New Rugged USB 3.2 Connectors & Cable Assembly Solutions Unveiled

Fischer Connectors is expanding its platform capabilities to meet the most demanding connectivity requirements for high-speed data transfer using the USB 3.2 Gen 2 protocol up to 10 Gbit/s.

Fischer Connectors’ high-speed solutions with USB 3.2 Gen 2 up to 10 Gbit/s meet the versatile requirements of a wide variety of applications, from surgical equipment in operating rooms and small computers and peripherals for soldiers, to outdoor test & measurement applications and civil and military drones. 

The Swiss-based company has developed new USB 3.2 connectors and cable assembly solutions in three of its flagship product lines, designed to meet signal integrity and harsh environment requirements for medical, defense, industrial, and instrumentation applications.

SWaP-Critical Applications
Suitable for miniature body-worn computers and peripherals, high-performance lidars, and high-speed intercom boxes. Choose the ultra-miniature Fischer MiniMax™ Series, available with 9 pins in Ø 12.9 mm (size 08 plug) or 12 signal and power pins in Ø 14.9 mm (size 10 plug), supporting high power up to 8A.

Drones and MIL-SPEC Applications
Designed for civil and military drones with USB3 cameras and various military specifications. Opt for the rugged Fischer UltiMate™ Series with 9 pins in Ø 18.5 mm (size 11 plug), featuring 360° EMC shielding and resistance to shock, vibration, and corrosion for up to 1,000 hours of salt mist.

Surgical Equipment
Ideal for operating room surgical tools, USB3 cameras in orthopedic surgery, endoscopic devices, and instrumentation applications like assembly production lines and outdoor inspections in radiation or contaminated areas. Use the versatile Fischer Core Brass Series with 9 pins in Ø 15.5 mm (size 1031 plug), which is resistant to chemicals and sterilization processes.

High-Quality Cable Assembly to Ensure Signal Integrity Performance

Fischer Connectors’ three series offer IP68 sealing, with IP69 and hermeticity available for the Core and UltiMate series due to a resin-sealed contact block. They are designed to withstand extreme operating temperatures: MiniMax from -40 °C to +135 °C, Core from -70 °C to +250 °C, and UltiMate from -55 °C to +135 °C.

The connectors support high mating cycles—up to 5,000 for MiniMax and up to 10,000 for Core and UltiMate. They feature three locking mechanisms: push-pull and quick-release for all series, with an additional screw option for MiniMax. UltiMate also offers blind mating with a robust mechanical keying system.

Data protocols are constantly evolving to enable interoperability and reliable transfer of increasing amounts of data at the highest speeds between more and more connected devices. Fischer Connectors’ latest expansion is designed address this technological challenge.

Designing high-speed interconnect solutions requires expertise in cable assembly, high-performance connectors, and signal integrity simulation, testing and design.

During the design and characterization process, engineers must address a highly complex combination of parameters such as impedance matching, line delay, insertion/return loss, crosstalk and EMC shielding.

High-quality cable assembly is critical to ensure reliable and efficient data transmission, signal integrity and overall system function. Ameny Chaabani, Signal Integrity Engineer at Fischer Connectors, explained, “To achieve successful high-speed data transfer from a device´s transmitter to its receiver, connectors and cables must be cross-optimized and undergo a series of compliance tests at the system level. 

“USB 3.2 is a stringent protocol. Connector design, cable length, cable performance (loss), and the controlled and repeatable cable assembly and potting processes above 1 Gbit/s are some of the influencing parameters to consider. We must also study the full physical layer of a link as a whole, what we call system-level testing.”

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