Series 15 – Episode 5 – Introducing floating connector technology

As Harwin recently released a technical paper on this topic, Smart provided valuable insights into the challenges and solutions faced by designers in the electronics industry.

Designing high-performance electrical systems while minimising board space and weight is a significant challenge for developers. "Designers face significant demands to create high-performance electrical systems while using minimal board space and reducing weight where possible," explained Smart. This growing need for robust, compact connectors to handle increased data and power transfers between PCBs further complicates the design and manufacturing process.

The pressures on lead times and time-to-market push customers and EMS providers to prefer high-speed automated assembly lines. "Misalignments during this process can lead to production issues," Smart noted. To address these challenges, Harwin recommends using floating connectors, which can absorb small movements and misalignments across different axes.

Modern electronic systems must balance high-speed performance with reduced size and weight. "Developers can address these needs through several solutions," said Smart. Integrating high-speed connectors like Harwin's Flecto series can offer higher data transfer rates within a compact form factor, maintaining signal integrity while minimising loss. Using lightweight materials in connectors and housing also helps reduce overall weight without compromising performance.

Floating connectors are designed to transfer data, power, or both while absorbing misalignments during manufacturing. Unlike traditional connectors, floating connectors feature a spring-like mechanism on the contact that provides elasticity, reducing stress on solder joints and contacts, and preventing damage. "The pins are designed with a bend, allowing them to flex within the housing and accommodate misalignments," explained Smart. This is crucial when using multiple connectors between PCBs, as it mitigates issues related to tolerance stack-up and side loading, which can affect performance and lead to electrical discontinuity.

To facilitate high-speed manufacturing and automated assembly processes, Harwin's floating connectors are available in tape-and-reel formats. "The floating technology helps mitigate misalignments during the mating process by allowing movement within the male connector, easing potential stresses," said Smart. Harwin’s products can offset by up to 0.8mm in some variants, providing significant misalignment tolerance.

Harwin's connectors suit various applications across different industries, but key markets include electric vehicles (EVs) and smart factory applications. "In EVs, connectors are crucial for battery management systems, infotainment, and advanced driver assistance systems (ADAS), where space is at a premium and durability is essential," Smart highlighted. In smart factories, particularly robotics, Harwin’s connectors handle high levels of shock and vibration, making them ideal for AGVs and AMRs, ensuring reliable data transfer in dynamic environments.

Harwin's Flecto range has received strong, positive feedback from distribution partners and customers, who are impressed with the ruggedness and misalignment capabilities of the design. "Many customers had not seen a floating connector in action before and are pleased with the amount of movement it accommodates," Smart shared.

The 'Floating Board-to-Board Connectors' whitepaper can be downloaded free of charge here.

To hear more about floating connectors and much more, you can listen to Electronic Specifier’s interview with Ryan Smart on Spotify or Apple podcasts.