HARTING says there is immense potential for this new technology in robotics applications, where the cables are subjected to strong torsional forces, the reduced number of wires means thinner and more flexible cables, which prolongs their service life.

Single Pair Ethernet (SPE) will be one of the technological cornerstones that helps to shape the success of the IIoT. The factory of the future will require high data streams and the industrial sector needs connectivity solutions which adapt themselves to increasingly growing demands.

The T1 Industrial supplies both data and power via Power over Data Line (PoDL) across a single pair of wires in an IEC 63171-6 industrial interface, bringing Ethernet from the cloud to every sensor and enabling Industry 4.0.

Key aspects of the T1 include the space-saving and weight reduction benefits achieved by the move to a single pair of wires. This means the compact T1 can be easily incorporated into smaller products and Ethernet interfaces can be designed onto simple sensors, cameras, reading/ID devices or similar miniaturised equipment.

For maximum flexibility, the T1 mating face can be integrated into standard housing forms as required, including interfaces in M8 and M12 housings. HARTING not only has connectors and other components in mind but a complete Single Pair Ethernet system which will quickly and securely deliver higher bandwidth and large volumes of data, right down to the printed circuit board.

Matthias Fritsche, HARTING’s Ethernet communications expert, comments: “SPE is about conveying the Ethernet protocol with another physical layer using only a single pair of wires. So just as one is currently using four-pair copper cables, fibre-optic cables or radio today, SPE is another form of physical layer, designed for communication down to the field level.”

Highlighting the benefits of SPE for the user, Marian Duemke, HARTING global product manager, adds: “The idea behind SPE is to bring Ethernet to the field level, where it isn’t available yet. SPE means Ethernet interfaces can now be integrated onto simple sensors, cameras, reading/ID devices or similar miniaturised equipment. As a result, there is immense potential in the T1, which can supply both data and power across a single pair of wires in an IEC 63171-6 industrial interface.”

Addressing some of the other markets that could benefit from SPE, Duemke says: “Within transportation, an Ethernet cable weighs approximately 4.6kg per 100 metres, whereas an SPE cable only 3kg. Over an average train carriage lifetime of 40 years, each kilogram of saved weight delivers savings of around £12,000 per carriage. If you consider how many carriages the average train has and how many miles of cable are found in the train, it soon becomes apparent how great the savings potentials are.”

Discussing how the HARTING T1 Industrial connector was developed, Fritsche says: “For the concept, we examined the trends of recent decades and what the ideal plug connector should look like. To do this, we looked at the pain points of the RJ45. We decided on a pin and socket system as these are already established for many industrial connectors. We also enabled a safe interlock so that shocks and vibrations don’t interrupt the data transmission.

“Companies are starting to understand SPE’s benefits and are working on projects already. This has shown us that we are on the right track and that people understand that this is not just some kind of new Ethernet interface. It’s a completely new world that harbours an incredibly great potential.”

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Research carried out by the World Economic Forum in 2020 found that companies with a highly flexible and technologically advanced risk-averse model were able to maintain their operations much more effectively and were more resilient to uncertain conditions.

The characteristics of a risk-competitive model include responding and adapting to changing customer needs, investment in advanced manufacturing technologies and the ability to offer reliable and local support via strategic relationships and collaboration with partners.

Using connectivity from the right connectivity partner can help companies make the shift to flexible manufacturing, a more risk-averse operating model which ensures they are better prepared for the future.

In the past, a manufacturing floor was static, meaning lines remained relatively fixed with upgrades occurring every few years. Machines were placed with the intention that they would perform the same tasks for the duration of their useful life. Now, manufacturing floors need to be rearranged frequently to customise products to customer-specific needs. With the addition of cobots and modular machinery, floors can be reorganised quickly to manufacture entirely different products.

When manufacturing plants were static, connections for bringing power, signal and data could be hardwired. This meant all connections going in and out of the machine were permanently fixed to terminal blocks. Although this method was cheaper, there were drawbacks; installation or disassembly had to be done by a skilled electrician, which was time and cost intensive, and hardwiring errors were costly and to repair and resulted in long machine downtimes.

On the other hand, ‘plug and play’ connectorisation makes flexible manufacturing possible as machines can be disconnected and reconnected quickly, without the need for skilled labour and with no risk of miswiring. Manufacturers no longer need to spend an entire day disconnecting a machine now that plug and play solutions exist. Connectorisation, simply put, is the backbone of a successful risk-competitive structure.

As a leading supplier of connectivity technology, HARTING strives to deliver cutting edge technological developments to make innovations such as flexible production and miniaturised products possible.

For example, the Han 1A has been designed to be versatile and take up less installation space. By using a modular system of inserts, it can integrate contacts for the delivery of data, signals and power, an economical design based on fewer components which greatly simplifies material supply.

Modules for Cat. 5 or Cat. 6A are available for data transmission, while a shielded variant can be employed in areas that are particularly susceptible to interference. Additionally, only two components are required to quickly assemble an IP20 solution, while additional housing elements or single wire seals can be used to enhance ingress protection to IP65.

As referenced above, the Han 1A’s ‘plug and play’ design allows the connector to be assembled in seconds without using any specialist tools. Rapid onsite installations are made possible using screw contacts, as well as the pre-assembly of separate units with crimp contacts.

For the ultimate in versatility, HARTING has the Han-Modular series. This range allows you to design connectors to supply machinery and equipment by combining individual modules for different transmission media, such as signals, data, power and compressed air, in standard-sized industrial connector housings.

You can even design your own customised industrial connectors using the new and improved Han Configurator, an online 3D tool which allows you to build a bespoke connector using the vast Han-Modular portfolio. Once done, you can easily download all technical data (including STP files) and quickly save and share your configuration within a team, an ideal solution if you’re working remotely or in a different location from your colleagues.

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Across three inspiring days, you’ll hear keynote speeches, expert talks and enjoy technical sessions with solution experts, thought leaders, IIoT pioneers, and representatives from a range of global brands.

Harting solutions for the delivery of fast Ethernet include the ix Industrial, a robust, space-saving connector to replace the traditional RJ45. It has a 70% smaller PCB jack and a high current-carrying capacity that supports Power over Ethernet (PoE) applications. It complies with IEC 61076-3-124 and conforms to the shock and vibration resistance levels set out in EN 50155.

Experts have also suggested that Single Pair Ethernet (SPE) will be one of the technological cornerstones that helps to deliver high data streams amid increasing demand. Up until now, industrial Ethernet has come with restrictions as it has only been able to reach the control level before it needs to switch to bus systems via gateways. SPE allows equipment to connect via end-to-end IP-based communications right up into the field level.

The T1 Industrial SPE connector from Harting supplies both data and power via Power over Data Line (PoDL) across a single pair of wires in an IEC 63171-6 industrial interface. The compact size of the T1 means Ethernet interfaces can be designed onto simple sensors, cameras, reading/ID devices or similar miniaturised equipment.

Harting sees immense potential in this new technology in robotics, with sensors, actuators and network nodes all able to be networked and supplied with power via the T1.

Click here to see the agenda and register for Industrial Ethernet Week.

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Delivering even more flexibility and ease of use for preLink connection technology, the preLink termination block is now available in a black PROFINET version. It is suitable for AWG 22/23 stranded wire and comes with printed standardised wire assignment for PROFINET and industrial Ethernet. Wire assignment is clear, so that assembly is quick and easy.

Also available is a white preLink cube, which is optimised for AWG 24 wires and suitable for a large number of ultra-flexible robot cables with AWG 24/19 wire configuration.

With its preLink connection technology, Harting has successfully managed to separate a previously fixed connection between cable and connector into two independent and re-usable components. The preLink termination block is fitted with an inlet for 4- or 8-wire Ethernet cable, which can be securely assembled in the field in a single stage with the appropriate preLink tool.

The termination block fits the related RJ45 and M12 jacks and connectors. The benefit of this system is that the termination block can be removed and inserted in another connector in a matter of seconds over and over again, meaning that cables and connectors can be switched independently of one another.

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Okura Yusoki, a leading manufacturer of transport equipment and logistics systems, chose Han-Yellock connectors from Harting for its new palletizer robot. Han-Yellock provides IP65/IP67 protection and an internal locking mechanism with push buttons instead of conventional locking levers to ensure reliable connection while enabling space-saving installation and single-handed operation.

Okura Yusoki adopted Han-Yellock to transmit signal and power between robot and controller. The modules of the housing mounted on robots can be easily disassembled and reassembled not only from the mating side but also from the termination side, which makes servicing simple.

By combining a wide range of modules, the connector can integrate multiple signal transmissions and power supplies in one housing, leading to fewer connection points.

By adopting Han-Yellock, Okura Yusoki has achieved improved maintenance, integrated connection and a ‘smart’ design.

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