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maku AnyConnect – by POLO: Connector and Cable Systems for Industrial Signal, Data, and Power Transmission

maku AnyConnect – by POLO provides robust connector and connection solutions for industrial applications where space, durability, and reliable electrical contacts are crucial. The product family includes modular multi-connectors, individual circular and rectangular connectors, customizable interfaces, and suitable sealing and strain relief solutions. Typical applications include machine controls, control cabinets, manufacturing cells, conveyor technology, and mobile machinery. The focus is on reproducible contact quality, easy handling during installation and maintenance, and compatibility with normative requirements (e.g., IP protection classes, UL, VDE).

Materials and Designs

Housings and contacts are designed for industrial stress in terms of materials. Housings are predominantly made of glass-fiber reinforced polyamide or PBT to ensure increased strength, temperature resistance, and dimensional stability. Metallic frame variants are available in anodized aluminum or stainless steel when increased shielding or corrosion-resistant installation is required. Contacts consist of copper alloys with surface coatings such as tin, nickel, or gold-plated, matched to current carrying capacity, contact resistance, and life cycles. Sealing elements are made of EPDM, NBR, or silicone, depending on chemical resistance, temperature range, and plasticizer compatibility.

Designs range from compact circular connector systems with quick-lock, screw, or bayonet locking to space-saving rectangular multicontact solutions and housings with integrated cable glands. Variants with front or rear cable entry allow flexible housing integration and accessibility for maintenance. Integrated shielding surfaces and customizable shield connections ensure EMC requirements.

Connections, Contact Assignment, and Conductor Cross-Sections

maku AnyConnect connectors support conductor cross-sections from fine signal wires to massive power wires. Signal and data contacts are designed for fine-stranded wires from 0.14 mm² as well as for twisted data lines; powerful power contacts carry currents up to the double-digit ampere range depending on contact material and cooling conditions. Versions are available for push-in, screw, crimp, and solder connections, each with clear labeling and polarity-protected mechanics. Data contacts are compatible with standard Ethernet cabling, industrial fieldbuses, and serial interfaces. For special requirements, hybrid connectors are available that combine power, signals, and optical fiber in one housing.

Seals, Protection Classes, and Environmental Resistance

The sealing concepts are modularly designed to achieve different protection degrees such as IP54, IP65, IP67, or IP69K. Seals on flange surfaces, cable entries, and housing transitions use molded foam or O-ring seals in appropriate hardness grades. Chemical-resistant materials enable use in cleaning and process environments. Temperature resistance typically ranges from -40 °C to +125 °C, and even beyond with special materials. Corrosion protection through coated metal parts and insulated contact guides minimizes failure risks in humid or salty atmospheres.

Electrical and Mechanical Properties

Electrical parameters are documented: rated voltage, rated current, insulation resistance, dielectric strength, and contact resistance at specified test load. Mechanical life cycles are specified between a few hundred to several thousand mating cycles, depending on the product. Vibration and shock resistance comply with industrial standards; mounting holes and assembly aids are provided for easy retrofitting in control cabinets and machine frames. Mounting surfaces are often standardized for front panel mounting or DIN rail adapters.

Application-Specific Variants

For food and pharmaceutical production, versions with smooth, easy-to-clean surfaces and FDA-compliant sealing materials are available. Variants for automotive and transport technology are vibration-resistant and temperature-stable. Explosion-proof versions are offered with ATEX/IECEx marking if required. For welding applications, heat-resistant and splash-proof variants are available.

Assembly, Installation, and Service

Customizable products allow: crimping, potting, assembly of pre-fabricated cable harnesses, and customer-specific assignments. Industrial assembly services can produce pre-assembled cables with specific lengths, markings, heat shrinks, and strain reliefs upon request. Installation-friendly features such as snap-in lugs, locking indicators, and color coding shorten installation times and reduce wiring errors. Spare parts and repair kits (seals, locking inserts, contacts) are available to minimize on-site downtime.

Application Examples and Practical Integration

Practical Example 1 – Machine Control in a Production Line: In an assembly cell, multiple sensors, actuators, and a fieldbus controller are connected via maku AnyConnect hybrid connectors. The hybrid solution combines power-carrying contacts for actuators, signal contacts for sensors, and a shielded data contact for Ethernet. The connector is front-insertable, and the housing is IP67-sealed and mounted on the protective wall. Wiring and replacing a defective actuator take less than five minutes thanks to push-in contacts and clear polarity identification.

Practical Example 2 – Control Cabinet Installation in a Harsh Environment: A control cabinet on a conveyor line requires a robust external connection for power and control. A rectangular AnyConnect multi-connector with a metal frame provides mechanical protection, the seal achieves IP69K, and the contacts are gold-plated to reduce contact resistance and corrosion. During maintenance cycles, the entire cable harness can be quickly disconnected and tested outside the production line.

Practical Example 3 – Mobile Machine and Vibration Load: A mobile hydraulic unit uses maku AnyConnect circular connectors with screw locking and special strain relief. The contacts are dimensioned for high currents, and the glass-fiber reinforced polyamide housing minimizes weight. Thanks to tensile cable glands and internal spring contacts, electrical connections remain secure even though the machine is exposed to strong vibrations.

Further application examples and technical integration notes can be found at maku Application Examples, and detailed solutions and technical data at maku Technology.

Specifications, Selection Criteria, and Tests

When selecting, attention must be paid to rated current, rated voltage, contact material, number of contacts, protection class, and necessary certification. Dimensioning is based on the loaded current and ambient temperature. EMC requirements necessitate shielded housings or additional shield connections. Tests include continuity testing, insulation testing, vibration, shock, climate tests (humidity, salt spray), and, if required, high-pressure cleaning tests.

• Key selection criteria: electrical rating, protection class, material resistance, mounting type, number of contacts, testing and certification requirements

Scope of Delivery, Customization, and Documentation

Products are supplied complete with seals, mounting accessories, and installation instructions. Upon request, maku offers customer-specific labeling, colored housings, special contact assignments, and pre-assembled cable harnesses. Technical data sheets, test reports, and material characteristic values are available to demonstrate conformity with operational and safety requirements.

Maintenance, Replacement Cycles, and Lifespan

Regular inspection of seals and contacts extends service life. Critical applications benefit from preventive replacement cycles of seals and contact surfaces according to documented maintenance intervals. Replaceable contact modules and repair kits simplify on-site maintenance and reduce machine downtime.

Compatibility and System Integration

The system is designed for easy integration into existing industrial control architectures. Standardized interfaces, mechanical adaptations for standard drilling patterns, and optional shield connections enable combination with other manufacturers and facilitate retrofit projects.

FAQs

1. Which protection classes are available with maku AnyConnect and how do I achieve IP67?

maku AnyConnect products are available in versions up to IP69K. You achieve an IP67 seal by correct installation of the factory-fitted O-rings or molded seals, use of the specified cable glands, and adherence to the recommended torque for screw connections. Technical notes can be found in the respective data sheet.

2. Can I use AnyConnect connectors for Ethernet and power simultaneously?

Yes. Hybrid variants combine shielded data contacts with separate power and signal contacts in one housing. Pay attention to correct wiring and shielding connection, as well as the specified conductor cross-sections and permissible total currents according to the data sheet.

3. Which sealing materials are recommended for chemically aggressive environments?

For chemically stressed environments, EPDM or special fluororubbers are suitable. NBR is suitable for many oils, silicone for high temperatures and cleaning cycles. Selection depends on temperature range, media contact, and hardness; detailed material tables are available in the technical documentation.