Cable solution with know-how: Complex requirements for point-of-sale systems

Payment by card has become indispensable in commercial outlets. In doing so, the highest demands are placed on security and serviceability of the technology used at the point of sale. For the company CCV, Elektrosil has developed a complex cable solution, which far exceeds the required standards, for reliably connecting payment terminals to point-of-sale systems.

The challenge

The client’s requirement was to develop a single cable for all connections between terminal and point-of-sale system which represented the technological state of the art. As a heavy duty application, it was to be robust as well as flexible: integrated printed circuit board with COM, DC, USB and LAN ports, one cable for all interface connections, high tensile loading capability and compliant with the foodstuffs standards.

One thing was clear to Elektrosil’s engineering experts: standard products would have to be modified and combined to form a completely new, innovative product – with printed circuit board and dimensions as the only specific reference points.

The solution

In order to design one cable for all connections, the specialists initially concentrated on the size. They slimmed-down the individual cables, used smaller conductors and provided thinner cable sheaths. The performance was maintained, even for gigabit transmission connections, as verified by transmission rate tests carried out by external specialists.

Concerned about particular serviceability, the team designed a spiral cable as an alternative to the linear cable for effective stress relief, e.g. in the case of EC card terminals on a swivel arm.

The cable experts decided to use polyurethane (PUR) as a superior material for the cable sheath. Halogen-free cables were required and the use of PVC and plasticisers were prohibited due to the foodstuffs standards. The engineers overcame the specific difficulties resulting from the materials with a wealth of moulding experience. In a later expansion stage, the sensitive printed circuit board was incorporated into a stabilising housing in order to protect it against the severe stress of insert moulding with PUR.

From brainstorming to prototype, almost daily communication with the client kept the development on course. The simpler version of the cable was produced at the end of 2011. The following type with improved features was implemented by the end of 2012.

CCV is impressed by Elektrosil’s talent at both designing and implementing good ideas in combination with a high quality of manufactured products.

One cable for everything: the solution integrates all interface cables, connections, the printed circuit board and is highly tensile

Secure payment with the card: payment terminals in supermarket checkouts are subject to numerous critical conditions

Elektrosil’s strengths

Elektrosil demonstrated its typical qualities in this project: a special, interdisciplinary expertise in cable assembly, printed circuit board development and plastics moulding during the development. In production, Elektrosil was able to call upon excellent long-term supplier relationships, which were distinguished by a high level of expertise and high manufacturing quality.

Advantages and Benefits

Elektrosil’s “one-cable solution” for point-of-sale systems ideally replaces the functions of the individual cables. End customers in the commercial sector benefit from a practical, space-saving product. The client can meet new expectations and address new target groups with an innovative product which will strengthen his brand. The comparatively low development costs were determined right at the calculation stage.

Thanks to Elektrosil’s extensive interdisciplinary know-how and excellent market relationships, a new innovative product was developed in more than 50 operations.

Are you looking for a suitable solution for your system and a competent partner? Then give us a call.

Elektrosil develops and produces cable solutions for point-of-sale systems and payment terminals. Customers include a globally leading supplier of payment transaction solutions as well as market leading representatives in Germany and Europe.

  • Application advice, development supervision, design-in support
  • Quality Assurance
  • Engineering and production
  • Completely customised applications

Your contact

Matthias Eckhardt

Product Manager Connection Technology

Tel: +49 40 84 00 01-503


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