Ensuring Quality and Reliability of Cables and Connectors in the AI Ecosystem

As AI transforms industries such as healthcare, education, and manufacturing, the demand for reliable and efficient data center infrastructure is growing. The full potential of AI can only be realized when all components within the ecosystem are interconnected and powered. In this context, cables and connectors are indispensable. They serve as fundamental components of AI systems, enabling essential power delivery and data transmission between servers, GPUs, data centers, sensors, edge devices, and other critical elements of AI workflows. The reliability of communication and power within these systems hinges on the quality of cables and connectors.
Recent advancements in server power designs to enhance AI data processing efficiency have further underscored the need to ensure electrical safety. While our previous issue explored the electrical safety of servers, this issue focuses specifically on ensuring the safety and reliability of cables and connectors—key components in maintaining the integrity and performance of AI infrastructure.

 

Role of Cables and Connectors in AI Ecosystems

  1. Data Transmission: AI applications, such as machine learning and real-time data processing, require high-speed data transfer and efficient handling of large data volumes. Cables are essential for linking servers, GPUs, and other data-intensive devices. High-quality connectors and cables help minimize data loss and signal degradation, ensuring the integrity of the data being processed.
  2. Power Delivery: AI systems, particularly those involving deep learning models, demand substantial and reliable power for hardware components, including servers, GPUs, and other computational devices. Power cables and connectors can support high power loads while maintaining stable connections to prevent disruptions and ensure uninterrupted operation.
  3. Scalability: Cables and connectors that support modular configurations are vital for building scalable AI ecosystems. Modular cables allow for flexible expansion and adaptation as AI applications evolve and demand additional computational resources. Additionally, connectors that facilitate easy upgrades and maintenance ensure minimal downtime, supporting the seamless growth of the system.

Key Electrical Safety Testing Requirements for Cables and Connectors

  1. Hipot Testing: This test evaluates the ability of the cable and connector insulation to withstand high voltage without failure. By applying a specified voltage, hipot testing ensures that the insulation can handle electrical stress without breaking down. This is vital for preventing electrical shock hazards and ensuring safety under abnormal conditions.
  2. Ground Bond Testing: This test confirms that the grounding connections of connectors provide a low-resistance path to the ground, which is essential for safety in the event of a fault. Effective ground bond testing helps ensure that fault currents are safely directed away from sensitive components.

Cables: Hipot Testing for Safe and Reliable Performance

The AI ecosystem includes various cables, including power, communication, management, and control cables, each with its own safety standards. To verify that the cables’ insulation can withstand high voltages without failure, hipot testing is essential. For instance, UL 444 standard for communications cables requires hipot testing voltages that vary based on cable design, generally ranging from 0.75 kVac to 3 kVac (or 1 kVdc to 5 kVdc). The test duration is typically 2 seconds, and the cable must pass without any breakdown.

Connectors: Comprehensive Hipot and Ground Bond Testing

Connectors, crucial for data, signal, control, and power applications, also require rigorous testing. Both hipot and ground bond tests are necessary for ensuring electrical safety. According to IEC 61984, hipot testing for connectors involves voltages from 0.37 kVac to 4.26 kVac, with higher-rated connectors tested up to 6.6 kVac. The test duration is 60 seconds. For ground bond testing, a current of 1.5 times the rated current is applied, with a maximum test current of 25A. The resistance between accessible metal parts and the ground should be less than 0.1Ω.

Associated Research Testing Solution

To achieve precise and reliable testing, we recommend the HypotULTRA® Series Electrical Safety Tester. This series is well-suited for comprehensive hipot and ground bond testing, offering voltages up to 5 kVac and 6 kVdc, and featuring a ground bond testing capability of up to 40A. This ensures your components meet rigorous safety standards and perform reliably. Connectors typically require hipot testing between each pin; therefore, bundling with SC6540 Multiplexers simplifies the testing setup and solves complex wiring problems.

For applications requiring higher testing voltages, the HypotMAX® Series High Voltage Hipot Tester provides advanced solutions. The 7705 model supports up to 10 kVac, while the 7710 model offers up to 12 kVdc, catering to the most stringent testing needs. "These models are ideal for components requiring higher voltage safety verification.

As the landscape of AI and data infrastructure evolves, ensuring your manufactured components meet the highest safety standards is crucial. If you are looking for cable and connector electrical safety testing solutions, please contact us.