热度 23
2015-2-6 17:44
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In the fast-paced world of active devices and the very tangible area of test equipment, the lowly cable and associated connectors sometimes seem to be almost invisible, in both the prototyping and production cycles. That's not only unfair to their self-esteem (to use the trendy parlance), but unwise. Sure, we hear that "everything is going wireless," but the reality is that hard-wired signal interconnects are an indispensable and irreplaceable part of nearly all systems. It gets more challenging: as more design engineers work on projects that extend into the gigaHertz and higher range, they'll have to learn to give more consideration to the cable assembly as a critical and even dynamic part of the design. If you look at RF/microwave-centric publications and web sites, about one-third of the ads and content are devoted to the subject. It's a world where second- and third-order parameters such as phase matching between two nominally identical assemblies (such as used for phased-array radar) become critical; even the temperature coefficient of a cable's specifications can be a concern. The assemblies are carefully engineered, modeled, tested, and fabricated energy waveguides with precise dimensions, special internal and external insulating materials, and more. Fortunately, cable assemblies are getting some attention from diverse perspectives, as shown by these unrelated features I have seen in the past few months: We hear a lot about counterfeit components—mostly ICs and passives—but we don't see much about the situation with cabling. Yet, it seems to be a serious problem, especially as the cable may work to some extent if not full spec. According to Cabling Installer, their 2011 article on the subject Counterfeit cable exposed was among their top 10 articles in 2014, three years after publication! (Also see Counterfeit cable is getting ugly .) The result is a cable assembly that doesn't fully meet the operating spec and may sort-of work but only support lower data rates, or a PoE (Power over Ethernet) installation unable to provide the specification's power. It's not just electrical performance, either. On the safety side, a cable’s insulation in most installations must be fire-rated to not support combustion, yet these fakes fall far short— and it's an issue that you won't know about until a fire breaks out. Would you have even imagined presumed copper cable that was really brittle aluminum, but with a copper cladding? Think of the installation and performance surprises on that one! The thing about cable is that it is so easy to make a fake, and put almost any rating you want on it. After all, who "tests and verifies" the cable's performance when data rates go down and BER goes up? Who checks the insulation? You may take it as a "given" that if it says Cat5/UL rated, it actually is, but that's naive. Note that this is not a new concern. Even in audio, non-RF applications, I often wondered about the super (aka "monster") audio cables that were sold as OFHC (oxygen free, high conductivity) ostensibly because of their superior performance potential. How do you really know the vendor isn't shipping plain copper slapped with an OFHC label? Problems with RF/microwave cables in complex installations. I saw an ad (yes, a print ad!) from W.L. Gore stating that "a recent study for the aerospace industry showed that more than 29 percent of microwave cable assemblies fail during installation , and aircraft manufacturers have accepted the practice of simply replacing them." Wow, I thought, that has to be costly and time-consuming, in so many ways! Gore's solution is to provide a simulator to evaluate the stress of installation, with features which replicate bend radius, routing guides that induce torque, and abrasion bars to simulate routing across sharp edges of access holes in the airframe structure. Finally, there's the world beyond extending to 100 GHz, well beyond modest 1 to 10 GHz, where spectrum is available and new components make reachable. What sort of cables and connectors can you use there? It's a brave new world of tiny, tinier, and tiniest, with hair-thin cables and corresponding matchhead-sized connectors. This V Connector (male and female) from Anritsu provides coaxial coverage to 65 GHz, with a 1.85-mm geometry endorsed by IEC (International Electrotechnical Commission); it mates with standard available 2.4-mm connectors. Cabling seems to be one of those things with which engineers have both love/hate and ignore/fear relationships, it often seems to me. For example, my cable modem and wireless router sit next to each other, but they are connected with a 20-ft. (7-m) Ethernet cable, because that's what I had handy on the day of installation. Yet when recently I found a 2-ft. (0.7-m) cable in my spare-cable collection, I wasn't sure if I should swap the shorter one in for the longer one. On one hand, the shorter one is more elegant and appropriate, and wouldn't need to be coiled up and tied back; on the other hand, everything is in place and working, so why take a chance and upset things? While basic cable-assembly connectivity and continuity is very easy to verify with an ohmmeter, the actual performance to specifications of the assembly is not—especially for non-electrical parameters. What's your relationship with cables, connectors, and assemblies? Have you ever overlooked something that came back later to cause you design, debug, or production aggravation?