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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
Connectors Trade Analysis Rev. A
Author: Alonso Moreno, Mechanical Engineering, RIT
Multi-Disciplinary Senior Design I
RIT Ruggedized Camera Encoder (P14571)
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
Table of Contents
1. Module 1: International Protection Marking (IP Code)Table breakdown of IP Code
2. Module 2: Connector Trade AnalysisIntroduction and ApplicationLEMO M Series Rugged USB Connector (IP68)Molex USB Type A Panel Mount PCB Receptacle/RJ-45CONEC 17-200601 USB ConnectorAMPHENOL MRJ-5380-01 - Connector: RJ45Mini HDMI, SD Card, Serial Connectors
3. Module 3: SummaryTable Breakdown of major characteristicsConclusions/Recommendations
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
I. International Precision Marking (IP Code)
IP First number - Protection against solid objects
0 No special protection
1 Protected against solid objects over 50 mm, e.g. accidental touch by persons hands.
2 Protected against solid objects over 12 mm, e.g. persons fingers.
3 Protected against solid objects over 2.5 mm (tools and wires).
4 Protected against solid objects over 1 mm (tools, wires, and small wires).
5 Protected against dust limited ingress (no harmful deposit).
6 Totally protected against dust.
IP Second number - Protection against liquids
0 No protection.
1 Protection against vertically falling drops of water e.g. condensation.
2 Protection against direct sprays of water up to 15o from the vertical.
3 Protected against direct sprays of water up to 60o from the vertical.
4 Protection against water sprayed from all directions - limited ingress permitted.
5 Protected against low pressure jets of water from all directions - limited ingress.
6Protected against temporary flooding of water, e.g. for use on ship decks - limited
ingress permitted.
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
7 Protected against the effect of immersion between 15 cm and 1 m.
8 Protects against long periods of immersion under pressure.
IP Third number - Protection against mechanical impacts (commonly omitted, the third number is not a part of IEC 60529)
0 No protection.
1Protects against impact of 0.225 joule
(e.g. 150 g weight falling from 15 cm height).
2Protected against impact of 0.375 joule
(e.g. 250 g weight falling from 15 cm height).
3Protected against impact of 0.5 joule
(e.g. 250 g weight falling from 20 cm height).
4Protected against impact of 2.0 joule
(e.g. 500 g weight falling from 40 cm height).
5Protected against impact of 6.0 joule
(e.g. 1.5 kg weight falling from 40 cm height).
6Protected against impact of 20.0 joule
(e.g. 5 kg weight falling from 40 cm height).
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
II. Trade Analysis
Introduction & Application
A Ruggedized Camera Encoder (RCE) is a compact and robust system that analyzes a stream of image data in real-time. Typically, video analytics are completed using post-processing techniques on a unit that is separate from the camera stream. This system will eliminate the need for post processing, which cuts down on turnaround time and the need for a secondary system.
The goal of this project is to deliver a working prototype that will have a small enclosure, with one tethered camera input (expandable to four), acquiring HD 1080p 30fps image data. The system will be capable of processing the image data in real-time running different video analytics algorithms. It will be capable of streaming compressed image data over GigE to a standard video client for diagnostics.
The purpose of this document is to provide a detailed comparison of current rugged connectors to be possibly used on the enclosure. For the purposes of this document we will focus on the first two numbers of the IP code, which deal with the dust proofing and water proofing of the connectors. We will focus on the on the protection of mechanical impacts as an enclosure as a whole.
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
LEMO M series rugged USB connector (IP68)
This LEMO ruggedized USB connector comes in four configurations as shown above. When mated these connectors are rated per IP 68. From section 1, IP 68 means t the connector is totally protected from dust and protected against long periods of immersion under pressure. These connectors are suited for variety of different applications including military use, which is probably the highest application of our overall system. A major advantage of this connector is also its small panel cut-out which will play a factor into the sizing of our enclosure.
LEMO USB Connector Purchasing
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
Molex USB Type A Panel Mount PCB Receptacle/RJ-45
The Molex USB rugged connector is rated for IP67. Similar to the first connector this one is dust tight however; a couple major differences are this one can only be immersed in water from 15cm to 1 m for a period of half an hour. Also the operating temperature for this connector is from -40 to 60 degrees Celsius which is 25 degrees below the upper limit desired by the customer. The connector only requires about a 26 mm diameter cut out. An advantage of this connector is that it is readily available in a kit with an RJ-45 connector also rated IP67. The RJ-45 connector has a better temperature of -40 to 80 but still falls short of the upper limit by 5 degrees.
Molex USB Connector Data Sheet
Molex USB Connector Drawing
Molex RJ-45 Data Sheet
Molex RJ-45 Drawing
Molex USB/RJ-45 Kit Data Sheet
Molex USB/RJ-45 Purchasing Kit
CONEC 17-200601 USB Connector
The Conecn USB connector shown is rated IP 67 and is able to operate between temperatures of -40 to 80 degrees Celsius. A disadvantage of this connector is that it is currently not in stock, but is on order. Another disadvantage is that it is only rated for IP67 when it is mated with a cap or connector.
CONEC USB Connector Purchasing
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
AMPHENOL MRJ-5380-01 - Connector: RJ45
The Amphenol RJ-45 connector requires a 24mm panel cutout. As with most o these ruggedized connectors the panel cut outs are not big but the connector outside the panel is a bit bulkier which should be fine for the ruggedness we are looking to achieve. The connector is able to operate in temperatures ranging from -40 to 105 degrees Celsius.
Amphenol RJ-45 Connector Drawing
Amphenol RJ-45 Purchasing
Mini HDMI, SD Card, Serial Connectors
One of the issues we rune into is that certain connectors it is difficult to find ruggedized version of them. There s no readily available mini HDMi ruggedized connector we could find. An alternative to this is identifying how many pins the connector requires and using a circular connector to match it. Just for reference, a mini HDMI connector requires 19 pins. We are not sure if this is ideal for the enclosure and it is a question to be posed to the customer.
Another issue is the SD card slot. SD card slots are small in size and a rugged connector seems counterproductive and not readily available. A possible alternative is to use a regular push-push SD card slot and possible design a small cover to g over it.
For the serial connector it is a simple three pin connector that can be replace by a rugged circular connection, but again we are not sure if this is desired by the customer.
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Ruggedized Camera Encoder P14571 Hornyak, Jason, Moreno, O’Connor, StreatMay 25, 2023
III. Summary
A summary of the connectors is presented in the table above. As we can see some of the connectors are missing. This is due to not being able to find a ruggedized version of certain connectors such as, the mini HDMI, SD Card and serial connector. Until alternatives are discussed with the customer the preliminary decision can be reached that only some of the connectors can be ruggedized and waterproof. If this is the case, then it is not feasible to waterproof only some of the connectors.
If we were to move with waterproofing though, The LEMO connector would probably be the best preliminary choice. Although the Molex kit would be nice both connectors do not meet the operating temperature range we are looking for. The Amphenol RJ-45 would be a better choice over the Molex RJ-45 connector due its high operating temperature.
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