Case study: This customised connector is designed for use with robust lighting systems.
It is imperative that construction site lights function reliably, even in extreme conditions. For a medium-sized company, we developed a customised plug connection that can withstand moisture, dust and mechanical stress in the long term – from development to series production.
Ensure the safety of plug connections for construction site luminaires in challenging conditions.
Between 2019 and 2020, a new mobile construction site light was developed in collaboration with a manufacturer of professional lighting systems. The company is renowned for its robust, energy-efficient, and high-quality lighting solutions, which are utilised by government agencies, emergency services, on construction sites, in industry, and at events, among others.
The project focused on developing a custom solution tailored precisely to the connector. Instead of a compromise solution from the standard portfolio, the customer received a connection solution precisely tailored to the application – reverse-polarity protected, IP65-rated, with a bayonet lock, and available in various colour options.
For the customer, this means a technically sound and reliable interface that enables both charging and operation of the light via the same connection. Through coordinated implementation – from development and component selection through to series production – the coordination effort was reduced and seamless integration into the new product was ensured.
THE CHALLENGE
We are pleased to inform you that a reliable connection has been established for the new construction site lighting.
Our client was planning to develop a new, particularly robust construction site light.
The project necessitated a bespoke connector that would need to satisfy a number of criteria.
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The product is equipped with a 2-pole reverse-polarity protected design, featuring a bayonet lock for secure fastening.
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The product must meet the IP65 protection class or higher.
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It is possible to charge the device and provide it with a power supply at the same time.
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We are pleased to inform you that there are a variety of colour options available for the different design lines.
The market did not offer a suitable standard solution, so a custom development was required.
OUR CONTRIBUTION
Development and manufacturing services provided from a single source.
Design and Component Selection
The location is Tuningen.
The development of a custom-fit connection solution for a particularly robust construction site light was undertaken with a focus on protection class, reverse-polarity protection and a reliable bayonet lock.
Tooling and Mass Production
We are pleased to inform you that we have established a partner network in the Far East.
Our efficient tooling and cost-effective series production, carried out in close collaboration with our long-standing partner network, ensures consistently high quality and reliable supply.
Customized solution
Please find below the customer's technical specifications.
The connection solution has been customised to meet the client's exact requirements for protection, mechanical locking, and integration into the existing lighting system.
THE RESULT
We are pleased to present a solution that we believe will meet your technical and practical requirements.
The developed connector can be integrated directly into the new lighting concept. Today, the customer enjoys the following benefits:
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This is a technically sophisticated and robust connection solution.
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The objective is to implement a uniform interface for charging and operational processes.
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A partner who provided consistent support for the project from its inception to its completion, contributing to the successful development of the series.
| At a glance | |
|---|---|
| Project content | S2-pin special connector with bayonet |
| Features include: | IP65, color variants, reverse polarity protected |
| Field of application | Mobile construction site luminaires, performance, development, component selection, production |
If you are planning a similar project, we would be interested in hearing from you.
Whether you are looking for connectors, cable assemblies, or custom solutions, we are here to work with you to develop the optimal solution for your specific application.
Please do not hesitate to contact us if you would like to discuss how we can assist you with your project.
