Hybrid interfaces have been used in IT for a long time. Everyone is familiar with the USB and power over Ethernet (PoE) interface standards, through which end devices are supplied with both data and energy. These developments are also in demand in the more general industrial environment.
Data transmission rates are increasing and industry standard interfaces such as RJ45 and M12 connectors now cater for data transmission rates from 100Mbit/s up to 10Gbit/s, but transmitting data, signals and power at the same time places new demands on the cabling structures used to date.
This challenge is addressed by IP65/67-rated hybrid connectors which combine multiple Ethernet contacts in Cat.6A (RJ45) configuration and power contacts up to 5A.
Smart interfaces
As industrial Ethernet becomes better established, more and more applications will require special configurations. The simultaneous transmission of data and power via a single cable and one connector will therefore become increasingly attractive. This will enable the connectors themselves to become smarter by incorporating diagnostic and monitoring functions.
Industry bodies are currently working together to establish standards for the connection of different machines, systems and components under the Integrated Industry concept, but the emergence of smart power boxes which offer connection options for Ethernet in combination with a power supply gives one indication of the way things are developing.
In the field, this approach allows much simpler and less costly wiring for systems compared to the terminal boxes that are otherwise necessary. Data can be retrieved from field devices via software within the box or by the industry standard OPC-UA framework, while the components can be supplied with electricity at the same time. The software can also be used to monitor power consumption, simplifying maintenance and diagnosis.
Power over Ethernet
Power over Ethernet (PoE) has been used in IT up to now to connect Ethernet devices such as hard drives and WLAN adapters to one another. The relevant IEEE standard 802.3af-2003 for the parallel transmission of energy and data via twisted-pair cables has been established for some years.
The original IEEE 802.3af-2003 PoE standard provides up to 15.4W of DC power to each device.
With the PoE+ standard (IEEE802.3at) the transmit power is increased to 25.5W and potential y even higher.
Modularity, scalability and flexibility have always been required in industrial production systems, but Integrated Industry – with its decentralised, distributed intelligence and modular, self-organising systems makes these requirements even more critical. This, however, is an evolutionary process for automation and mechanical engineering companies, since current machinery must function within the existing environment while simultaneously being capable of migrating to Integrated Industry.
Machinery and modules with adaptive program code and flexible interfaces are evolving from earlier manufacturing systems with non-changeable process sequences and rigid structures.
Interfaces have been tasked with a key role in this evolution towards adaptive, highly flexible production systems: not just communication interfaces but interfaces between all machine elements and at all levels of the production process.
In connector terms, this has involved the introduction of scalable, pluggable interface solutions for power, control, signal and data connections.
Industrial integration
The functionality of these interfaces has been expanded to meet the special requirements of, and the migration to, Integrated Industry. For example, the connector interfaces can be integrated with RFID systems to enable the identification of all elements involved in the production process, which includes work pieces, tools and machine modules, in addition to allowing flexible data storage directly on the elements or with reference to the element.
In addition, data storage directly in the industrial connector is also an option with modules, which are mechanically constructed so that they can be assembled into modular connectors directly alongside other power, data and signal modules.
On the control side, these modules communicate directly with machine controllers, such as PLCs and industrial PCs, via industrial bus systems or discrete I/O.
These features will allow for migration to hybrid interfaces which will be important elements in flexible manufacturing systems of the future.
Writer is Kevin Canham, product and applications manager at Harting
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