These small components store electrical energy and play a fundamental role in powering circuits—but are often responsible for the failure of electronic equipment if not securely built. Capacitors are susceptible to sparking, shorting, and excessive voltage or temperature, all of which lead to failure. That’s why it’s important for capacitors to be able to withstand harsh environments, especially when used in extreme temperature settings, such as in industrial freezers or boilers or automotive applications. Some capacitors are also built with the ability to self-heal—they can recover from the damage caused by a spike in current. Additionally, some new capacitors have an inbuilt fuse inside of them, providing protection from short circuit conditions.

This electrical component present in most circuits is susceptible to many environmental factors, from temperature to moisture to the presence of certain elements or materials. Environment must be taken into consideration when choosing a resistor’s structure—different materials can react to different environmental factors. Carbon-based resistors, for example, will degrade over time when exposed to moisture as the water reacts to the carbon. One solution to this vulnerability is using silver to make the resistors, but that material can react to sulfur, which is present in many rubbers and lubricants used in other areas of a product. Other resistors must be able to withstand shock, requiring additional components that absorb vibrations.

Connectors, the plug-in points between a system and a cable, are critical to electrical system operations—and are especially susceptible to harsh environments. These components are relied upon not only to create secure connections but to mate and disconnect easily, all while protecting entry points from the elements. Connector design is constantly evolving, as well, to facilitate a growing fiber count and reliable operation in increasingly harsh environments, such as agriculture, where a connector might be exposed to a day of dirt and heat, followed by a high-pressure washdown, all of which could lead to mechanical failure.

The presence of electromechanical components with moving parts, such as relays or switches, in potentially explosive areas could be catastrophic if not properly protected—one small spark produced by a malfunctioning switch could cause disaster in a hazardous location. Stringent requirements have been imposed on electrical components used in flammable, combustible, or otherwise hazardous locations to ensure the safety and reliability of the equipment. Standards on electrical equipment and installation vary depending on the continent and type of hazardous environment, so switches and relays that comply with multiple ratings make international trade, inventory, and installation easier.

As more sensors are being integrated on the fields and in factories to automate and control operations, they must withstand harsh environments while remaining connected. The durability of sensors is especially being put to the test in the oil and gas industry, where they are not only exposed to extreme temperatures, pressure, explosive environments, shock, dirt, and moisture, but must accurately and continuously monitor these extreme conditions. Today’s sensors are expected to withstand what humans cannot in order to provide crucial data while keeping workers out of harm’s way. And when employees are exposed to potentially hazardous environments, they rely on sensors to keep them safe—some hard hats utilize a sensor that alerts the wearer when to replace the hard hat due to UV exposure.