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Sensing light is immensely useful in many applications. Want to check everything on your production line is stood up and oriented correctly? Need to count small items your manufacturing system is making? And want to do it all reliably, cost-effectively, and quickly? Then light sensing is going to be your technology of choice.
Photoelectric sensors take light, typically visible or infrared, and convert it into an electrical signal. Originally developed around the middle of the last century, the technology has developed substantially since the original phototransistors and photodiodes.
Today, sensors have become far smaller and more sensitive, while often integrating analogue-to-digital conversion and a digital interface. Developments are being partly driven by new applications, such as ambient light detection in smartphones, but manufacturing and packaging remain the biggest market.
Photoelectric sensors can detect objects many metres, or even tens of metres, away. They can pick up targets less than a millimetre across, and can even be used to analyse the colour of an object.
Three basic types
For most applications, the choice of photoelectric sensor comes down to one of the three commonest types: through-beam, retroreflective and diffuse.
Through-beam sensors use an emitter that sends out a beam of light towards the sensor, which detects when an object obstructs the beam’s path. Through-beam sensors are reliable, but require the emitter and sensor to be accurately installed in two different places, which can be awkward and costly.
Retroreflective sensors emit a beam of light that is sent back by a reflector, and an object is detected when it breaks this light beam. Like through-beam sensors, retroreflective sensors still require two items to be installed (the emitter/receiver, and the reflector). They typically have lower precision and sensitivity, and can struggle to spot shiny objects like metal cans. They are, on the other hand, often a little lower in cost.
The third type is the diffuse sensor, which also has its light emitter and receiver in the same place, and often in the same casing, thus making it easier and cheaper to install. An object is picked up when it reflects some of the light back to the receiver – so the performance depends on the colour and reflectivity of the target object.
With diffuse sensors, there is also the risk of light that has been reflected by a background being erroneously detected. Various techniques have been applied to overcome this, including using multiple receivers and focussing one where the object is expected and one on the background, and then comparing the signals.
In terms of operating distance, through-beam sensors have the advantage of the longest range, often working at 30m or more. Retro-reflective sensors can typically operate up to about 10m distance, while diffuse sensors usually work over much shorter ranges. Of course, in practice you may only need a very short range, and sensors working over just a few millimetres are widely used.
Slimline yet robust
Whichever type you choose, for manufacturing automation and industrial automation one of the key criteria is something we’ve not mentioned yet – ruggedness, and ability to function reliably in harsh conditions. Bulgin has designed a range of slim line photoelectric sensors specifically to meet the tough demands of these kinds of applications,
The Bulgin sensors provide high levels of mechanical and electrical stability, with a watertight and dustproof seal to any standard M5 interface, and a Stainless Steel 316 shell, sealed to IP67. The sensors are only 4.5mm thick, and optionally supplied with a 2m cable. They offer a sensing range of up to 40mm.
For more information, visit https://www.bulgin.com/en/products/range/sensors.html
Since it was first introduced in 1996, the Universal Serial Bus (USB) standard has become the interface of choice for an enormous range of computing and communications applications, both for data transfer and for charging.
We've become used to standard Type-A ports on our laptops, with Type-B connectors common on printers and other peripherals. The space-saving mini and micro versions have become ubiquitous on mobile phones, tablets and other portable equipment.
In 2014, the USB Implementers Forum published the USB Type-C specification, with a new rotationally-symmetrical 24-pin connector. It doesn’t matter which orientation you plug in the Type-C connector, it’s always correct. At a stroke, this overcomes the oft-maligned version of Murphy’s Law which seems to dictate that with a USB Type-A connector, it’s always the wrong way round no matter which way you insert it.
Adoption of Type-C has been gradual but is now gaining momentum, and is about to take off, supported by hundreds of vendors. For example, Apple now provides USB Type-C on all of its laptops, as well as on its most recent iPad Pros, although not yet on the iPhone.
The popularity of Type-C is also being driven by its compact dimensions – about the size of an existing micro-USB connector, and much smaller than Type-A. Additionally, Type-C can provide more power, up to 100W, meaning phones can be charged faster.
Speed matters
When USB 1.0 originally launched, it offered speeds up to 12 Mb/s, but this quickly became an unwelcome limitation. The USB 2.0 standard upped this figure to 480 Mb/s, then USB 3.0 took it further to 5 Gb/s.
While USB 3.0 is more than enough for many applications, it can be a limitation for today’s fast solid-state disks. 5 Gb/s is also not up to the job of transferring data for high-speed, high resolution industrial vision systems, or transferring high-resolution video in some automotive applications. This has been addressed by USB 3.1, which supports up to 10 Gb/s, and USB 3.2, which can go all the way up to 20 Gb/s.
So far, so good – but there is a potential for confusion about how the changes in physical USB connector relate to the data transfer speeds supported by the various versions of the standard.
The key point to remember is that the data transfer speeds are defined by the version numbers of the standard, such as USB 3.0, 3.1 and 3.2, so long as they are supported by the connectors used.
When different standard peripherals or connectors are used together, the newer versions are backwards compatible, and the data transfer speed achievable drops to the lowest supported by any component that is connected. For example, if you connect a fast USB 3.0 drive to a USB 2.0 host, the top speed achievable is 480 Mb/s, which is the limit for USB 2.0.
Picking the right connector
How does the required speed relate to the physical connectors used?
USB Type-C supports much higher data rates than previous types of USB connector, and a Type-C connector is needed for the 20 Gb/s maximum of USB 3.2 – which is achieved by sending data over multiple ‘lanes’ simultaneously. While the newer ‘SuperSpeed’ versions of Type-A and Type-B connectors will handle up to 10 Gb/s, that’s their limit. Looking further ahead, USB4 is in the pipeline, and will support up to 40 Gb/s – but only on Type-C connectors.
It’s not just about speed, of course. Depending on the application, it’s vital to pick a connector that also has the physical robustness needed to achieve the right level of reliability. For example, Bulgin’s new range of USB Type-C connectors provides a rugged option for protection in harsh environments, such as industrial and medical, with an extended temperature range from –40ºC to +80ºC, and protection against dust and moisture tested to IP69K and IP68.
Visit Bulgin’s Connectivity Community forum and blog for expert advice on connectors.
While most of us live and work in relatively protected and safe indoor environments, much of the world’s most critical electronic systems and equipment operate in harsh conditions. Whether it is water, dust, extreme weather, explosive atmospheres or pressure, a range of harsh environments can create challenging conditions for these systems and their connectors to operate in.
One of the most common points of damage in any electrical system is where cables get plugged in - the connector. Connectors are at the junction of system and cable, needing to have the flexibility to mate and disconnect easily yet securely, all while keeping the elements out. As the guardians of the entry points to both system and cabling, their integrity in harsh environments is critical.
Since they’re at the entry point to the system, connectors face the same hazards as any electronic system, including water, dust/dirt, extreme temperatures, potentially explosive “ATEX” environments, pressure/weight, and salinity.
What Defines a Harsh Environment?
Wet or dirty environments with water, high humidity/water vapour, dust or dirt can wreak havoc on electrical equipment, causing short circuits or malfunctioning equipment. If salinity is a factor, such as in a seaside environment, corrosion can also be a serious issue.
Electrical systems are also often sensitive to temperature extremes, which can cause components to fail or malfunction. For data connections, Electro-Magnetic Interference (EMI) can be an issue as it can disrupt wired communication.
Physical force is another hazard which can come in the form of mechanical shock and vibration or pressure. To withstand shock and vibration, a robust mating method needs to be in place.
Connectors in undersea, aerospace or pressurized environments also need additional ruggedization.
For connectors used in explosive environments, an additional requirement is that they do not have any way to set off a spark, either mechanically or electrically, and cause a hazardous explosion.
Rugged Applications
The range of rugged applications is extremely varied and crosses many industry lines. Ruggedized systems and connectors are used in industrial, marine, oil and gas, transportation and infrastructure, telecom, and more.
Industrial
In industrial environments, automation, machinery and measurement come together to create today’s hyper-efficient manufacturing systems. Industrial environments are often exposed to a variety of harsh elements including water, vibration, chemicals and temperature extremes. The move to greater automation and “Lights-out” manufacturing means environmental challenges will only increase as equipment now increasingly has the freedom to operate in inhospitable conditions.
Industrial equipment such as food slicers, saws, sandblasters, food processors, coating machines can generate significant shock and vibration, as well as create dust or airborne contaminants. Sealed, rugged metal or plastic housing connectors with IP66, IP67, IP68 and IP69K ratings can withstand these harsh conditions and keep power, signal and data connections secure.
Because of the noisy EMI conditions in industrial environments and the dependence on sensors and communication, EMI is also a concern for data connections. In these cases electrically shielded connectors are ideal.
Marine
Marine applications include surface and undersea environments. Surface marine applications such as boating equipment, ship deck systems, or marina facilities face threats from corrosion due to high salinity, as well water ingress, making robust, sealed components essential.
IP rated components should be chosen depending on the level of water and dust protection needed, with IP66 and IP67 sufficient for many surface applications while IP68 or IP69K will be necessary when connectors may be submerged. For undersea applications such as diving electronics, depth loggers or undersea remotely operated vehicles, IP69K or other pressure-resistant designs are important.
Oil & Gas
The Oil & Gas industry faces many of the same environmental hazards of industrial and marine environments, but also must deal with explosive atmospheres which require the use of ATEX / IEC Ex rated equipment. For offshore platforms, both marine hazards and explosive atmospheres exist. In addition, the oil and gas industry makes extensive use of underwater ROVs for drilling and construction support as well as exploration.
These underwater remotely operated vehicles are essentially remote-controlled robots. They require power, data, and often fiber optic lines, have to operate in rough undersea conditions, and are often asked to go to depths beyond what’s possible by a human diver. Bulgin’s ROV tether connector is designed to keep these robotic helpers working reliably in uncertain waters. Made of 316 marine-grade Stainless steel, it is a Pressure Balanced Oil Filled (PBOF) cabling solution that uses oil as a compensating fluid for water pressure, allowing ROVs to go to depths of 7000m.
Other applications
From transportation and infrastructure to automotive and agriculture, a wide variety of applications operate in the outdoors. These use cases require connectors that can weather extreme temperature changes, water and dust ingress, physical duress, and more.
Key Features
IP rating – IP ratings define the level of protection from dust and water ingress of the component. The first digit indicates the level of dust protection and goes from 0 to 6, while the second digit indicates liquid ingress protection. For harsh environments, sealed connectors should always be dust-tight, with water ingress protection depending on the application.
IP66 - protection against powerful water jets, and IP67 - immersion up to 1m, is suitable for many above water applications where systems may be rained on, or otherwise repeatedly exposed to water. Connectors which may be continuously submerged should be at least IP68 (immersion to 1m or more) or greater, and for undersea applications, IP69K (close-range high pressure and high-temperature spray downs) provides protection even under pressure.
Besides undersea and immersion applications, IP68 and IP69K also have medical and food processing use cases as these ratings allow the equipment to be regularly washed and sanitized without harm to electrical components.
Locking/coupling mechanisms
With many connectors being exposed to environments with shock and vibration present, a robust coupling mechanism is a must. There are many different types of connector couplings, including ring, twist locking, threaded, bayonet, push-pull and quick disconnect couplings, all with different attributes for various types of applications. Some, like the bayonet connector, provide better security against shock and vibration, while others like push-pull and quick disconnect provide greater ease of use when connectors may need to be disconnected often.
Housing and insulation
The material the connector is made of helps it resist the challenges of its environment. For applications with temperature extremes as well as plenty of moisture and dust, a corrosion resistant metal housing may be appropriate. If lightweight and flexibility are key, temperature-resistant plastic composites will be more attractive.
Connector Design
The connector’s shape, mating mechanism and pin positioning also play a part in its ruggedness. Circular connectors have the benefit of easy engagement/disengagement, as well as the capacity to fit a wide variety of contacts. Circular connectors also are easy to seal and less likely to wear out. An intelligent “scoop proof” design can be used to avoid pin damage while trying to mate the connector.
Making the Right Connections
Our world is becoming increasingly connected. From outdoor cellular base stations to connected factories, to IoT sensors on oil and gas platforms, electronics are being placed in every environment imaginable. The electronic systems have to be guarded against all the forces of nature.
As the point of entry to the system, connectors have to be robustly designed to seal off and protect against all environmental challenges present - from shock and vibration to dust and water, or EMI. Thankfully today’s connectors from companies like Bulgin provide strong ruggedization for just about every application on the market. Through choosing the right IP rating, locking mechanism, housing material, and connector design, almost every rugged use case today can be made to work reliably with the right connector.
Visit http://www.bulgin.com/ for more information
For any fiber optic network, it’s important that the fibers are connected properly. A reliable connection will maintain efficient network operation by minimising light loss, and will avoid any problems from moisture or dirt getting in to the connector.
To connect to other devices or equipment, an optical fiber needs to be terminated. This means either fitting a connector to its end, or connecting it directly to another fiber, known as splicing. If a connector is used, the two fibers can later be disconnected for testing or to change the routing of the cable, while splicing is permanent.
Splicing methods compared
There are two main methods of splicing: mechanical and fusion. In mechanical splicing, the ends of the two fibers are lined up so light can pass, and then a cover is used to hold them together permanently. Fusion splicing typically uses an electric arc to melt the ends of the two fibers, and bond them together in a permanent weld.
Comparing these two methods, mechanical splicing is straightforward, and the covers are small and low cost. Fusion splicing, on the other hand, requires the use of an expensive fusion splicer machine, but creates a connection that has lower transmission losses than mechanical splicing and lower reflectance, as well as providing a more reliable connection, with no polishing required. Light can be lost or reflected if fibers are not properly aligned, if there is an air gap, or if there is dirt or moisture between the two fibers.
Connector termination methods
For termination with a connector, one method is to use a ‘pigtail’, which is a short single optical fiber, with a connector pre-installed at one end. The bare fiber end can be spliced, typically using fusion splicing, to the main fiber we wish to terminate. If it is a multi-fiber cable, each of the component fibers can be connected to a separate pigtail, and hence to a separate connector.
An alternative method is to use a ‘fanout kit’, also known as a ‘breakout kit’. This enables each fiber in a multi-fiber cable to be terminated by using an empty ‘jacket’ that fits over the end of the fiber, and which can then be attached to a connector. One advantage of this method is that no splicing is required, saving time and cost.
The choice of method used depends on the application, the performance required, and whether we are using single-mode or multi-mode fiber. Single-mode fiber requires a cleaner, more accurate connection to avoid loss and reflectance, so is often pre-terminated in a factory, while multi-mode fiber is easier to terminate in the field.
The role of crimping
To attach the connector to the fiber, the installer can use glue or crimping. An epoxy or other adhesive can be used to glue the fiber into the connector’s ferrule, and the end of the fiber then polished. The epoxy needs curing, which can take overnight, or be speeded up using a curing oven.
An alternative is to connect the connector by crimping, where a crimping tool is used to apply mechanical force to a crimp barrel (a small metal sleeve or ring), thus deforming it and forming a tight bond with the connector itself. Crimping is faster than gluing, but is typically more expensive, and can result in slightly higher light losses than a glued connection.
For successful crimping, make sure to use the correct crimping tool and sleeve, as recommended by the connector manufacturer. The operator also needs to use the specified force when crimping, to avoid damage to the connector and potentially the fiber itself. While the procedure is not overly difficult, the operator must be properly trained, particularly when they are required to install multiple different types of connector and cable, and to select the right crimping tool every time.
Connection in harsh environments
Whichever method of termination is used, the connector should be robust and reliable enough for the conditions. For outdoor applications, this means selecting a rugged connector such as the 4000 series from Bulgin. This protects the ends of the fiber from dirt and damage, and provides a seal to prevent any moisture ingress and thus ice forming.
The 4000 series provides an industry-standard LC interface as specified by IEC 61754-20. To save time and simplify installation, the connectors are available as pre-terminated options, already connected to a suitable cable of up to 450m in length.
4000 Series Fiber product code: PXF4050
For duplex fiber connections, the 6000 Series Fiber would be more fitting. Like the 4000 Series Fiber, the 6000 Series Fiber connector is suited for outdoor broadcasting, FTTx, server room engineering, civil engineering and aviation & rail applications.
The 6000 series harsh environment optical connector is designed for years of service in areas where unprotected physical contact fiber, isn’t an option. Featuring a secure, yet easy to operate 30 degree locking mechanism, this series has field proven IP68 and IP69K performance.
In comparison to the simplex 4000 Series Fiber connector, the additional glass fiber on this duplex cable can double the data transmission capabilities where required.
6000 Series Fiber product code: PXF6050
Visit Bulgin’s Connectivity Community forum and blog for expert advice on optical fiber connectors and installations in harsh environments.
Optical fiber is everywhere: carrying huge quantities of data at the speed of light. Glass or plastic, fiber is super-fast, flexible and thin, around the thickness of human hair.
The fiber carries data as pulses of light, and has nowadays overtaken copper wire as the medium of choice – primarily because it is lower cost, faster and less bulky. Optical fiber is also harder to hack than copper, making it more secure and safer because it doesn’t generate heat.
There is, however, a challenge to be overcome: the delicate nature of the optical fiber means installation and maintenance must be carefully managed. Tiny amounts of grease, dirt or moisture can affect the transmission of light. While the fibers themselves are protected by an acrylic layer, the connectors joining each fiber can be vulnerable in harsh environments.
This is particularly true in outdoor applications such as broadcast, telecommunications, civil engineering, FTTx (fiber to the x, including fiber to the home), and marine. Optical fiber must be robust enough to cope with being run between communications masts for telecoms links, across freezing ground for television outside broadcasts, and alongside roads to carry video from traffic cameras.
Damage from freezing temperatures
One specific problem is how the fibers and connectors cope with sub-zero temperatures. Water can make its way into the conduit or duct carrying the fiber, typically if there are any gaps or imperfect joins at the connectors. In fact, standard interface connectors are simply not robust enough to avoid water ingress in harsh environments.
When the temperature drops, the water freezes, and ice forms around the fiber – with the large resulting forces causing the fiber to deform and bend. This degrades the signal passing through the fiber, at the very least reducing the bandwidth, but quite possibly stopping data transmission altogether.
To mitigate this problem, one approach is to only install fiber cables buried below the frost line, so there is no threat of ice. But this solution can be extremely expensive, and is difficult to follow when cables need to be routed along a bridge or other structure. Another solution can be to add antifreeze liquids or gels to the fiber conduit, but again this can have a high cost.
Rugged connectors
If we want to cost-effectively protect an optical fiber against extreme temperatures, it is therefore essential to protect the end points and connections from any water that can leak into the conduit, and later freeze. A suitable connector, which is specifically designed for harsh environments, can ensure the fiber conduit is sealed, and the fiber itself is safe from the risk of ice formation.
There are three common types of fiber connectors: SC, ST (bayonet-twist) and LC (push-pull locking). The LC connector is most commonly chosen, because it is much smaller than the other two, and also provides a secure clip connection.
Unfortunately, the standard LC connector does not provide sufficient protection against water ingress. It is possible to build a custom enclosure to protect a connector, but this is usually bulky and costly.
Instead, a much better approach is to specify a rugged LC connector that is specifically designed for harsh environments. For example, Bulgin’s 4000 Series Fiber connector is the smallest sealed standard interface connector on the market. The fiber connection is UV resistant, salt spray resistant and sealed to IP66, IP68 and IP69K, while still providing an industry-standard LC interface as specified by IEC 61754-20.
The connector and its housing can be completely immersed in water up to a depth of 10 meters, for a period of up to two weeks (based on IP68 rating tests), without allowing water to gain access to the conduit and hence potentially to freeze and damage the fiber. The connector can also handle temperatures from -25 to +70c and protects the fiber against dirt and dust.
4000 Series Fiber Simplex Connector
4000 Series Fiber product code: PXF4050
For duplex fiber connections, the 6000 Series Fiber would be more fitting. Like the 4000 Series Fiber, the 6000 Series Fiber connector is suited for outdoor broadcasting, FTTx, server room engineering, civil engineering and aviation & rail applications.
The 6000 series harsh environment optical connector is designed for years of service in areas where unprotected physical contact fiber, isn’t an option. Featuring a secure, yet easy to operate 30 degree locking mechanism, this series has field proven IP68 and IP69K performance.
In comparison to the simplex 4000 Series Fiber connector, the additional glass fiber on this duplex cable can double the data transmission capabilities where required.
6000 Series Fiber Duplex Connector
6000 Series Fiber product code: PXF6050
With a suitable rugged connector, engineers can now plan their fiber deployments in harsh environments without fear of damage from ice – and without the cost of antifreezes, or the inconvenience of bulky enclosures.
Visit Bulgin’s Connectivity Community forum and blog for expert advice on optical fiber connectors and installations in harsh environments.
The market for photoelectric sensors is expected to grow to more than US$2 billion by 2025, driven in part by the rise of the Internet of Things (IoT). They are used in many different applications, often in manufacturing and packaging, and have some significant advantages over other sensors. In this article we’ll explain how they work, and compare the different types, then list seven typical uses.
How photoelectric sensors work
In basic terms, the sensor detects visible or infrared light emitted from a transmitter. By sensing how much light is received, and hence how much has been reflected or blocked, it can determine useful information, such as the presence or absence of an object – for example, on a production line.
Compared to other types of sensors, photoelectric sensors can detect objects a relatively long distance away, up to several metres, and provide fast, accurate results. They also do not require any contact with objects, improving reliability, and can detect almost any kind of item, whatever it is made from.
There are three main types of photoelectric sensors in common use:
A light beam is sent towards the object of interest, and the sensor detects reflected light.
Light is sent towards a reflector, and the sensor detects the reflected light – an object being detected may block the transmitted or reflected light.
Light is sent to a separate receiver, and the object of interest blocks the transmitted beam.
Within these main types, there are various different kinds of sensor with specialized uses. For example, some sensors can suppress the background, making it easier to detect an object close to reflective surroundings.
Applications for photoelectric sensors
There are too many applications to list in one article, but here are seven good examples:
Checking objects on production lines or conveyors: photoelectric sensors can detect items’ sizes to spot any errors, or simply spot their absence, as well as picking up problems like misaligned caps on bottles. They are widely used in the food and pharmaceutical industries, and in packaging plants.
Counting small objects: in some production environments, small items will fall from a vibrating conveyor belt into a packaging system or bag – and a photoelectric sensor can count them.
Detecting colours: by scanning independently in red, green and blue light, with applications in multiple processes in the printing and packaging sectors.
Monitoring bigger areas for objects with light grids: instead of using multiple sensors, a ‘light grid’ uses parallel beams of light to cover a two-dimensional area.
Measuring distance: with multiple sensors, a triangulation process compares reflected laser beams, and can be used to accurately determine position and distance, for example to check the location of manufacturing systems, or in automated transport applications.
Logistics and materials handling: automated warehouses with robotic pickers or trucks rely on position and object sensing to operate efficiently and safely.
Automatic doors: in buildings or public transport, photoelectric sensors detect when someone is standing by a door.
Reliable sensing
There are many, many more applications for photoelectric sensors, but it can be seen that a lot of them are in industrial or manufacturing settings – where the environment can be harsh, and components must be rugged and reliable.
To meet these demands, Bulgin's slim line photoelectric sensor range provides a cost-effective and flexible solution, with high levels of mechanical and electrical stability.
Photoelectric Sensor
A simple and secure design enables a watertight and dustproof seal to any standard M5 interface. The sensors are made with a robust Stainless Steel 316 case, sealed to IP67, making them well-suited to manufacturing and industrial automation operations.
Product codes: SLLP3002M5, SLDP3002M5, SLLN3002M5, SLDN3002M5, SLLP4002M5, SLDP4002M5, SLLN4002M5, SLDN4002M5, SLLP3002CL, SLDP3002CL, SLLN3002CL, SLDN3002CL, SLLP4002CL, SLDP4002CL, SLLN4002CL, SLDN4002CL
For more information, visit https://www.bulgin.com/en/products/range/sensors.html.
We’ve come to rely on the internet today, for communicating, shopping, watching TV and a million over things. It’s only a slight exaggeration to say internet has become as basic a utility as a telephone, or mains electricity.
For most of us, fast broadband is easily accessible, and is competitively-priced – whether it’s via fiber or legacy phone networks, using ADSL.
But in rural areas, it’s not so simple. With lower population densities, the cost for telecom operators to roll out broadband networks is perceived as just too high in many areas. Even if you do get connected, the speed you can achieve depends on the distance to the local exchange or other infrastructure, so people in more remote areas struggle with slow connections.
How many Broadband options?
There are various different technologies that can be used for rural broadband. Most simply, the internet can be accessed using ADSL over existing copper phone lines, but to get an acceptable speed, the provider needs to upgrade the nearest exchange. In many rural areas, they’re not prepared to invest that money just for a few subscribers, leaving them stuck on slow, unreliable links.
Another option is the 4G mobile data network, accessed either via a router or SIM card in a phone, tablet or computer. But coverage is limited in rural areas, and many people can’t get a good enough signal. Satellite connections are an alternative, but the price is often prohibitively high.
This leaves fiber as the best solution for many people, although how accessible it is depends very much on which country you are in. The UK has fiber available to something like 90% of the population, although of course the 10% missing out are mostly in rural areas, whereas for some countries, like the USA, that percentage is far lower.
Fiber all the way
To address this issue, governments in different countries have placed legal requirements on the telcos to provide subsidised broadband, usually backed up with some kind of financial assistance. For example, the UK has for several years had a programme called Broadband Delivery UK (BDUK). This has used £1.7bn of public money to help extend so-called ‘superfast’ broadband (defined as 24Mbps and above) to more than 5 million premises in rural areas since 2013.
More recently, in May 2019 the UK government launched a two-year programme called Rural Gigabit Connectivity (RGC), which provides £200m to support the roll out of full fiber-to-the-premises (FTTP) connectivity in remote areas of the country. The government has also pledged to bring fiber to every home by 2025.
Is this kind of programme money well spent? It can be very expensive, with BT estimating the cost of connecting rural homes at typically £4,000 each, which is ten times the price for cities. FTTP is still not in common use in the UK, reaching only 7% of households.
But for areas where their only existing alternative is satellite broadband, it can look like good value. For example, Grimsay in Scotland’s Outer Hebrides islands has recently had fiber broadband installed – giving it fast internet access to replace its costly, slow satellite links. People here can now work remotely more easily, as well as run their businesses and appeal to tourists more. This can make an enormous difference to quality of life, as well as helping slow down or reverse the emigration of young people to cities, which is an issue both in countries like the UK, and in developing economies.
If we are to provide fast, reliable broadband to rural populations, fiber seems like the way to go in most cases. It can be relatively expensive to install, but is much cheaper in terms of operating costs than wireless or mobile solutions.
To help providers meet their cost targets, the technology they choose must be reliable, rugged and simple to use. Specifically for fiber connectors, Bulgin can provide many different options to meet the varied needs of new networks.
4000 Series Fiber Simplex Connector
The 4000 series provides an industry-standard LC interface as specified by IEC 61754-20. To save time and simplify installation, the connectors are available as pre-terminated options, already connected to a suitable cable of up to 450m in length.
Product code: PXF4050
Like the 4000 Series Fiber, the 60000 Series Fiber duplex connector is suited for outdoor broadcasting, FTTx, server room engineering, civil engineering and aviation & rail applications.
6000 Series Fiber Duplex Connector
The 6000 series harsh environment optical connector is designed for years of service in areas where unprotected physical contact fiber, isn’t an option. Featuring a secure, yet easy to operate 30 degree locking mechanism, this series has field proven IP68 and IP69K performance.
In comparison to the simplex 4000 Series Fiber connector, the additional glass fiber on this duplex cable can double the data transmission capabilities where required.
Product code: PXF6050
Visit Bulgin’s Connectivity Community for expert advice and for more information on optical fiber connectors please visit the Bulgin website.
Optical fiber is an excellent way for the transmission of data, using light signals that travel down the length of a glass fiber. Super-fast, flexible and thin, it is rare that fiber optic cable rarely needs amplification, even over long distance transmissions. It can be a challenging material for network engineers to get to grips with, even with all the obvious benefits.
The most basic way to assess the performance of fiber optic is to measure the optical power that is emitted from the end of the fiber. This is measured in decibels (dB). To best understand the power measurement, it can be looked at in terms of optical loss. Splitters, fusion splices, connectors and other intermediary network components can all contribute to attenuation in signal, otherwise known as insertion loss (IL).
Balancing the power and loss “budgets”
If you’re just getting started with working with fiber optics, you’ll start to often come across the terms “power budget” and “loss budget”, so it’s important to understand the difference between the two. The term power budget refers to the maximum amount of loss that an entire datalink (from transmitter to receiver) can tolerate in order to operate properly. Sometimes you might find that the power budget has both a minimum and maximum value. This means it needs at least a minimum value of loss so that the receiver doesn’t get overloaded, whereas the maximum value of loss will ensure that the receiver has sufficient signal to operate on.
The loss budget is the total amount of loss that your end point should have. To calculate this, you’ll need to add up the estimated average losses of all the components used in your cable plant to get the estimated total end-to-end loss. This figure is then compared to the start point at the network’s data source to determine whether or not the cable is functioning optimally.
What tools will you need?
In order to measure power, continuity and loss in a fiber optic cable, a light source and a power meter are required. Before using a power meter in the field, read the manual and run some practice tests. Make sure you have the proper safety equipment such as eye protection before testing fiber optic cables with a power meter. You may also need reference test cables, mating adaptors, a visual fault locator and a fiber optic cleaning kit to keep the tiny, hair-like cable ends safe from contamination, particularly in outdoor or industrial environments.
While optical power meters are the most basic of power measurement instruments for fiber, optical loss test sets (OLTSs) and optical time domain reflectometers (OTDRs) are also useful tools for accurately measuring power in testing loss, particularly in outdoor installations.
Using the power meter
When measuring fiber optic power with a power meter, attach the meter to the cable. Fiber optic power meters have inputs for attaching fiber optic connectors and detectors designed to capture all the light coming out of the fiber. Power meters generally have modular adapters that allow connecting to various types of connectors. Typically both receivers and transmitters have receptacles for fiber optic connectors; so to measure the power of a transmitter, attach a test cable to the source and measure the power at the other end. For receivers, disconnect the cable attached to the receiver receptacle and measure the output with the meter. Compare your actual measurement with the specified correct power guidelines for that particular system to be sure it’s not giving out too much or too little power.
Calculating loss
The basic formula used to calculate dB is: dB = 10 log (measured power / reference power).
Whenever tests are performed on fiber optic networks, the results are displayed on the meter readout in dB. Optical loss is measured in dB while optical power is measured in dBm. Loss is displayed as a negative number, such as –2.1 dB.
There are different loss calculation guidelines to follow for connectors, splices, multimode fibers, and singlemode fibers. You can refer to more resources on the Fiber Optic Association website (www.thefoa.org) for standard formulae for calculating loss before you get started.
Visit Bulgin’s Connectivity Community forum and blog for expert advice on optical fiber connectors and installations in harsh environments.
The maker movement has become increasingly popular, giving a huge range of people the chance to get involved in technology, and to build projects for themselves. Open source hardware and software has enabled makers to create almost anything you can think of, using their skills in electronics, computing, metalworking and woodworking. Makers are continually pushing boundaries in terms of innovation.
Whether it’s a new robot, a better toaster, or something truly unique, whatever a maker builds has to deal with the real world. This may mean it needs to handle exposure to the elements if it flies outside, or to cope with immersion in water, or invasive dust. You might be making something like a drone or submersible that obviously needs protection – or simply an electronics item that needs to function in the open air.
It’s simple enough to build your project in a robust, waterproof case, but when it comes to linking it to anything else, the connectors can easily be a point of weakness, where moisture and dirt can get to where they really shouldn’t be.
Whether it’s carrying data, power or an analogue signal, you need the right connector that is up to the job. This beginner’s guide will help you select the appropriate rugged connectors for your project
A selection of Bulgin's rugged connectors
A guide to IP ratings
The first task is to review the kind of environment your project will be used in, and what kind of problems you might encounter. Here, it helps to understand the ‘IP rating’ system. Short for ‘Ingress Protection’, the IP rating is a standard that defines how much an enclosure protects users, how much it protects its contents, and its resistance to moisture and liquids.
The IP rating consists of the letters ‘IP’, usually followed by two digits. The first digit specifies the level of protection against foreign bodies and particles – for example, ‘5’ signifies partial protection against dust and particulates, to avoid damage. Also, ‘6’ denotes full protection, including a vacuum seal.
The second digit relates to protection against moisture and liquids. Here, ‘7’ means protection against full immersion in water at up to 1m depth, for up to half an hour (with some water ingress permitted, as long as there’s no damage). Together with the first digit, that gives a complete code such as ‘IP42’ or ‘IP67’. There are many more possible variants – search online if you need more detail.
As well as the IP rating, you’ll need to consider the expected temperature range for your project, both in terms of when it’s operating and when it’s stored. Also look at whether there’s likely to be mechanical shock or vibration, which could shake connectors loose even if it doesn’t damage them.
Types of connector
Once you’ve thought through the likely hazards, and the level of protection you might need, then you can look for suitable connectors – whether that is circular power connectors, data connectors, optical fiber connectors, or anything else.
Why not turn to an expert for help? Bulgin has a wide range of rugged connectors, which are specially designed to protect from dirt, dust, water, moisture, temperature extremes and shock. This includes the Buccaneer waterproof circular connector range for power, signal and data, which are rated to IP66, IP67, IP68 and IP69K.
For smaller designs, the 400 Series Buccaneer is just as tough, but fits in a small footprint. And if you need to connect optical fiber, the 4000 Series optical connector provides a secure, quick twist bayonet connection.
As a provider of rugged connectors and other electronic components, Bulgin is a proud supporter of the maker community, and we believe we have the right products for any maker project.
For information on any of Bulgin's rugged connectors please visit: www.bulgin.com
You can also visit Bulgin’s Connectivity Community for expert advice on connectors.
We hear a lot about fiber optic networks for broadband internet, but there’s more than one way they can be constructed.
While the main network will always be fiber, there are alternatives as to how to connect the ‘last mile’ – the few hundred metres nearest the consumer’s home or the business premises of the end user. This may use fiber to the home (FTTH) or curb (FTTC), where the last few metres are handled with copper cables – together, these variants are known as FTTx.
In most countries, it’s simply too expensive to run a dedicated, or direct, fiber link all the way to each subscriber. If there is already existing copper telephone cable run to each home, it will be cheaper to use that for the last few metres, but that makes the connection slower.
So, how should our network be constructed, so that fast fiber can reach all the way to the end user, but without the prohibitive cost of everyone having their own private connection?
What are AON and PON?
There are two common ways this problem can be solved, both based on the principle of splitting the signal, so that each fiber from the central office in the network’s core is shared between multiple end users. The two methods are called Active Optical Networks (AON) or Passive Optical Networks (PON), and in both case the split into individual fibers for each user happens fairly close to the customer; within a few kilometres at most.
The key difference between AON and PON is how the signal is split between the multiple fibers going to each customer. AONs use active, electrically powered devices to direct the appropriate signal only to the relevant customer. Ethernet is commonly used, and a switching device will typically route signals to up to about 500 customers.
In contrast, a PON uses optical splitters, which require no electrical power, to send the signal to each customer. Each switching cabinet can handle up to 128 end users. You can see in the diagram that each customer also receives signals intended for someone else, so encryption ensures privacy is maintained. For upstream signals sent back from customers, these are combined into one signal at the switching cabinet, typically using Time Division Multiple Access (TDMA). The PON also uses wavelength division multiplexing (WDM) to carry both upstream and downstream traffic over single mode fibers.
Benefits of each approach
PONs have a number of key advantages; for a start, because they don’t require electrical power for the splitter, they have lower installation and operating costs than AONs. They also use less energy, and less network infrastructure, than AONs, and are highly reliable. Compared to the copper wiring that is being replaced by fiber, using PONs means the fiber is smaller, easier to manage, and more secure than the legacy cabling it replaces.
On the other hand, AONs enable the fiber ‘last mile’ link to operate over longer distances than with a PON: typically, up to around 70 to 100km, compared to about 20km for PONs. Troubleshooting and finding a problem is easier with AONs than with PONs, because each fiber is carrying signals dedicated to one customer. AONs also don’t suffer from the drop-in speeds that PONs experience at peak times, due to multiple customers’ traffic being sent down each fiber.
Reliability essential
Both AON and PON are widely used today. Whichever approach is chosen, the key factor in building a successful fiber optic network is reliability. Connectors are an essential part of the FTTx network, and by working with a vendor such as Bulgin, you can be assured of choosing a rugged, dependable connector that will handle harsh outdoor environments.
4000 Series Fiber connector
The 4000 Series Fiber connector offers reliable performance regardless of the application environment. Its industry-standard LC interfaces feature color-coded O-rings and washers for ease of identification. Mounting body options include Flex, Flex In-Line and Rear Panel styles.
The ideal solution for where ease of connection, space, and appearance are important considerations.
Visit Bulgin’s Connectivity Community forum and blog for expert advice on optical fiber connectors.