Networking + IoT - Motion Control Tips

New inclinometer for pitch, yaw, and roll feedback from Joral

July 18, 2018 By Miles Budimir Leave a Comment

Joral’s new G-force compensated inclinometer provides feedback for pitch, yaw, and roll. The new technology uses sensor fusion, which is the combining of more than one complementary sensing method. The new Joral SGAM and DGAM incline sensors take input by a gyroscope, accelerometer, and magnetometer to provide a 3-axis output for X, Y, and Z as well as new feedback for pitch, yaw, and roll.

The GAM Series sensor provides steady feedback during motion, allowing users to eliminate complex sensor networks with a single G-force compensated inclinometer. Rather than depending on encoders, string pots, laser gates, and proximity sensors to monitor the position of a ladder, fork or platform, users can place one Joral GAM Series sensor on the application to get real-time feedback for absolute control.

Joral has designed the same level strength into the GAM series as other standard Joral products. Rated with a standard environmental protection of IP67, the GAM series sensors are 100% encapsulated. Designed to eliminate the drawback of accelerometer based incline sensors, the SGAM and DGAM inclinometers are J1939 capable, and available in a convenient form factor with common connection options, including a CAN Open connection.

For more information, visit www.joralllc.com.

More details on the trend towards Ethernet-based networking protocols

July 9, 2018 By Lisa Eitel Leave a Comment

In a recent survey of industry experts, many mentioned Ethernet-based networking protocols overtaking traditional fieldbuses.

Recall that industrial communication protocols (including those based on Industrial Ethernet) are messaging systems for automated installations. Some fieldbuses are more reliable than nondeterministic Ethernet offerings, but Ethernet speeds now lead.

“Some old bus systems have data rates in the range of 1 to 20 Mbit and no real-time reaction,” said Horst Messerer, HELUKABEL data, network, and bus technology sales manager. “Certain types of manufacturing can tolerate these rates … so bus protocol won’t go away entirely — but they’re seeing reduced market share.”

In fact, industrial Ethernet-based networks now connect some 40% of industrial communication networks.

“That’s why more bus systems are being replaced with Ethernet-based equipment,” said Messerer. “The advantage of Ethernet is its faster data rate — with a minimum of 100 Mbit — which lets industrial-automation manufacturers view manufacturing and production process data in real-time. Having this kind of data quickly allows for improved reaction time to optimize processes for higher output per hour.”

Another benefit is that even though older variations such as 802.3c is slower than 802.3ab (at 1 Gbit/sec, which is called GbE) all use Cat5e cable. That makes Industrial Ethernet implementation easier. Both Cat5 and newer Cat6 cables for Ethernet work with Gigabit Ethernet, though Cat6 Ethernet cable is displacing the former.

“We’ve seen continued robust interest in both Cat5 and Cat6 flat cables,” said Rich Buchicchio of Cicoil Corp. “Our versions of these cables typically go in applications that benefit from high cable flexibility and durability to survive extreme environments better than common versions of these Ethernet cables.” The cables meet (and typically exceed) platform requirements.

Besides speed, other reasons for Ethernet’s rise include its ease of use, and ubiquitous design; multi-protocol network acceptance; familiarity thanks to commercial off-the-shelf (CotS) Ethernet; and consolidation of network-interface hardware. Plus unlike traditional device and fieldbus networks (that can have multiple physical layers) Ethernet networks run on one.

Controls and related motion hardware often dictate which fieldbus communications an installation will use.

“We continue development of integrated motors that can be powered over Ethernet (PoE),” said Eric Rice of Applied Motion Products. “Combining power and Ethernet over a single cable is an excellent example of the evolution of integration in motors, drives, and industrial Ethernet communications.”

PoE-enabled integrated motor offerings from the manufacturer include NEMA 14 and NEMA 17 frame motors.

Traditional industrial components feature Ethernet connectivity for an increasing array of functions. “Today, there are scalable I/O options for PLC control … and new hardware to communicate with remote I/O includes multi-Ethernet products to cover major Ethernet such as SERCOS, EtherCAT, PROFINET, and EtherNet/IP,” Joaquin Ocampo, product manager of motors and drives at Bosch Rexroth.

In fact, five real-time protocols — CC-Link, EtherCAT, EtherNet/IP, PROFINET, and SERCOS III capitalize on Ethernet advantages and deterministic networking.

The CC-Link protocol (supported by the CC-Link Partner Association) includes field-device, controller, and information networking and gets speeds to 10 Mbps at 100 m. Versions include CC-Link, CC-Link Safety, CC-Link/LT, and CC-Link Industrial Ethernet (IE) Control and Field. One CC-Link standard is a Seamless Message Protocol to let Ethernet-ready devices work on CC-Link IE networks. A new version of a Control and Communication System Profile (CSP+) simplifies integration of engineering tools and device profiles (in part by outlining the data necessary for setup and operation of CC-Link-compatible devices). Automation-component manufacturers primarily offer CC-Link functionality for servomotors, drives, robots, digital and analog I/O modules, and controllers including PCs and PLCs.

The Ethernet for Control Automation Technology (EtherCAT) protocol uses Ethernet and twisted-pair or coaxial cables with BNC adapters over distances to 1,000 m and optical cable beyond that. It gets Ethernet transfer rates and can control up to 65,535 nodes. Data processing through dedicated software and hardware allows deterministic communications. EtherCAT accommodates any topology and handles 1,000 I/O points in 30 μsec — capable of communicating with 100 servo axes in 100 μsec. Axes get values and control data and report position and status. A simple version of an IEEE 1588 distributed clock technique synchronizes axes with less than 1 μsec of jitter.

Shown here is a maxon motor EPOS04 Compact 50/8 EtherCAT smart drive-controller for programmable positioning.

Ethernet/IP is an industrial application-layer protocol for communication between industrial controls and I/O. It uses standard IEEE 802.3 TCP/IP and communications; Ethernet hardware pairs with TCP and UDP ports. Certain permutations enable synchronized and deterministic multi-axis motion control.

In fact, this and other industrial-Ethernet standards drive many product-development decisions that Applied Motion Products makes. “This year we enhanced our support for EtherNet/IP networks by introducing a set of improved Add-On Instructions for Rockwell’s RSLogix 5000 software,” said Rice. “We also introduced a new family of cost-effective motor drives for EtherCAT networks … and have begun development on drives and integrated motors for use on PROFINET networks,” he added.

Serial Real-time Communications System (SERCOS) is an open protocol for serial communication of closed-loop real-time data — over Ethernet cable for SERCOS III. Specifically for motion controllers, drives, actuators, sensors, I/O, the IEC-standard protocol closes servo loops in the drive to reduce motion-controller burden (and synchronize more motion axes than otherwise possible). Such closing of servo loops also avoids delays between motion controls and drives.

SERCOS III gets deterministic bidirectional real-time motion and control. It also enables higher-level I/O and transmission of conventional protocols over one Ethernet network in parallel with SERCOS real-time communication — with cycle times to 31.25 μsec.

PROFINET is from the same organization from the same organization that gave the motion industry PROFIBUS (PROFIBUS & PROFINET Intl. or PI) PROFINET use of Ethernet means larger messages, better bandwidth, and theoretically unlimited address space … as well as avoidance of network collisions. Deterministic communications are possible through real-time and isochronous real-time (IRT) operation. The latter gets update times down to 250 µsec, while PROFINET IRT gets them down to 31.25 µsec for synchronizing networked components.

Of course, industry-specific communication buses endure and even grow, as connectivity imparts design sophistication even to turnkey operation.

“Products with integrated industrial communications protocols simplify operation,” said Laura May of Thomson Industries. “For example, integration of J1939 CAN bus communications — most commonly used in mobile off-highway markets — means a system can programmed to let each of its actuators run with real-time awareness of speed and position of other actuators — enabling self-adjustment and deploying multiple actuators to handle heavy loads,” May added.

She added the manufacturer has work in progress to better support protocols commonly used in plant-floor automation.

Of course, an ever-growing (and cost-effective) array of gateways simplify network connections where J1939 CAN (and other buses) must interface with Ethernet. It’s common for fieldbus components to connect to Ethernet blocks for connectivity via Cat5E cable and Ethernet RJ45 connectors. Ultimately, Ethernet can even facilitate IIoT functionality to connect enterprise-level systems with machine, I/O, and device-level operations.

Ethernet-driven cloud-based IIoT along with (IEEE-802-compliant) wireless variations unify data streams for:

I/O and motion communications and controls
Safety functionality to protect equipment and personnel
Diagnostics, machine-condition monitoring, and energy management
Final product tracking and documentation of plant-operation statistics

“One of three smart Han modules available is the Mini Ethernet Switch Module,” said Mark Kojak, V.P. of product management and business development in the Americas at Harting Inc., manufacturer of interconnect components. This module incorporates a four-port Ethernet switch within the connector. The module can replace or reduce the port count in systems needing a multi-port Ethernet switch … and excels in systems that use a daisy-chaining architecture.

Case study: Slip rings use CC-Link IE for gigabit data transfer

By John Wozniak, P.E. | Manager of CC-Link Partner Association (CLPA) Americas

Manufacturer of mobile electrification and data transfer systems for industrial machinery Conductix-Wampfler now uses CC-Link IE open gigabit Ethernet (GbE) for high-performance connections in its slip rings. Traditionally used to supply continuous power and data communication to equipment on rotating assemblies, the slip rings are for new and existing machinery needing Industry 4.0 data connectivity.

Conductix-Wampfler specializes in power, signal, and data-transmission systems for container handling, tunneling, mining, and bulk material handling. Their slip rings find use on rotating arms and gantries, cranes, wind turbines, manipulators, and cable reels.

As a CLPA member, Conductix-Wampfler has technical specifications to develop compliant product … even for custom connectivity solutions that work with Ethernet up to 1Gbps.

“Our slip ring technology excels in everything from industrial machinery to theme park rides … and we see need to transfer an increasing amount of data in a secure and easily accessible manner,” said product manager at Conductix-Wampfler Matteo Mosconi. So the company joined CLPA to focus on CC-Link IE because it’s the first and only open protocol that works at 1Gbps with real-time characteristics — and the organization that supports it offered the technical support Mosconi wanted.

“Slip rings certified for CC-Link IE can transmit power … as well as data at very high transfer rates.”

Founded in 2000, CLPA is an international open-network organization with more than 3,000 members (and the leading open industrial-automation network technology in Asia) dedicated to technical development of CC-Link open automation networks. Main activities include the development of CC-Link IE and CC-Link technical specifications; conducting conformance tests and development support. CC-Link IE is an open GbE solution for Industry 4.0 automation with unmatched bandwidth.

CC-Link Partner Association (CLPA) member Conductix-Wampfler used CC-Link IE open GbE technical specifications to develop compliant slip rings.

Safety brakes and intelligent monitoring from mayr for brake technology 4.0

June 28, 2018 By Lisa Eitel Leave a Comment

Safety brakes by mayr power transmission are equipped for the challenges of the Industry 4.0. The coordinated system guarantees the highest level of operational and functional safety …

… and increases the productivity of machines and systems through predictive error detection and maintenance.

Brake technology 4.0 stands for intelligent monitoring modules; modules such as the ROBA-brake-checker and the ROBA -torqcontrol monitor safety brakes easily and quickly or facilitate the even and smooth deceleration of machines and devices.

mayr power transmission as the leading manufacturer is already offering reliable safety brakes, which are equipped for the challenges of the forth industrial revolution.

Permanent brake monitoring and predictive maintenance

The ROBA -brake-checker module operates without sensors. Instead, it analyzes current and voltage and recognizes the movement of the armature disk. So it knows the condition of the brake. In addition to the switching condition, the module can also deduce the temperature, wear and tension path or tensile force reserve — in other words, whether the magnet still has sufficient force to attract the armature disk.

On reaching the tensile force reserve, the ROBA-brake-checker emits a warning signal, early enough so that a defined operating time of the brake is still possible. Within this time, the machine operator can undertake specific maintenance in coordination with their work process – maintenance with foresight, so to speak. The ROBA -brake-checker is now available in a design for AC voltage. In addition, another version of the module will also in future take on the supply of the brake, and as a result, replace the rectifier. Switching condition monitoring and brake control are therefore combined in one device.

Braking movements gently and in a controlled manner

For applications, which need braking torque control in addition to status monitoring, mayr power transmissions provides the braking torque control module ROBA -torqcontrol. It shares the features of the ROBA -brake-checker and can also change the level of the braking torque in operation through purposeful influencing of current and voltage. As a result, devices and machines can be evenly and gently decelerated. The ROBA -torqcontrol module permits the development of control loops and brakes movements intelligently – the suitable basis for its use in smart, interconnected machines.

The brake control module ROBA -SBCplus performs reliable switching time monitoring. It is type-certified by TÜV Süd and can be used up to the highest Performance Level PLe and Safety Integrity Level (SIL) 3. Image: mayr power transmission

Another module to continuously monitor the switching condition of the brakes is the safe brake control ROBA -SBCplus. In this module, mayr power transmission offers safety brakes and safe brake control in a complete package. This module has been developed in collaboration with the company Pilz, especially for applications which have to fulfil requirements for the protection of people according to standards regarding functional safety. The ROBA -SBCplus module must reliably interrupt the current in the magnetic coil when the brake is switched off. For this purpose, the module operates with wear-free electronic semi-conductors, and as a result achieves practically unlimited switching frequency and switching reliability.

Brake technology 4.0 by mayr power transmission stands for monitoring modules of the latest generation: The modules such as the ROBA-brake-checker or the ROBA-torqcontrol allow permanent brake monitoring and make the safety brakes fit for the challenges of the Industry 4.0.

This brake control module performs reliable switching time monitoring. Furthermore, an integrated plausibility check is conducted through the evaluation of the release monitoring signals. The evaluations of the switching states and the return signal therefore permit reliable error diagnostics. This permits creep errors which influence on the switching times, for example increasing wear, to be detected in due time. The reliable ROBA -SBCplus brake control unit is type-certified by TÜV Süd (Technical Inspectorate, Southern Germany) and can be used up to the highest Performance Level PLe and Safety Integrity Level (SIL) 3.

SmartCamera delivers robust vision in simple package

June 5, 2018 By Paul Heney Leave a Comment

Balluff’s newly released SmartCamera takes inspection and identification applications, in color or monochrome, to a higher level. The SmartCamera simplifies overall usability in an otherwise complex world of vision-based technology, while still delivering a robust assortment of features like flexible connectivity and intuitive on-board image processing tools. The camera, the latest in in a line of Balluff tools designed to innovate automation, combines the power of the HALCON function library with the simplicity of the BVS-Cockpit user interface.

“Minimizing time of deployment and eliminating the over-use of plant resources to integrate vision technology is critical. The wizard-based programming tools allow for efficient set up, and simple adjustments can be made on the fly,” said Balluff Marketing Manager Wolfgang Kratzenberg. “The SmartCamera is also the most connected camera available. With an on-board IO-Link master in addition to Ethernet/IP, Profinet, TCP and UDP communication, this camera can be integrated into any major control network.”

Balluff’s commitment to vision as a solution includes offering a full line of accessories required to address applications in the industrial manufacturing environment. This broad offering includes: optics, lighting, displays, mounting hardware and power supplies along with a wide range of IO-Link products which can be directly controlled by the SmartCamera.

Balluff Inc.
www.balluff.com

Teledyne DALSA to preview multi-line CMOS camera

March 30, 2018 By Paul Heney Leave a Comment

Teledyne DALSA, and Teledyne e2v, both Teledyne Technologies companies and global leaders in image sensing technology, will be co-located at The Vision Show, in booth #517 from April 10th to 12th. Teledyne DALSA will display its newest and most advanced multi-line CMOS camera while Teledyne e2v will display their new OctoPlus range of line scan cameras for OCT applications in healthcare and industrial markets. The show takes place at the Hynes Convention Center, in Boston, Massachusetts.

The Teledyne DALSA team will present a wide-array of the company’s very latest imaging technologies. In-booth demonstrations include:

• A preview of Teledyne DALSA’s newest multi-line CMOS camera, offering options for monochrome, color, and NIR imaging, with fiber optic interface to an Xtium CLHS frame grabber.
• BOA spot vision sensor, which offers simple, affordable and reliable performance for automated quality inspections
• Calibir uncooled long wave infrared cameras for thermal imaging applications, featuring shutterless operations with GigE Vision, analog and MIPI CSI-2TM interfaces
• Genie Nano cameras, feature-rich and built around industry-leading CMOS image sensors with GigE or Camera Link interface
• GEVA 4000 vison system, with over eight times the processing performance of the entry level GEVA 300, ruggedized and robust for the factory floor.

In addition to live demonstrations, show attendees will see static displays of Teledyne DALSA’s newest area cameras, including the 86-megapixel Falcon4, frame grabbers, smart cameras, and image processing software. Visit the Teledyne Imaging booth to explore this wide portfolio of technologies designed for many markets and applications.

Hot Corner Topics

Teledyne DALSA subject matter experts will present in two Hot Corner topic discussions. Hot Corner discussions are open to all show attendees.

Tuesday, April 10, 1:00 pm – 3D Imaging Technologies – Raymond Boridy will present on current 3D technologies, applications and trends

Thursday, April 12, 1:15 pm – Multi-channel line scan imaging – Mark Butler and Philip Colet will deliver a presentation focused on the possibilities of multi-channel line scan imaging

The Vision Show 2018
April 10-12, 2018
Booth #517 (See booth location)
Hynes Convention Center, Boston, Massachusetts

The Vision Show is North America’s largest display of machine vision and imaging components and systems. Registration is free.

Teledyne DALSA
www.teledynedalsa.com

How to use SPI for dc motors?

March 27, 2018 By Miles Budimir Leave a Comment

SPI (Serial Peripheral Interface) is a method of data transmission. It’s designed to transmit data between microcontrollers and peripheral devices such as sensors, memory cards, and displays, among others.

At its basic physical level, it’s a 4-wire serial interface with data rates that can vary from a few MHz to upwards of 10 MHz, and claims of even higher rates in some cases. Data transmission is from 2 to 16 bits, depending on how it is programmed.

Evaluation boards for brushless dc motor control, such as the one pictured here from Microchip, feature on-board PWM signal generation as well as an SPI interface (upper left corner, horizontal 6-pin header.) (Image via Microchip)

With regard to how SPI applies to dc motors, the motors themselves aren’t driven directly via SPI but rather by way of a motor driver. Typically, the motor driver will have an SPI port that can be connected to a microcontroller which sends control signals such as PWM signals. Or in some cases the controller may reside on the same chip where the control signals are generated. Aside from control, SPI can also be used for diagnostic purposes.

The pros from a microcontroller programming point of view are that most microcontroller families have built-in SPI communication, making it easy to connect with peripherals. Another plus is that programming via SPI is fairly simple. The protocol is fairly simple and support circuitry is not complex and is easy to implement.

On the down side, it is generally a short distance communication link. Some of the largest distances have pushed the 100 m mark. However, with longer runs more signal delay is introduced, which affects timing of signal propagation.

Still, there are many examples of controlling dc motors with simple controller chips using an SPI interface, including the Raspberry Pi, Arduino, as well as motor drives from Microchip.

How to select a network for a motion controller?

March 16, 2018 By Miles Budimir Leave a Comment

Over a range of motion control applications, there is no one-size-fits-all approach for selecting a network. However, there are several key factors to consider when deciding on the best networking option for your particular application.

For starters (and perhaps most importantly), consider timing; that is, how quickly the system reacts to inputs or changes in the system as well as the network scan rate. Be sure that the rates are fast enough to accommodate the application. Otherwise, sluggish performance may be the end result. For instance, multi-axis motion control requires high levels of synchronization, so low levels of jitter or signal variability are essential. On the other hand, a relatively slow conveyor system may not require fast speeds at all and so jitter may not be an important parameter in that case.

Another factor is the existing control system. Selecting a network may depend on what network(s) the motion controller supports, or whether or not there is already a protocol in place used by other equipment, something like a legacy network. And it’s possible that using a network that one is familiar with and has experience working with can eliminate the need for a learning curve, saving development time.

Diagnostic capability may also be a key consideration. Older networking protocols had minimal diagnostic capabilities, but contemporary motion control networks generally have a range of diagnostic functions. These can include diagnosing communication issues, device errors and faults, as well as pinpointing the source of issues so they can be quickly identified and corrected.

Other points to consider may be the level of enterprise connectivity needed or required, third-party device support, and as always, cost.

Fortive selling Portescap, Kollmorgen, and Thomson to Altra Industrial Motion

March 9, 2018 By Lisa Eitel Leave a Comment

Fortive Corp. — a 2016 spinoff of Danaher — has agreed to combine four operating companies from its Automation & Specialty platform (A&S platform) with Altra Industrial Motion Corp. to form a global leader in the power transmission and motion control market.

The A&S business includes the market-leading brands of Kollmorgen, Thomson, Portescap, and Jacobs Vehicle Systems.

This A&S platform generated approximately $907 million in revenue for its fiscal year ended December 2017.

The $3.0 billion deal includes $1.4 billion in cash proceeds and debt reduction for Fortive and 35 million newly issued Altra common shares to Fortive’s shareholders — valued at $1.6 billion.

“We’re excited about this announcement, as it represents a major step forward in portfolio enhancement work towards increasing focus on software and service exposure, while adding significantly to our M&A capacity,” said James A. Lico, President and CEO of Fortive.

According to Lico, the combination represents value creation for Fortive and Altra shareholders, customers, and employees.

“We have great respect for the Altra team and their commitment to continuous improvement and customer satisfaction,” added Lico. “This combination of powerful brands and remarkable people creates an organization well-positioned to capture robust Industry 4.0 growth opportunities.”

“This transaction transforms Altra and represents a major milestone towards accelerating the acquisition strategy,” said Carl Christenson, Chairman and CEO of Altra. “The addition of the A&S platform bolsters our ability to compete effectively on a larger global scale in the broader automation space, to further our continuous improvement journey … and to optimize our portfolio in an expanded acquisition universe.”

The combination will be effected as a Reverse Morris Trust (and expected to be tax-efficient to Fortive). Fortive shareholders will get shares representing approximately 54.4% of the issued and outstanding shares of Altra after giving effect to the transaction and valued at approximately $1.6 billion. In addition, Fortive will directly receive added consideration of $1.4 billion through a combination of cash proceeds and debt reduction. Until closing (expected before the end of 2018) the A&S platform businesses will operate within the Industrial Technology segment of Fortive, and financial results will be reported in continuing operations.

Fortive will have the right to designate one member of Altra’s board of directors, expected to initially be Patrick J. Murphy — Senior V.P. of Fortive.

Fortive is a diversified industrial growth company comprised of Professional Instrumentation and Industrial Technologies businesses that are saw leaders in attractive markets. With 2017 revenues of $6.7 billion, Fortive’s well-known brands hold leading positions in field instrumentation, transportation, sensing, product realization, automation and specialty, and franchise distribution. Fortive is headquartered in Everett, Washington and employs a team of more than 26,000 research and development, manufacturing, sales, distribution, service and administrative employees in more than 50 countries around the world. With a culture rooted in continuous improvement, the core of the company’s operating model is the Fortive Business System. For more information, visit www.fortive.com.

Wireless condition monitoring prevents unplanned downtime with machine learning

March 8, 2018 By Danielle Collins Leave a Comment

Banner Engineering, a leading provider of technology for industrial automation, announces its wireless condition monitoring solution with machine learning for more intuitive predictive maintenance.

The QM42VT wireless vibration monitoring sensor from Banner continuously measures RMS velocity, high frequency RMS acceleration, and temperature. This enables the sensor to identify machine problems before they become severe and result in unplanned downtime. It also allows facility managers to plan maintenance more efficiently and reduce labor costs by eliminating manual checks.

Using a proprietary machine learning algorithm, Banner’s condition monitoring solution collects data from the sensor to establish a machine’s vibration baseline and automatically set warning and alarm thresholds.

When a threshold has been exceeded, the wireless node can provide local indication, send the vibration and temperature data to the gateway for long term collection and analysis, and send a text or email alert. The solution serves as a simple “check engine light” for machines; however, data on a variety of vibration characteristics can also be collected over time for more in-depth analysis of machine performance.

The wireless vibration and temperature sensor is ideal for a variety of machine monitoring applications, including motors, pumps, blowers, and other types of machines throughout a facility.

Manufactured with a robust zinc alloy housing, Banner’s wireless vibration and temperature sensor provides reliable performance in harsh environmental conditions. The sensors can be easily mounted using a standard bracket, a magnetic bracket, or a two-sided thermal transfer mounting tape to accommodate diverse applications.

Banner Engineering

Innovations in connectivity from cables and connectors for motion designs

March 5, 2018 By Lisa Eitel Leave a Comment

Easy connections to sensors, field devices, and other automation solutions are becoming the norm in motion control — that’s according to Brian O’Connor, director of product and market development at Aerotech. In fact, increasing affordability of electronics (and subsequent rise of IIoT) have spurred all branches of industrial automation to more networking. But even basic machine designs have benefitted from new cable and connector options that impart simplicity.

Our recent survey of connectivity experts yielded details on these and other cable and connector designs for power and networking components. This cable panel included Rich Buchicchio and Howard Lind of Cicoil Corp. and Eric Rice of Applied Motion Products; and Horst Messerer, data, network, and bus technology sales manager at HELUKABEL; and Mark Kojak, V.P. of product management and business development in the Americas at Harting Inc.

Read on for what they had to say — and be sure to visit motioncontroltips.com/category/networking-iot as well as wireandcabletips.com for additional insight from other sources on IIoT trends and where Ethernet-based networking protocols are overtaking traditional fieldbuses.

Image courtesy HELUKABEL

Buchicchio • Cicoil: Components with electronic functionality are clearly gathering and using more data than ever. We support this market segment with lightweight designs that exhibit reliability without signal degradation. More specifically, we’ve seen significant demand for data cable — including twisted shielded-pair data cables; Cat 5e, Cat 6A, and 50 & 75 W Coax cable; and HDMI, FireWire, Camera Link, and IDC ribbon cable.

Cicoil 0.025-in. IDC cable is suitable for tight spaces that need high signal density. Its ultra-flexible jacket is resistant to flames and harsh environments; single and double-row connections are suitable for mass termination — with up to 64 conductors. The cable also withstands temperatures to 260° C.

Messerer • HELUKABEL: We’re seeing a trend towards more use hybrid cables (those that combine power with control and data) for one-cable setups. More design engineers than ever are requesting these cables for use in drag-chain and torsion applications.

Related from sister site wireandcabletips.com: Single-cable solutions simplify servomotor design

Buchicchio • Cicoil: We stock and sell a wide variety of standard flat cable for motion control, data and video, and power-plus-signal applications … But engineering custom cable and assemblies is at the heart of our company. We manufacture sophisticated assemblies and cable harnesses for demanding applications — including those for military and aerospace, medical devices and diagnostics, and semiconductor-equipment manufacturers. We also offer value-added overmolding, box builds, plug-and-play designs, and other engineering design services … and custom assemblies are fully tested before delivery.

But others are taking a different tack to separate connections on relatively small motion components — to let engineers choose proprietary connectors only if they work for the application at hand.

Rice • Applied Motion Products: We now offer a daisy-chain board connector for NEMA-11-frame StepSERVO Integrated Motors that separates communication terminals into two standalone power and I/O connectors — making it easier to establish daisy-chain connections on RS-485 and Modbus RTU networks.

Some Applied Motion Products NEMA-11-frame StepSERVO integrated motors (left) separate terminals. In contrast, standard configurations integrate them.

In contrast, standard configurations of Applied Motion’s TSM11 (NEMA-11-frame) motors incorporate a single 12-pin header that provides a power supply, input, output, and RS-485 communication terminals in a small integrated space … without sacrificing input and output connectivity to other devices, controllers, or HMIs on the machine.

In traditional servo designs, the servo motor and controller connect by two cables — one for power to the motor and one for the transmission of sensor or encoder data. Now HELUKABEL TOPSERV single-cable solutions include conductor for the transmission of signals and power.

Of course, the materials from which cable and connectors are made continue to have significant impact on overall design.

Buchicchio • Cicoil: Our products are suited to an array of emerging applications. All of our flat cables feature flexibility and durability; the rugged outer jackets withstand environments that are hot, cold, indoors, outdoors, on land or sea or in the air … or even space. Our cable is also compatible with sensitive environments (that are cleanroom rated) and where designs require kink-free cable.

Related from sister site wireandcabletips.com: What are flat cables?

Messerer • HELUKABEL: We sell molded M12 connectors in D and X-coded versions (male and female) for use with Category 5 and 6A cables (which cover higher data transmission rates to 10 GBit/sec). But materials are important here; the metal casing of both the connector and socket makes the assembly robust and resistant to dirt and moisture — even to IP67.

Lind • Cicoil: Thinner-jacketed (more flexible) versions of our data cables maintain EMI/RFI protection … and we’ve recently developed round Cat5e cable, HDMI cable, and Micro IDC cable with a 0.25-in. pitch. These feature ultra-fine wire stranding and Flexx-Sil jacketing for unsurpassed flexibility, durability, and usability in extremely harsh environments.

Related from sister site wireandcabletips.com: Cat5e shielded industrial Ethernet patch cords

Messerer • HELUKABEL: PVC insulation in standard and hybrid cables is being reduced and replaced with PE or PP-based compounds. The latter compounds make cables low smoke and halogen-free (LSZH) … plus necessitate a smaller cable diameter (and lighter weight) because of reduced wall thickness. This in turn is due to the fact that PE and PP have higher insulation resistance than PVC compounds.

PVC is cheaper, but isn’t low smoke or halogen-free … and has limited insulation resistance (which is why cables with PVC jackets necessitate thicker walls to get adequate voltage-resistance levels).

Buchicchio • Cicoil: We’ve formulated a silicone rubber polymer called Flexx-Sil that works as a flat-cable outer jacketing … Plus we use ultra-fine wire stranding in conductors. The combination of this conductor wire and supple Flexx-Sil jacketing (made with our extrusion process) produces a cable unsurpassed in flexibility — one that weighs less and consumes less physical space than conventional round cable with comparable electrical and signal performance.

In addition, Flexx-Sil cable jacketing is translucent and waterproof; UV and chemical resistant; and can withstand temperature extremes (operating from -65° to +260° C and remaining flexible even at -100° C); has the natural flexibility of silicone rubber (which is more than twice as flexible as PVC and PTFE insulation); and exhibits high material stability and low outgassing (with zero halogen). The cable jacketing is also durable with a durometer rating of 65 (Shore A) or a durometer rating of 85 (Shore A) in a SuperTuff version.

When asked about cable and connector options to impart simplicity or turnkey operation, our sources cited modular and universal systems.

Messerer • HELUKABEL: Our UL/CSA-approved pre-assembled data cables for Industrial Ethernet systems can include molded M12 and RJ45 industrial connectors, so engineers can modularly assemble any possible combination of cables and connectors to design product built exactly for their needs. Plus with high-speed data cables (with transmission rates to 10 GBit/sec) the molded M12 and RJ45 connectors guarantee a faster and more reliable connection within control cabinets, machinery and in-the-field operations.

Kojak • HARTING: Connectivity components must be compact, so we’ve expanded the Han-Modular product line with Smart Han modules that allow connection of active components. Using the same footprint as other Han-Modular modules, these let engineers create custom connectors using off-the-shelf modules that join in any combination to integrate power, control signals, and data into a single connection. This connector series revolutionized the industry when released in 1994 and remains our fastest-growing product line.

Messerer • HELUKABEL: We offer one RJ45 connector that has bandwidth to 500 MHz and supports data rates up to 10 GBit/sec … so it’s suitable for demanding industrial applications. The connector comes in a linear or angled version so works in industrial areas with limited space.

Lind • Cicoil: EZ-Flexx Flat Cable features a new external profile and inner jacket that makes it just as easy to strip and terminate with connectors as conventional round cable — even allowing use of automated stripping equipment. This lets OEMs and other commercial users to capitalize on the advantages and benefits of flat cable attributes and performance, without the labor overhead experienced with other types of flat cable.

Rice • Applied Motion Products: Designing very small integrated motors — motors with a NEMA 11 frame size, for example — means fitting as much functionality as possible into a tiny footprint. Because many users of our NEMA-11 motors had space for a slightly larger connector arrangement, we configured a new three-connector arrangement as an optional add-on component to three lengths the TSM11. (These integrated motors include TSM11Q-1RM-H01, TSM11Q-2RM-H01, and TSM11Q-3RM-H01.) Owners of existing single-connector modules also can upgrade their TSM11 integrated motors in the field by purchasing the daisy-chain connector board separately.

Lapp Group USA ÖLFLEX SERVO 7TCE oil-resistant servo cable with TC-ER approval works on industrial machines and in cable trays — and eliminates the need for two cable or conduit types. A thermoplastic elastomer (TPE) jacket and cross-linked XLPE insulation can withstand temperatures to 105° C.

In some cases, sizing software simplifies the specification process.

Lind • Cicoil: Our online Flat Cable Configurator provides fast and easy custom cable design on desktop and mobile devices. Point and click to add any of a wide variety of conductors (including pre-configured modules) for many standardized functions — such as USB 3.0, Cat 6a, and Camera Link. A click-and-drag function lets users position their selected conductors anywhere they choose on the cable. Then engineering drawings, custom part numbers, and cost per foot are delivered immediately to the engineer’s email inbox.

More cable and connectivity offerings are designed with miniaturization or compactness in mind.

Buchicchio • Cicoil:

Micro IDC ribbon cable with 0.025-in. pitch is compact — and it’s more flexible (and can tolerate higher voltages) than standard designs … so is especially suitable for use in confined areas.

Machine monitoring is an option with igus intelligent robot cable that warns users of impending failure. If certain parameters are exceeded during dynamic cable operation, a warning is triggered, indicating that the cable must be replaced. The cable concept is based on igus’ Chainflex cables — stranded and shielded to maximize life with an array of jacket materials.