The growth of data transmission continues to accelerate rapidly. This is due to the increased use of image and video data, the growing use of AI applications and cloud services, and ongoing digitalization.
The annual statistics from DE-CIX, a German internet exchange point with globally distributed data exchange points, are a key indicator of international data exchange development. In 2024, DE-CIX recorded 68 exabytes of global data traffic, a 15 percent increase from 2023's 59 exabytes. The daily record increased from 22.36 to 24.92 terabits per second (an 11.4 percent increase).
Fiber optics: yes, but...?
This enormous growth is only possible thanks to the increasing use of fiber-optic connections, which provide high bandwidths with low latency. Advances in transmission standards and connectors enable the more efficient use of individual fibers and easier bundling in limited spaces.
Fiber optics are already standard in data centers, and households and businesses are increasingly switching from copper to fiber optics. However, there are still areas where this lightweight, fast technology has not been adopted because it is considered difficult to handle in some situations.
Transitions from one fiber to the next are sensitive to dirt and moisture. Mechanical stress and vibrations can also impair or interrupt data transmission. High temperatures and frequent plugging cycles are also considered arguments against using fiber optic cables.
Therefore, in harsh environments, users often rely on established copper cabling. This is the case in heavily contaminated environments, which occur in some areas of the manufacturing industries.
...of course!
The principle of beam expansion was a first step towards more robust fiber optic connectors. This principle was further optimized with the EBO (Expanded Beam Optical) ferrule concept (see below: "The Principle of Beam Expansion").
Next came the robust EBM (Expanded Beam Multifiber) series of connector systems. The S-RMC and MIL13 connectors are ruggedized connectors developed in-house by Rosenberger Hochfrequenztechnik in accordance with current industry standards. They combine robust EBO signal transmission with stable and insensitive housings. Inside, ferrules can accommodate between two and 16 single-mode or multimode fibers depending on the application. These connectors eliminate many concerns about using fiber optics in harsh environments.
- High resistance: The robust EBM connectors are designed for harsh conditions and can withstand up to 5,000 mating cycles.
- Stable connection: They provide reliable, low-loss connectivity with standardized formats (SC footprint).
- Plug-and-play: They enable quick, intuitive installation without extensive training.
- Lightweight and compact: The connector design is optimized for high performance with minimal space and weight requirements.
- Low maintenance: EBM connectors are easy to clean and do not require special tools.
Challenges in manufacturing industry
Network components in production face various challenges, including extreme or highly fluctuating temperatures, dust, dirt, liquids, chemicals, vibrations, and mechanical stress. At the same time, reliability is highly demanded. Unplanned failures or downtime result in excessive costs, so reliability is essential. EBM connectors' plug-and-play design and compact form factors (S-RMC, MIL13) simplify installation, minimize maintenance, and reduce system downtime. Their space-saving design, which accommodates 2 to 16 single-mode or multimode fibers in a single connector, takes into account the confined conditions in control cabinets and on switchboards.
Another challenge is the growing demand for bandwidth in factories. On the one hand, the growing digitalization of factories means that more sensors and actuators need to be connected. Additionally, the use of images and video recordings in the production process is rising sharply. This requires transmitting and processing increasingly large amounts of data, sometimes in real time. This goes hand in hand with growing automation, including partially autonomous systems. These systems require additional efforts to maintain safety and security. The resulting data volumes are best transmitted via fiber optics, which also minimize latency.
Conclusion
Fiber optics have several advantages, including high bandwidth, low weight, and insensitivity to electromagnetic interference (EMI). For a long time, handling was a weak point, especially in harsh environments. However, these limitations are now a thing of the past.
Fiber optic connections can now be used without restriction, even in harsh environments, thanks to robust connectors that use expanded beam optical technology for resistant signal transmission and can combine up to 12 fibers in a space-saving manner. These connectors are also available in standardized form factors.
The combination of fiber optics and robust connectors from Rosenberger meets the specific requirements of the manufacturing industries. This offers a future-proof alternative for expanding the performance of data networks while providing mission-critical reliability.
The connectors' resilience, durability, and ease of handling also offer efficiency advantages. These advantages result from reduced unplanned downtime and follow-up costs, as well as lower maintenance costs due to fewer maintenance cases and faster service case resolution.
The Principle of Beam Expansion
In harsh environments and outdoor applications, ensuring the reliability of fiber-optic connections poses a particular challenge. Traditionally, signals are transmitted from one fiber-optic cable to another via physical contact (PC). For this method to work, the two fibers must be precisely aligned, i.e., centered and on a common axis. Additionally, the contact surface must be extremely clean because dust and dirt severely impair signal transmission. There is also a risk of scratching the fiber-optic ends, which would affect their optical properties. Such connections are also sensitive to mechanical stress and vibrations.
Thanks to expanded beam technology, it is now possible to create connections that are less sensitive to contamination. Tapered spherical lenses at the end of the glass fibers expand the bundled light beam over a larger area and refocus it on the other side. Rather than making direct contact with the glass fibers, the light travels through a free field zone between the lenses. However, it still travels parallel to the glass fiber alignment, so there is a risk of signal weakening if the centering or alignment angle is not maintained exactly.
The EBO (Expanded Beam Optical) plug concept is a significant advancement. The expanded beam connection widens the light beam during the transition from one fiber to another, then refocuses it. This is not done along the axis of the glass fiber, however, but rather via lenses with an elliptical cut. These lenses act like collimating deflection mirrors, thus increasing the tolerance range. This ensures the light beams are correctly aligned even when the glass fibers are not precisely aligned due to vibrations or mechanical stress. Interference from particles is also minimized because pollen or dirt that enters the system only blocks a small part of the enlarged light area. The light beam is no longer completely blocked, but rather slightly attenuated. Therefore, the ability to transmit data is fully retained.
Author: Harry Jacob, freelance journalist
