Industry 4.0, Industrial Internet of Things, IIoT, Smart Factory, these words are getting closer and closer to us. They are not just buzzwords; they are the next generation defining trend that is changing the manufacturing industry.

Industrial automation is the direction of future development, and connectors play an indispensable part in realizing industrial automation. So the question is: why can such a small component play such a huge role in the innovation of the entire manufacturing industry? That's because connectors, it is not just a small component in Industry 4.0, but also a basic building block to realize the potential of many products.

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First of all, what is Industry 4.0?

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The term "Industry 4.0" gives companies hope: high-speed operational efficiency, total production transparency, implementation of predictive maintenance models, etc. However, these promises are usually presented as results without specific descriptions of how to achieve it.

In 2016, the Institute of Electrical and Electronics Engineers (IEEE) defined four key themes for Industry 4.0:

The ability of machines, devices, people and sensors to communicate with each other.

Information transparency. Operators are able to access and leverage information collected across all parts of the manufacturing process to identify where efficiency gains can be made.

Technical Assistance: The ability of technology to assist people in making decisions or performing unsafe tasks.

Decentralized Decision Making: The ability of cyber-physical systems to autonomously perform tasks and make decisions on their own.

Interconnectivity: Ethernet connectivity enables

Seamless communication from sensors to the cloud

Industry 4.0 applies to basically all devices, sensors, and machines, and one key aspect is the communication between them. Industry 4.0 turns this well-known practice on its head and allows all data to be used to build a complete picture of a system or machine.

Previously, data was important for “instant” functionality. In a sense, devices using different data protocols did not speak the same language. The cost of translating and collecting data was high, and storing data was even more of a challenge. As a result, data existed in silos.

The cloud is a game changer in that it can store and process large amounts of data without interfering with local servers and processes. Keeping data in dedicated servers at an affordable price allows companies to retain and use the data generated by their machines.

As a result, companies are starting to rethink their industrial networks. Old serial bus protocols are becoming popular, replaced by Ethernet, which is already widely used in cloud networks. The reason for this is that serial bus protocols eventually need to be converted to Ethernet. In addition, they are highly specialized and require years of experience and training to implement and support correctly. Over the past few years, Ethernet connectors have evolved from miniaturized versions of four-wire to eight-wire Ethernet connectors to single-pair Ethernet (SPE), which transmits Ethernet over two twisted pairs, reducing weight and copper costs. SPE is an economically viable option for every device on an industrial network.

T1 Industrial is the standard mating face for SPE, allowing Ethernet to be transmitted over two wires.

Smaller connectors enable information transparency without increasing

Device size

Devices are getting smaller. This applies to mobile phones and other consumer electronics, but also to the human-machine interfaces (HMIs) that people use when programming robots on machines. The components inside a device often limit the size of the device. For example, many mobile phones have eliminated the 3.5 mm headphone jack because, in addition to the popularity of wireless earbuds, this connection point is a factor that limits how slim a phone can be.

In Industry 4.0 networks, every device needs to generate data, provide more functionality, and connect to an operations center. This means the number of components on increasingly smaller devices is increasing. As a result, components must become smaller. As a result, the need for hybrid and smaller connectors has increased.

The ways in which industrial connector manufacturers reduce connector size vary, but may include removing internal locking mechanisms or latches for push tabs, reducing the overall profile of the connector, reducing the space required between connection points, or incorporating features such as magnetics directly into the connector. All of these design choices allow device designers to do the seemingly impossible—increase functionality while reducing size.

PushPull connectors use an internal locking mechanism that helps reduce the space required for connectors.

Tech Assistance: Connectors Enable Collaborative Robots

To Work Together with Humans

Collaborative robots, or cobots, were once the stuff of science fiction. While helpful home robot butlers are still a few years away, workers in manufacturing plants may find themselves working alongside small collaborative robots.

In the past, robots tended to be fixed in place. Hardwiring robots instead of using connectors is suitable for certain applications where robots repeatedly perform the same functions during their lifecycle. Today, collaborative robots are designed with flexibility in mind, both in the tasks they perform and in their location on the production floor. Connectors allow robots to move quickly without relying on skilled workers.

Decentralized Decision Making: Connectors

Enabling Decentralized Systems

Decentralized systems have become the preferred structure when designing production floors. These systems contrast with older centralized systems, where all machines and equipment were connected to a control panel and a room. Decentralized systems are much more efficient by allowing decisions to be made at the application site (or edge). By placing controls close to the application, parts of the system can operate independently. This is very important when flexibility is needed.

Changing centralized systems is time-consuming and expensive, as all connections and cables must be pulled out and rerouted to new locations. Likewise, changing centralized systems often requires troubleshooting to ensure that new processes do not interfere with old ones. Decentralized systems operate independently of each other, so changes can be easily made without jeopardizing the rest of the system.

In decentralized systems, hardwiring is not a viable option. Changing layouts or even replacing parts of machines is a common practice on modern production floors. Connectors make it easy for workers to make these adjustments quickly and easily without specialized tools, thus avoiding costly downtime. The most efficient connector is a modular connector, which allows multiple connection points to be combined into a single housing. The next level of connector modularity allows for customization of the module itself, ensuring that all space is used as efficiently as possible.

The Han -Modular Domino is a higher level of modularity. Users can customize the module with the specific interconnects required for the application.

Connectivity is a key area of Industry 4.0, and connectors are no longer optional when designing machines, devices, or sensors used in modern manufacturing equipment. Well-designed connectors that save space and feature modular designs can help manufacturers realize the promise of Industry 4.0 while using reliable, time-tested technology.