Innovative magnetic connectors with IP67 protection for mobile use
Modern analytical devices often have to operate under harsh environmental conditions: dirt, moisture, tensile stress, and mechanical strain are commonplace in workshops and during mobile service operations. A reliable magnetic connector system can play an important role here.
For a project, we implemented a design study for a magnetic connection solution that is precisely tailored to these requirements. customer-specific magnetic plug-in system combined with spring contacts. There is also one silicone keymat including integrated seal.
The aim of the development was to permanently protect the diagnostic device and at the same time create a secure and maintenance-friendly connection to the interface.
Project description: Modular design for maximum functionality
At the heart of the system is a magnetic adapter integrated into the housing of the diagnostic device. This serves as a central interface and contains reliable spring contacts for secure data transmission. This interface is complemented by a customer-specific silicone keymat with a circumferential seal. This creates a mechanical seal to IP67 level and reliably protects the system from dust and moisture.
Alternatively, depending on the application, a flat, hygienic membrane keypad with integrated sealing. This offers a cleaning agent-resistant and easy-to-clean operating solution, particularly in sensitive areas such as medical technology or hygiene-critical environments.
The corresponding counterpart is an external, classical pre-assembled diagnostic cableIt is equipped with an application-specific adapter (e.g., OBD-2) on one side and a magnetically guided round connector on the other. This connects intuitively, securely, and effortlessly to the magnetic adapter on the diagnostic device. The magnetic connector system enables convenient and reliable use in daily operations.
Core components:
- Magnetic plug with permanent magnets
- Spring contacts for reliable signal transmission (up to 15A per pin possible)
- Silicone keypad with integrated elastomer seal
- Mechanically protected device housing with IP67 protection class
Technological advantages of the Mangestecker at a glance
- Mechanical protection of the diagnostic device
The magnetic connection The magnetic connector between the connector and the diagnostic device not only ensures easy handling, but also provides effective strain relief and shock protection. If the cable is pulled or accidentally caught, the magnetic connector automatically disconnects from the device – without mechanical damage. This effectively prevents broken connectors, ripped-out sockets, or circuit board damage. - Protection class IP67 through silicone switch mat with seal
The integrated silicone keymat It features a circumferential seal that reliably protects the entire interface against dust and moisture. The combination of elastomer seal, spring contact connector, and closed device integration enables safe use even during cleaning processes or exposure to splash water. - Maintenance-friendly cable connection
The diagnostic cable is connected to the application as usual. The connection on the device is made via the magnetic connector. This simplifies replacement during service and reduces downtime. In addition, customer-specific cable lengths and plug-in variants can be easily implemented. - Reliable data transmission with spring contact technology
The pogo pins used transmit data and power reliably, even with mechanical tolerances or vibration. Depending on the design, up to 15 A can be transmitted per contact.
Application example: Vehicle diagnostics with safety requirements
This system was specifically designed for a readout unit that connects to the OBD2 interface in the workshop via a pre-assembled cable. The actual connection to the diagnostic tool is then established via a magnetic adapter. The device remains sealed, protected from dust and moisture. This technology can also be used in the following areas:
- Mobile diagnostic solutions in the automotive sector
- Charging and interfaces in medical technology
- Interfaces for IP-protected industrial electronics
- Communication modules with frequent connection changes
The developed magnetic connector system with integrated seal offers a highly functional yet robust solution for demanding applications. These require electrical contact quality, a high degree of protection, and ease of use.
Thanks to the clever combination of a silicone safety mat, spring contact plug, and magnetic connector, the system can be flexibly adapted. This applies to housing shape and current carrying capacity, as well as to various sealing concepts and seamless design integration into existing device concepts.
Request a consultation – we support you from the concept phase to series production.
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