Case Study: Underwater Robot Full-Chain Solution
Achieving reliable IP68 power and signal interconnection at 50m depth
An industrial underwater inspection robot manufacturer faced critical connector challenges:
(1) Reliable power and signal transmission in a single interface to reduce cabinet penetrations,
(2) IP68-rated waterproof connectors that maintain sealing under 50m water depth pressure,
(3) High resistance to vibration and impact during underwater operation.
We designed a five-layer hierarchical connectivity architecture:
Battery Cell/Module Level — A1002 series (1.0mm pitch) for individual cell voltage and temperature sampling. Ultra-compact footprint for confined battery module spaces.
Module-to-BMS Level — A2001/A2002 series (2.0mm pitch) with positioning walls for module-to-BMS acquisition board connections, providing mechanical stability under vibration.
BMS Board Level — A2501 series (2.54mm pitch) for board-to-board connections and auxiliary power interfaces.
High-Power BMS — ES01 rectangular floating blind-mate connector (200A) for simultaneous power and signal transmission, floating mechanism eliminating tolerance issues during blind-mating.
PCS/EMS & Main Power — DP21 2-3 pin high-current connectors (up to 30A) for main DC bus, DP29 multi-pin for PCS communication and EMS external interfaces, all with IP68 protection for outdoor installation.
Single-source supply for all five hierarchy levels reduced procurement lead time from 6 weeks to 2 weeks.
A1002 cell sampling connectors achieved <0.5mΩ contact resistance variance across 10,000+ connections, ensuring BMS measurement accuracy within ±2mV.
DP21 main power connectors passed 2,000-hour salt spray testing and 500 thermal shock cycles (-40°C to +85°C) without degradation.
IP68 outdoor connectors showed zero field failures after 18 months of continuous outdoor operation.
Modular BMS architecture enabled 40% faster cabinet assembly compared to hardwired approach.
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