WS20 Series Circular Connectors for Circular Conveyor Systems in Germany

Project Background

A Germany-based cable assembly manufacturer with over 15 years of experience in industrial automation connectivity was commissioned to supply connection solutions for a chain-type conveyor system used in a high-speed electronics assembly line. The project demanded extreme reliability, compact installation, and strong resistance to vibration and environmental interference.

Application Challenges

The chain conveyor system was designed to support multi-station synchronous operations, including material loading, screw fastening, vision inspection, and laser marking. With a takt time of 0.8 seconds per unit and positioning accuracy requirements of ±0.05 mm, the electrical connection system faced several critical challenges:
• Unstable signal transmission caused by continuous motion and vibration
• Insufficient protection against dust and light oil contamination
• Limited installation space within compact modular conveyor structures
• High maintenance frequency due to connector wear and contact degradation

Solution: WS20 Series Circular Connector Configuration

To address these challenges, the cable manufacturer selected the WS20 Series Circular Connectors as the core connectivity component for the chain conveyor system. The solution combined robust mechanical design with compact form factor and reliable signal performance.
The WS20 connectors feature an IP67-rated sealing structure using integrated rubber gaskets and threaded coupling, effectively preventing dust, oil, and moisture ingress. Gold-plated contacts and optimized contact spring design ensure stable electrical performance under continuous vibration conditions ranging from 10 to 2000 Hz.
In addition, the compact housing design reduced connector volume by approximately 25%, allowing seamless integration into space-constrained conveyor modules. Customized pin configurations ranging from 8 to 16 contacts supported synchronized signal transmission across multiple workstations.

Implementation and Validation

The project followed a structured implementation process. A dedicated engineering team conducted on-site analysis to evaluate mechanical layout, signal parameters, and environmental conditions. Prototype cable assemblies were produced and subjected to comprehensive testing, including vibration testing, IP67 environmental protection verification, and 72-hour continuous signal transmission trials.
After validation, the solution entered mass production. Technical support was provided during installation and system integration to ensure optimal performance within the chain conveyor platform.

Key Results and Customer Benefits

Following deployment, the chain conveyor system demonstrated significant performance improvements:
• Signal transmission failures were eliminated, reducing equipment downtime to below 0.1%
• Maintenance intervals were extended from monthly servicing to once every 12 months
• Installation efficiency improved by 40% due to compact connector design
• Overall maintenance costs were reduced by approximately 85%
The WS20 Series connectors also enabled replacement of imported alternatives, reducing procurement costs by 20% while shortening delivery lead times to seven days.

Industry Applicability

Beyond chain conveyor systems, WS20 Series Circular Connectors are well suited for a wide range of industrial automation equipment, including battery production lines, automotive assembly systems, and precision electronic manufacturing platforms. With customizable pin layouts and reliable environmental protection, the WS20 Series provides a dependable connectivity solution for demanding automation environments.