Floating connectors with considerable tolerance compensation and high-speed data transmission
When it comes to board-to-board connectors, there are numerous versions: small and large pitches, low and tall designs, robust and simple connectors. The Finepitch FS 0,635 series connectors with floating properties are a new addition to the Phoenix Contact portfolio. What makes floating board-to-board connectors so special? Where are they used? And are high-speed data transmission and floating a contradiction in terms?
Features of a floating connector
Board-to-board connectors consist of the contacts that establish an electrical connection and a housing that protects and fixes the contacts. While floating connectors have two housing parts connected by contact metals. The inner housing contains the pin connector pattern, while the outer housing protects soldering surfaces and contacts. The floating contacts are long and curved, allowing the inner housing part to move within the limits set by the outer housing. This allows the pin connector pattern to be moved within a large tolerance range while the soldering area remains fixed. The FS 0,635 series allows a tolerance of 0.6 mm in the plug-in direction, known as wiping. The FS 0,635 floating female connector strip can be combined with three male connector strips to create different stack heights.
Direct, on-site mobile marking for electrical installations
The increasing importance of clear marking in networked components, particularly in plant, control cabinet, and distributor construction, has made the development of mobile printing systems necessary in the field of electrical installation.
On-site marking demands are increasing, necessitating clear and consistent marking of terminals, wires, cables, equipment, and systems, as well as compliance with a growing list of standards.
Digitalization of marking processes
Phoenix Contact introduces the THERMOMARK GO thermal transfer printer. A mobile system solution that offers high flexibility, short working paths, and no accidental double processing of missing markings. The printer, software, and marking materials – THERMOMARK GO – are all integrated with the MARKING system app, allowing easy smartphone interaction with the printer.
Climate change and population growth are posing a global challenge. How to stop global warming and increase energy consumption while protecting the climate? The All Electric Society vision aims for a sustainable, affordable energy system where renewable sources, such as sun, wind, and water, are used. Researchers at Oregon State University predict that photovoltaics could cover all energy requirements globally, using less than 1% of the earth’s surface. However, achieving this energy revolution requires extensive renewable energy expansion of renewable energy and the technological approach of sector coupling.
Sector coupling
Sector coupling involves the comprehensive electrification, networking, and automation of all relevant areas of our lives and economies. Including industry, energy, mobility, infrastructure, and buildings. In the All Electric Society, these sectors are networked to create a self-controlling system that optimizes energy efficiency and energy savings by balancing loads, producers, and storage systems. This ensures stability and availability of power supply without excess capacity. Making energy storage systems a core element of sector coupling.
The role of energy storage systems in an All Electric Society
To ensure a stable power supply based on renewable sources like sun, wind, and water, reliable storage systems are necessary. There are various technologies for temporarily storing electrical energy, with the main difference being their physical principles. Mechanical storage converts electrical energy into mechanical energy. While purely electrical storage uses capacitors or inductors. Electrochemical storage uses electrochemical potentials and electrolytes to store electrical energy in batteries. Thermal storage generates heat and drives electrical generators.
High-speed data transmission for industrial applications
IDC predicts that by 2027, the volume of data created and replicated will reach 284 zettabytes, a 21-zero figure, threatening the Internet of Things without a nationwide broadband expansion, highlighting the need for significant data storage and replication.
The first transatlantic fiber-optic cable was operational in 1988, enabling high-speed data transmission between continents. The mid-1990s saw broadband expansion, adding more long-distance routes and moving fiberglass transmission paths closer to end devices like data centers, industrial plants, and personal computers, known as the “last mile.”
Data transmission across continents, countries, and municipalities requires high security and reliability. Speed, immunity to interference, and failsafe performance are basic requirements for industrial and semi-industrial data transmission.
The advantage of fiber optics
Fiber-optic cables (FO) transmit data in light over long distances by converting electrical signals into photon packets and sending them to the receiver via plastic or fiberglass. The light signals are then converted back into electrical signals for evaluation and processing.
This blog article explores the advantages of data transmission through fiber-optic cables over copper transmission, focusing on their characteristics.
Speed and distances
Fiber-optic cables use photons to transmit electrical signals, which are faster than electrons in copper conductors. Photons can travel up to 70% of the speed of light, with minimal signal loss. This allows for longer transmission distances of up to 50 km and data rates of up to 40 Gbps. The actual range depends on the chosen fiber-optic cable, making them suitable for long distances and large data volumes.
Reliability and security
Fiber-optic cables are reliable for data transmission due to their non-conductive cores made of glass or plastic, eliminating the need for complex shielding. They are metal-free, insensitive to EMC and ESD interference, allowing parallel use with other cables. Impedance problems and crosstalk are not issues. Fiber-optic cables with coatings protect against environmental influences in a much better way.
Fiber-optic cables offer enhanced cybersecurity due to their lack of external signals, requiring direct access via bend connectors or contact points, making them significantly more secure against eavesdropping than copper cables, despite not providing 100% protection against unauthorized access.
Costs
Fiber-optic technology has disadvantages such as complex assembly, precision, expensive equipment, complex measurement technology, and the need for well-trained specialists. Manufacturing and monitoring production are costly and require extensive expertise in this specialist field.
Simple implementation with the PSRmodular and AXL F series
Phoenix Contact offers two series of analog signals for monitoring physical variables in process engineering systems. These signals are standardized as either a (0)/4 … 20 mA or a 0 … 10 V signal, with current signals being more robust against electromagnetic interference and having high measuring accuracy over longer cable lengths. Furthermore, the concept considers whether the sensor is powered by the evaluation module or supplied by an external source.
Consideration of load and measurement information
The analog evaluation module distinguishes between active and passive inputs, requiring external supply for passive inputs. Load consideration is crucial when engineering analog signals, and signal conditioners are recommended if it exceeds active inputs. Moreover, NAMUR recommendation NE43 defines signal levels for failure information of digital measuring transducers with analog output signals, with current values outside these limits considered invalid or failure information. The evaluation unit must provide corresponding information or respond to deviations.
Design of functional safety
Single-channel analog signal generators can be used for safety-related circuits up to SIL 2/PL d. While two-channel signal generators can be used up to SIL 3/PL e. MTTFD values can be determined based on sensor manufacturer failure rates. Furthermore, Diagnostic coverage (DC) is required for safety-related analog signals, but plausibility comparison is difficult due to measurement inaccuracies and ambient conditions. Two-channel architectures should allow short-term deviations outside the tolerance range, without impacting functional safety.
In this blog article, we will explain the magneto-optic effect’s principle for monitoring surge currents in lightning strikes. We will use the example of a lightning monitoring system in wind power plants, monuments, and power transformation substations.
Lightning monitoring on exposed objects
Lightning strikes can cause severe damage to buildings and systems, especially in residential or commercial buildings. One can quickly evaluate the extent of damage and immediately repair it, preventing consequential damage. However, employees cannot continuously monitor exposed objects or large surfaces like wind power plants or railway systems. That’s why the use of Intelligent monitoring systems is becoming more common to permanently monitor system function states and send results to a central control unit. This allows for immediate response in case of malfunctions and prevents consequential damage and long downtimes. Until now, no measuring system could reliably detect and evaluate lightning strikes.
New monitoring technology with the Faraday effect
A new monitoring system uses the Faraday effect and magneto-optic effect to analyze surge currents in lightning arresters. Moreover, a fiber optic cable transmits signals, preventing lightning currents from influencing the light signal. This ensures reliable and EMC-protected signals for the evaluation unit electronics, ensuring efficient and reliable monitoring and measurement.
Structure of the measuring section
The measuring section is a transparent dielectric with polarizers at either end, positioned 90 degrees to the current flow direction in the down conductor. Consequently, Ensuring that the propagation direction of a light wave is parallel to the surge current’s magnetic field.
DC technology: Test facility shows potential savings
DC grids in the automotive industry are a key step towards climate neutrality. A production plant in Dingolfing, Bavaria, uses Phoenix Contact components to supply a unique DC grid system for robotic arms and automotive parts.
It was AC power supply in the beginning
In the late 19th century, Thomas Edison (DC) and George Westinghouse (AC) fought over large-scale power grid supply. Ultimately, choosing alternating voltage is due to AC voltage’s ability to be transformed up and down.
The advantages of direct current
DC technology offers efficient direct current usable at a low cost. Making it suitable for electronic devices, electric cars, and renewable energy. Furthermore, DC grids can eliminate lossy AC/DC conversion and integrate renewable energy systems efficiently. Moreover, Phoenix Contact provides solutions for intelligent control of power flow and networking, ensuring high availability and supply security.
Direct current as a key technology
Phoenix Contact, a family-owned company, has been supporting BMW in their research into using Direct Current (DC) technology in a production cell at their Dingolfing plant. The company, a member of the Open Direct Current Alliance, has been able to provide rapid support and optimize the existing DC product portfolio through practical applications. This move aims to use renewable energy efficiently and conserve energy and material resources in an All Electric Society.
From theory to practice
Phoenix Contact’s High Power Systems range converts public AC grids into DC grids with 19-inch devices connecting DC subnetworks. Moreover, the wide output voltage range allows gradual ramping up the grid. Furthermore, the performance parameters can be parameterized via the PLCnext platform. Phoenix Contact’s Contactron ELR HDC DC circuit breaker and ArcZero connector ensure safe plugging and unplugging under load.
A key technology in the digitalization of our world
Digitalization and the Industrial Internet of Things (IIoT) are driving the demand for faster, seamless networking in various industries. Ethernet has proven effective in intelligent device networking, but Single Pair Ethernet (SPE) will replace serial fieldbus communication protocols in the future. SPE’s innovative characteristics make it valuable for advanced communication infrastructures. Phoenix Contact offers cross-industry expertise and an ideal product portfolio for SPE implementation in various fields. Ethernet solutions typically require two wire pairs, but Gigabit Ethernet may require four for increased data transmission rates. Single Pair Ethernet, which works with a single wire pair, can transmit data and power simultaneously. Its transmission rates range from 10 Mbps at 1,000 meters to 1 Gbps at 40 meters, making it suitable for demanding tasks like networked sensor technology. This technology is suitable for fields previously affected by limitations in data rates, ranges, and seamless communication.
Connections of up to 1,000 meters
Standard Ethernet solutions have limitations, such as a maximum of a 100-meter point-to-point connection distance. Furthermore, To cover longer distances in industrial systems, additional repeaters or switches are needed. SPE technology allows devices to be connected over 1,000 meters with 10 Mbps transmission speed and Power over Data Line (PoDL) technology with only one cable, potentially replacing specific fieldbus technologies in the future.
Speeds of up to 1 Gbps and more
Single Pair Ethernet (SPE) is a reliable solution for complex network topologies with gateways, offering transmission speeds ranging from 10 Mbps to 1 Gbps. Hence, IEEE 802.3 consortia is discussing further SPE standards for higher data rates and distances which will open up the spectrum for SPE for even more fields of applications.
Digitalization for more sustainability and productivity
Phoenix Contact has developed a solution for the energy-intensive pharmaceutical production industry to achieve the Net Zero Factory climate target. The solution uses the open IIoT framework from PLCnext Technology to digitalize all machines, systems, and processes. The Digital Factory from Phoenix Contact covers all stages of the value chain, addressing digitalization requirements in all stages. Rapid climate change, demographic development, deglobalization, and global political changes present opportunities for sustainable digital processes, new business models, and agile working methods.
Minimally invasive digitalization approaches
The All Electric Society envisions a world where renewable energy is the primary source of electricity, available abundantly, inexpensively, and carbon-neutral. Industry plays a crucial role in developing solutions for electrifying sectors like energy, infrastructure, buildings, and mobility. Addressing all factory areas, including raw material warehouses, production, power supply, packaging, and buildings, is essential for reducing greenhouse gases and complying with environmental and materiality analysis directives.
Less maintenance effort thanks to contactless data and power transmission
SHL AG has been developing systems for automated grinding, polishing, and deburring since 1989. The company uses NearFi contactless power and real-time Ethernet solutions from Phoenix Contact for wear-free and maintenance-free communication. SHL’s systems include flexible robot cells, grinding, polishing, and deburring cells, as well as complete production cells. The company supplies users from various industries, including faucets, automotive crankshafts, and titanium and ceramic for medical applications. With 95 percent vertical integration, SHL reduces production costs through better cycle times. However, shorter cycle times and movements can lead to more wear, resulting in downtime.
Data exchange via slip ring was previously prone to interference and wear
Surface processing requires workpieces to swivel 360 degrees, and rotary tables with swivel units are used. The system consists of three areas for the various processing steps: insertion onto the carrier, ithe initial processing of the workpiece by sanding robots with coarse grit, and finally processing by sanding robots with fine grit. The rotary table rotates the workpiece to the next processing station. Bernhard Mattes, Senior Director of Engineering at the Böttingen plant, introduced contactless NearFi technology for wireless data exchange, which is mounted on each rotary axis for the three endlessly rotating swivel units.
Simple startup without configuration effort
NearFi enables contactless data and power transmission using base and remote couplers that can be flexibly positioned without precise alignment. It reduces maintenance costs, enhances system availability, and simplifies startup with quick, configuration-free connection via 24V and Profinet cables, communicating Ethernet protocols at 100 Mbps full duplex.
