Written by Art Pini, DigiKey
Smart factories are becoming increasingly automated through decentralized intelligence and control, utilizing modular robotic machine concepts. This physical distribution of control functions necessitates connectivity via wires and cables that ensure reliable and secure connectors matched with the environmental demands of the modern factory.
Such connectors must have low resistance, adequate contact surface area to handle their rated currents, and strong locking mechanisms to resist vibration and shock. Additionally, they must be easy to assemble and modify, enabling rapid updates and changes.
This article provides a brief overview of the connectivity demands of industrial robots and factory automation. It then introduces a series of connectors from TE Connectivity AMP and shows how their features can be applied to support the power, signal, reliability, and safety needs of these applications.
What is a smart factory?
A smart factory is an integrated facility that uses digitally interconnected machines, robots, and local sensors for control, real-time data collection, analysis, and decision-making (Figure 1). Such factories are becoming increasingly decentralized and modular, allowing them to be easily reconfigured to meet changing production needs. The modular organization favors local control and smaller machines to enhance production flexibility.
Figure 1: The smart factory employs networked machines, robots, and interconnected sensors to ensure efficient operation. (Image source: TE Connectivity AMP)
These facilities use modular workstations equipped with independent or collaborative robots (cobots). Mobile robots, such as automated guided vehicles (AGVs) or autonomous mobile robots (AMRs), move products between workstations.
AMRs and AGVs have the advantage over stationary robots in that they are highly mobile and can rotate and translate between and among workstations. With AGVs, AMRs, and cobots working together, a production line can have different tasks taking place within separate cells. Robots can pivot between workstations or be reassigned as needed, thereby improving overall efficiency.
These workstations are frequently located in harsh environments, so designers must factor in that robots and other automated machines may be exposed to high temperatures, humidity, dust, corrosive chemicals, and shock and vibration.
Sensors monitor all operations. Depending on the design, the sensors may be wired or wireless. Wireless sensors are commonly connected via the Industrial Internet of Things (IIoT). Mobile robots are also monitored and controlled using the IIoT.
As is typical of electronic systems, the industry trend is toward smaller robots, machines, sensors, and controllers. The small size and light weight translate into lower power requirements and more available floor space for increased production. They also translate to smaller printed circuit boards (pc boards), which require components with high volumetric efficiency.
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