A-Male Use Case: Creating a sealed pass-through port on an enclosure (e.g., kiosks, PLC cabinets). Requires a protective cap on unused female side 0.3 m, 0.5 m, 1 m, 2 m, 3 m, 5 m Type-B/A Cable Assembly Panel-Mount B-Female ↔ Standard A-Male Use Case: Connecting instruments, printers or diagnostic ports with a Type-B port to a host PC (Type-A). Common for instrument panels. 0.5–5.0 m Type-B/B Cable Assembly (WPUSBBB Series) B-Male ↔ B-Male (USB 2.0 Compliant) Use Case: Controller-to-device runs where both endpoints are Type-B. 2.0 m, 5.0 m USB 3.0 IP67 Assemblies (U3A00017 Series) Various (e.g., IP67 B-Male ↔ Standard B-Male) Designed for SuperSpeed (higher data rates). Includes options for shrouded IP67 male and panel-mount female connectors for high-bandwidth peripherals (e.g., machine vision). 1.5 m Bulkhead Jacks & Connectors Panel-mount A/B Jacks Use Case: Mounting connectors cleanly through a sealed panel or enclosure wall to maintain the IP rating. Mates directly with waterproof cable assemblies. 10-inch lead versions available Port Protection Cover (WPCVR-USB-1394) Waterproof Cap (USB/FireWire Compatible) Use Case: Sealing and protecting unused IP67 female panel connectors. Features a rubber lanyard to prevent loss. Essential for maintaining the IP67 rating when the port is idle. NA Table 1: Comparison of L-com IP67 Waterproof USB Cable Assemblies and Accessories Summary In challenging environments where standard USB cables and connectors are subjected to wash-downs, rain, dust, oils, or shock and vibration, signal integrity degrades and operational risks increase. IP rated waterproof assemblies featuring threaded collars and O-ring seals, robust backshells, and reliable contacts, significantly reduce corrosion and intermittent faults without sacrificing USB interoperability. With a comprehensive portfolio and proven durability, L-com’s waterproof USB solutions are the ultimate building blocks for industrial connectivity that you can mix and match to meet any application requirement. Secure and Reliable Industrial Connectivity Starts with L-com WPUSBAF Waterproof USB Type A jack with 10" wire leads Buy Now WPUSB-CVR USB cover, waterproof/firewire Buy Now WPNUT-13/16-28 Nylon nut for housing size 13/16-28 Buy Now U3A00026-1M USB 3.0 cable, waterproof Type C female-Type A male Buy Now WPUSBCN-A-3 IP67 Waterproof USB 3.0 Type A field installable connector Buy Now WPUSBABSH Series USB Cable, shielded waterproof Type A Male-Type B Male Buy Now ABOUT THE SPONSOR L-Com offer a wide range of high-performance, UL-rated solutions across many key industries, including electronics, medical, industrial automation, military, and telecom. For more information, click here.ip68IP67 Type Al-comIP-ratedE14-LCOMindustrial waterproof USBhttps://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/achieving-deterministic-latency-with-the-amd-kria-k24-somMon, 27 Apr 2026 10:05:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:c12a8068-557e-4433-82fc-0d58b942c751e14sbhargavIntroduction In industrial environments, it is imperative that digital signal processing (DSP)-intensive applications at the edge deliver efficient performance. Applications such as electric drives and motor controllers require high compute throughput and deterministic, low-latency performance for precise control. Failure to do so can cause compute-intensive DSP workloads to exhibit unpredictable or inaccurate behaviour. The result can be performance degradation, reliability concerns, and even safety risks. Traditionally, overcoming these challenges required complex hardware design and lengthy development cycles, making it difficult to balance performance with cost and time-to-market. The AMD Kria TM K24 System-on-Modules (SOMs) and Kria KD240 drives starter kits address these challenges. The K24 SOM offers a power-, performance-, and cost-optimized platform in a compact production-ready form factor. This article explores how the K24 SOM and KD240 starter kit enable architects and engineers to create reliable, high-performance motor control and DSP solutions at the edge. The kit bridges the gap between development efficiency and industrial-grade deployment. 2. Latency and Determinism in Industrial Motion Control Definitions Latency is the time delay between an input signal and the corresponding system response. In industrial motion control, it is the time between an input and the corresponding motor output. Even microseconds of delay can compromise motion precision. Conversely, determinism is the ability of the system to execute consistent and predictable control loops. This eliminates jitter and ensures reliable performance under load. A deterministic system helps ensure that every operation executes within a defined time frame. Impacts of High Latency and Low Determinism In industrial motion control, high latency and low determinism can degrade accuracy, as latency and determinism directly influence system performance, reliability, and safety. Machines can sustain optimal operating speeds only if there is precision, a lack of which results in reduced throughput and unpredictable response time. Performance degradation can extend to inconsistent control timing. There can be greater wear, heat buildup, and vibration. The result is shortened equipment lifespan and higher maintenance costs. Traditionally, these challenges were reduced using custom ASICs, DSPs, or FPGAs, which require deep hardware expertise. To identify the position of the moving rotor, the controller uses a sensor attached to the stator that provides the angled position of the rotor based on an agreed reference point. In short, it's reporting an angle measurement. Based on this angle, the controller tries to optimize the drive, creating the proper amount of current for every motor phase and enabling the motor to operate at maximum efficiency. Without this information, the motor would spin inefficiently, consuming a lot of current and eventually overheating, or it would spin and not efficiently produce the maximum amount of torque possible. Solution: AMD Kria TM K24 SOM In industrial motion control, it is critical to achieve low latency and high determinism. This is because jitter or unpredictable delays can compromise efficiency, safety, and performance. Motor control solutions based on standard microcontrollers are limited when it comes to switching frequency. The AMD Kria TM K24 SOM, paired with the Kria KD240 drives starter kit, directly addresses issues such as low latency and high determinism by offering deterministic control loops and significantly lower latency than traditional SoCs. In fact, tests show up to twice lower latency in single-axis drives than competitive devices, with even greater benefits as the number of motor axes scales, thanks to FPGA logic that enables independent rather than time-multiplexed loops. 1 The K24 SOM is equipped with built-in pulse-width modulation (PWM) capabilities. It uses programmable logic to enable continuous current measurement and real-time processing, ensuring smooth, accurate, and energy-efficient operation. By fine-tuning voltage modulation, the K24 SOM enables precise motor speed control while simultaneously reducing electromagnetic interference (EMI). Unlike traditional software-driven control loops, AMD hardware-based execution provides deterministic performance for demanding industrial drives by reducing interrupt delays and jitter. This hardware-first approach simplifies design and enhances system reliability by solving common issues associated with software routines. The key advantages of using this solution are: AI-enabled intelligence – The K24 SOM collects and analyzes parameters like current, torque, and position to enable predictive maintenance, anomaly detection, and functional safety. Scalability for multi-motor systems – FPGA parallelism allows synchronized control of complex setups such as six-axis robotics or multiple coordinated drives. Flexible multiprotocol support – Compatibility with encoder/sensor standards like EnDat, BiSS, and Hiperface DSL ensures adaptability and future-proof motion control designs. Advanced modulation capabilities – Engineers can implement scalable, custom modulation schemes in programmable logic, spreading harmonics to reduce acoustic noise and torque ripple. Deterministic real-time performance – Hardware-accelerated control loops deliver sub-millisecond latency, supporting high-frequency SiC-based power electronics and ensuring consistent, reliable motor control. 3. Introducing the AMD Kria TM K24 SOM Features and Operation The AMD Kria TM K24 SOM is a powerful solution for next-generation electric drives and motion control applications at the edge. It is built on the AMD Zynq TM UltraScale+ TM MPSoC and integrates programmable logic, dual-core Arm ® Cortex ® -R5F real-time processors, and high-performance cores. It integrates FPGA-based adaptive system-on-chip technology into a compact, production-ready format, designed specifically for high-performance, real-time motor control in industrial applications. This architecture allows hardware acceleration of time-critical paths while minimizing jitter, making it ideal for compute-intensive DSP workloads. The design also supports modern power electronics, such as silicon carbide devices, by providing fast, deterministic loops at high switching frequencies. The K24 SOM is optimized for power efficiency and reliability in industrial environments, with ECC memory, thermal robustness, and extended lifecycle support (Figure 1). The K24 SOM also offers two security features: dedicated hardware built into the MPSoC and an on-board trusted platform module (TPM) device. It allows synchronization of multiple motors and offers on-board error correction and system monitoring. Figure 1: Picture showing the front and back sides of the AMD Kria TM K24 SOM Some of the key benefits of the K24 SOM for motor control include: Security Features : AMD motor control solutions offer multiple security features, from tamper monitoring to license management. Multiple Industrial Networking Protocol Support : AMD solutions support multiple industrial networking protocols, delivering high design flexibility. Functional Safety : AMD solutions are built to support the latest functional safety standards. Low Latency : AMD motor control solutions deliver low latency between IT and operational tasks for high-speed performance. Standard Industrial Networking : Besides TSN, it can support other industrial networking standards, such as EtherCAT ® , PROFINET ® , EtherNet/IP ® , and many more. Standard Fieldbus : The K24 SOM supports the CAN interface, and the KD240 drives starter kit offers a connector for the CAN 2.0 interface. 4. Getting Started with the AMD Kria TM KD240 Drives Starter Kit The AMD Kria TM KD240 drives starter kit is the latest out-of-the-box ready development platform in the Kria portfolio. This starter kit serves as a platform for developing electric drives and other size and cost-constrained applications. The kit consists of a non-production AMD Kria K24 SOM plugged into a drives application carrier card and equipped with a passive heatsink. The K24 SOM included in the starter kit is based on the AMD Zynq TM UltraScale+ TM MPSoC and paired with 2 GB of LPDDR4 memory. The starter kit is also drives-application ready because it features a three-phase inverter, quadrature encoder interface, brake control, and torque sensor interface. Beyond the drives-specific interfaces, there are host of other interfaces for general purpose developers including connectivity through Ethernet and USB ports, and flexible I/O expandability via a Pmod connector. Figure 2 shows the details of the components of the KD240 drives starter kit. Figure 2: AMD Kria TM KD240 Drives Starter Kit Software Support The solution is pre-certified for industrial use, simplifying both hardware and software development requirements. It is simplified signal processing supports many design flows, including familiar design tools like MATLAB, Simulink, and languages like Python, with its extensive ecosystem and support for the PYNQ framework. The Kria Robotics Stack (KRS), a ROS 2 superset, enhances AMD Kria TM K24 SOM by enabling hardware-accelerated robotics development. It provides optimized libraries, secure compute architectures, and seamless integration for industrial-grade robotics. With support for low latency, determinism, real-time performance, and high throughput, KRS empowers ROS 2 developers to build and deploy advanced robotic solutions faster and more efficiently on adaptive computing platforms. Out-of-the-box Demo Information The AMD Kria TM K24 SOM, coupled with the Kria KD240 drives starter kit, is an out-of-the-box-ready tool for developers building compute-intensive motor control applications. It benefits from a rich ecosystem, including pre-built motor control libraries and the KD240 kit, which enables out-of-the-box validation without FPGA expertise. It leverages multiple development flows, including Python, the MATLAB ® Simulink ® environment, and more. This demo highlights how quickly engineers can set up the KD240 drives starter kit and run a sensor-based Field-Oriented Control (FOC) hardware accelerated application. After flashing the provided microSD card with the latest AMD image and mounting the kit to the motor accessory plate, users simply connect Ethernet, USB-UART, motor accessory kit cables, and power. The setup requires no FPGA expertise. Once powered, the kit boots into Ubuntu, where the FOC motor control application is installed and launched. A browser-based GUI allows engineers to remotely control and monitor motor performance, such as adjusting RPM in real time. www.youtube.com/watch The entire setup from unboxing to running the FOC application takes less than an hour, showcasing the KD240 drive starter kit’s ease of use and rapid prototyping capability. Beyond this demo, engineers can explore additional accelerated applications through the Kria App Store, enabling quick evaluation and deployment across motor control and DSP use cases. With production-ready Kria SOMs available, the KD240 drivers starter kit provides a seamless path from development to deployment in both commercial and industrial environments. 5. Conclusion Summary Latency and determinism are critical challenges in industrial motion control. Traditional microcontroller-based systems often fall short, introducing unpredictable delays and limiting the adoption of modern high-frequency technologies like SiC. The AMD Kria TM K24 SOM and the Kria KD240 drives starter kit provide engineers with a production-ready, adaptive platform that ensures deterministic, low-latency control. By integrating programmable logic, robust security, and OTA update capability, the K24 SOM delivers long-term value for industrial edge deployments. With its out-of-the-box usability, scalability, and proven reliability, the K24 SOM allows engineers to move quickly from prototyping to deployment—achieving higher precision, safer operation, and extended equipment lifecycles. To explore the AMD Kria TM K24 SOM and Kria KD240 drives starter kit, visit: AMD Kria TM KD240 Drives Starter Kit AMD Kria TM K24 SOM Boot Kria Starter Kit Linux on AMD Kria TM KD240 1 Based on AMD internal analysis in August 2023, using the latency results reported by TI for a full control loop implementation on a Texas Instruments AM64xx standard SOC using a Texas Instruments benchmark vs. the latency results of a full control loop implementation using a Field Oriented Control algorithm designed by Qdesys. System configuration for the TI AM64xx SOC system: TMDS64EVM board; configuration for the Kria K24 SOM system: KD240 starter kit. The latency advantage improves up to 7x as the number of motor axes increases. Actual results will vary. (SOM-003) AMD, and the AMD Arrow logo, Kria, UltraScale+, Zynq, and combinations thereof are trademarks of Advanced Micro Devices, Inc. Other product names used in this publication are for identification purposes only and may be trademarks of their respective owners. About the sponsor AMD drives innovation in high-performance and AI computing to solve the world’s most important challenges. Today, AMD technology powers billions of experiences across cloud and AI infrastructure, embedded systems, AI PCs and gaming. With a broad portfolio of AI-optimized CPUs, GPUs, networking and software, AMD delivers full-stack AI solutions that provide the performance and scalability needed for a new era of intelligent computing. Learn more at amd.com .testingKria KD240amdK24 SOME14-AMDhttps://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234242Fri, 06 Mar 2026 06:15:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:553f320e-171a-4233-8ca4-9dfe00e32bf6Knighthawk_140A how to guide to read mnemonic triangle. A new day where the ELITE are EDUCATEDhttps://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234239Fri, 06 Mar 2026 02:21:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:48693706-6f82-41b2-9799-6a9f33fca406shabazI think it's easier to derive from the formula; the arrangement of the four variables in a triangle doesn't work (whereas with three variables, the V=IR triangle makes sense, and same for other relationships like these). Here's a four-variable representation which makes sense.. although this was quickly done with AI, so check it before use. The style however is (or was) very popular back when electronic calculators were not common (and often precise values are not needed, just a ballpark, because of component tolerances). This can be done for all manner of formulae (was popular for 555 timer calculations too).https://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234238Fri, 06 Mar 2026 01:09:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:3b941d15-ecd6-4620-b6a4-9108bad78cbbKnighthawk_140AND ONE BECOMES TWOhttps://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234177Wed, 04 Mar 2026 21:34:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:eb425459-5a38-4eeb-a702-2810117074b1robogarylooks like a jet turbine :-) compression, ignition, delta temperature , delta Velocity then whoosh !https://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234174Wed, 04 Mar 2026 16:22:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:4879ce32-292d-4ed4-9b6a-4e922be85134dougwhttps://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234173Wed, 04 Mar 2026 16:02:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:2b2d9483-1cd3-4110-b324-d4a7cc85df07michaelkellettWell Doug, I probably won't forget that ..... But I think I'll stick with classical maths notation when I need to do sums. MKhttps://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234172Wed, 04 Mar 2026 15:57:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:ec34aff1-a921-41a6-896f-69a631f37082dougw☺https://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234171Wed, 04 Mar 2026 15:29:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:06e4f8d3-51f5-42fd-93e3-9a3a1f340b4eKnighthawk_140https://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234170Wed, 04 Mar 2026 13:57:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:583e4017-bfc5-470b-88ed-f08b0dc4c93bobonesAnd here I was thinking I'm the only one not to get this...https://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234169Wed, 04 Mar 2026 13:33:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:695aec96-55ae-4388-b142-ce8c7ea066b6michaelkellettHow interesting - to me it looks like those meaningless diagrams that people use to illustrate corporate time-wasting presentations The equation is T = (C * dV)/I or dV = (T * I) / C (dV because its the change in V while I and C are constant) I just can't see how the diagram shows that. If a vertical bar means * and a horizontal bar means / then what does the horizontal bar below T mean ? I can't work out a consistent decode of the diagram. I know that some people associate colours with numbers or letters (synesthesia) - I don't. Maybe "seeing" this diagram is a similar thing. MKhttps://community.element14.com/learn/learning-center/stem-academy/f/forum/56737/mnemonic-triangle/234168Wed, 04 Mar 2026 12:38:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:3777a611-d0a0-4c33-ab54-fe686024f576chloroNice mnemonic! Triangles like this make it much easier to remember the relationships when working with capacitor ramp circuits. Simple visual tricks like these are actually very useful when doing quick calculations or explaining concepts. Thanks for sharing it.