Technical Overview | Connection Technology

In modern industrial automation systems, the transmission of power, signals, and data between various devices is essential, and this all relies on a key technology—connection technology. Connectors are not just simple electrical components; they are the links that ensure the reliable operation of equipment. This article will introduce common types of connectors in industrial automation, explore their features, applications, and the connection technology behind them, and explain how to choose the right connectors and cables based on actual needs.

1. Connectors for Sensors and Actuators

In an automated factory, sensors and actuators are indispensable "eyes" and "arms" on the production line. How to reliably connect these key components has become a crucial part of system design. Below is a detailed introduction to M8 and M12 connectors used for sensor and actuator connections.

Compact and Durable M8 Connectors

The M8 connector, with its compact design and powerful functionality, has become the best solution for connecting sensors and actuators. M8 connectors typically offer 3-pin or 4-pin configurations, suitable for signal transmission in limited space. It has excellent protection performance, maintaining stable connections in dusty, humid, and vibrating environments.

Cable Selection: In automated production lines, M8 connectors are typically paired with 24 AWG to 26 AWG signal cables. These multi-core cables can transmit small currents and signals well. In scenarios requiring higher anti-interference capabilities, shielded cables are a better choice.

Application Scenarios: M8 connectors are widely used for connecting sensors, photoelectric switches, and micro-actuators, ensuring that every detail of the production process is accurately monitored and executed.

Stable and Reliable M12 A-Code Connectors

M12 A-Code connectors typically offer 4-pin or 5-pin configurations, capable of handling complex signal and power transmission needs.

Cable Selection: M12 A-Code connectors are often used with 22 AWG to 24 AWG control cables. For environments requiring protection against electromagnetic interference, shielded cables can further enhance their anti-interference performance, ensuring stable signal transmission.

Application Scenarios: M12 A-Code connectors are widely used in factory automation, process control, and robotics systems, suitable for use in high-vibration and harsh environments.

2. Communication Connectors

In industrial automation, data transmission is equally critical. Whether in fieldbus systems or industrial Ethernet, communication connectors are key to achieving efficient data transmission. Below is the application of M12 B-Code, D-Code, and RJ45 connectors in communication.

M12 B-Code Connectors Designed for Bus Systems

M12 B-Code connectors are mainly used in industrial bus systems, such as Profibus. Their design emphasizes the stability and anti-interference capability of data transmission, usually providing 4-pin or 5-pin configurations, suitable for data communication in complex electromagnetic environments.

Cable Selection: M12 B-Code connectors are typically paired with shielded twisted pairs or specialized bus cables to reduce external interference and ensure reliable data transmission.

Application Scenarios: M12 B-Code connectors are widely used in machinery manufacturing, factory automation, and process control systems, ensuring the stable operation of data networks.

High-Speed Data Transmission with M12 D-Code Connectors

M12 D-Code connectors are specially designed for industrial Ethernet, supporting data transmission rates of up to 100 Mbps. With a 4-pin configuration and shielded design, they ensure high-speed and stable data transmission, making them ideal for critical connections such as PLCs, industrial PCs, and network switching equipment.

Cable Selection: M12 D-Code connectors are typically paired with Cat5e or Cat6 shielded twisted pair cables, which can reduce crosstalk and electromagnetic interference, ensuring signal integrity and transmission speed.

Application Scenarios: D-Code connectors are widely used in high-speed data communication scenarios in industrial networks, such as industrial Ethernet and control system communication.

Standardized Interface for Industrial Networks—RJ45 Connectors

As the standard interface for Ethernet, RJ45 connectors also play a vital role in industrial environments. Industrial versions of RJ45 connectors have higher protection levels and can withstand more demanding working conditions, supporting transmission speeds of up to 1 Gbps.

Cable Selection: RJ45 connectors are usually paired with Cat5e, Cat6, or Cat6a cables, with shielded or unshielded cables chosen based on the application scenario. In industrial applications, shielded cables are more common, effectively preventing electromagnetic interference.

Application Scenarios: RJ45 connectors are widely used in industrial control, data centers, communication stations, and other scenarios, ensuring the reliability of high-speed network connections.

3. Power Connectors

For industrial equipment, a stable power supply is critical. Whether powering large equipment or providing electricity to precision instruments, power connectors play a key role in the transmission of current. Below is a detailed introduction to M12 L-Code and 7/8" connectors.

High Current Transmission with 7/8" Connectors

The 7/8" connector is a circular connector designed for high power transmission, capable of handling currents from 10A to 15A, usually in a 5-pin configuration. Its robust casing performs well in industrial environments, widely used in industrial automation, control cabinets, and motor drive systems.

Cable Selection: 7/8" connectors are typically paired with 16 AWG or thicker cables. These high-power cables can maintain low resistance during long-term high-current transmission, ensuring the efficient operation of equipment.

Application Scenarios: 7/8" connectors are often used for high-current power supply to industrial equipment, such as motor drivers and power connections in control systems.

Compact and Powerful M12 L-Code Connectors

M12 L-Code connectors are designed for high current transmission, supporting currents of up to 16A, typically in a 5-pin configuration, suitable for use in space-limited scenarios with high current demands. They are widely used in industrial automation equipment for power connections, such as servo drives and power transmission systems.

Cable Selection: L-Code connectors are typically paired with 14 AWG to 16 AWG high-current cables, which usually feature high-temperature and wear-resistant materials like PUR or TPE to ensure long-term stability.

Application Scenarios: M12 L-Code connectors are suitable for power supply in high-power equipment in industrial automation systems, such as drives, power transmission, and control equipment.

4. Choosing Between Pre-Cast and Field-Installed Connectors

When selecting connectors, it's also essential to decide between pre-cast and field-installed connectors based on specific needs. Both types have their characteristics and are suitable for different application scenarios.

Pre-Cast Connectors

Pre-cast connectors are manufactured by the factory, with cables and connectors fixed, molded, and tested to provide a high protection level (e.g., IP67). They are suitable for harsh environments, such as wet, dusty, and high-vibration industrial settings. They reduce the complexity of on-site installation and minimize the risk of unreliable connections due to improper handling, making them ideal for standardized installations and large-scale wiring.

Field-Installed Connectors

Field-installed connectors allow users to install or replace cables on-site, providing greater flexibility and ease of maintenance. They are suitable for scenarios requiring customized cable lengths or frequent wiring adjustments, such as frequent equipment changes or test equipment wiring. Field-installed connectors require a higher level of installation expertise but offer significant advantages in scenarios that demand flexible responses to complex wiring needs.

How to Choose the Right Connectors

Professional advice is crucial when choosing the right connectors. Our company has a team of experienced technicians who can provide customized connection solutions to ensure optimal results in any application environment. Whether you need pre-cast connectors with high protection levels for harsh environments or field-installed connectors for flexible wiring or frequent maintenance scenarios, our team can help you make the best choice.

Conclusion

From compact sensor connections to high-speed data transmission to high-current power supply, connectors play an indispensable role in industrial automation. Different connectors have their unique characteristics, meeting various application needs. Additionally, the choice between pre-cast and field-installed connectors should be made based on the specific application environment and wiring needs. A well-informed choice can help optimize installation efficiency, improve system stability, and reduce subsequent maintenance costs.

By selecting the appropriate connector types and cable combinations, industrial systems can achieve higher efficiency, greater stability, and longer service life. Whether it's the M8, M12 series, or the 7/8" and RJ45, each connector plays a key role in specific application scenarios. As industrial technology continues to advance, connection technology also keeps improving, helping various industries achieve intelligent manufacturing and efficient production.

Customer Support and Service

If you want to learn more about SENTINEL products, please contact our sales team or call the company at 022-83726972. You can also visit the SENTINEL website at www.sentinel-china.com. The website provides comprehensive product information, selection guides, CAD and Eplan files, as well as configuration files and tutorials, ensuring that users can easily obtain the information they need.

We have a professional technical team ready to provide customized customer support and efficient after-sales service, ensuring that every user’s interests are maximized.