Visions of a factory conjure up a large space, big machinery and many people working hard to keep products rolling on the production line. 

Modern manufacturing introduces challenges that often can’t be addressed through expansion of physical space. The vast majority of manufacturers can’t afford to tear down and rebuild factories to incorporate the latest ideas and capabilities.  

Modern manufacturing leveraging Industry 4.0 means more data, faster analysis, Internet of Things (IoT) and advanced embedded technologies like machine learning and computer vision. Together they transform the process of making products, parts, components and assemblies by making all parts of the manufacturing processes “smart.” 

It’s an added challenge to make manufacturing more efficient, effective, flexible and responsive — doing things never before possible — while supporting required workflows. 

Previous manufacturing facilities were designed to be productive, resilient and stand the test of time. In terms of traditional IT technology, supervisory control and data acquisition (SCADA) networks and physically connected industrial controllers were very typical. These technologies have limited bandwidth and may not take advantage of the latest technology advances as compared to Industry 4.0. 

Miniaturization plays an important role in incorporating new capabilities. By physically miniaturizing the technologies, they can more easily fit into the footprint of existing factories while delivering significant technology advancements. 

There’s a clear need to move beyond old technology to enable new capabilities. But a conceptual step must be taken first: Miniaturization everywhere — because the paradigm shift in factories requires a new, innovative approach to network architecture.

Not long ago, an advanced factory used sensors and industrial controller collected data from automated machines and equipment. The data was pushed out over proprietary networks that brought the information to central servers that ran the software to undertake analysis and provide reports to managers for analysis.

The current state-of-the-art factory involves highly decentralized networks using edge computing at the controller or even sensor level. Embedded circuits are specialized computers that can run sophisticated software, including artificial intelligence apps, to perform a first level of data processing. These edge devices transform the monitoring and control processes into collections of intelligent subsystems that pass along digested data in the form of information. The result is higher throughput of digital intelligence.

Decentralized network architectures and remote processing systems are in buildings that can’t be easily expanded to provide additional space. The network channels and all the control and monitoring devices, inside and outside, need to be as small as possible to operate at the functional and performance level required. 

Modern factories need the ability to move data from one area to another, collect the data and then process the data centrally. Add to this the need for Industrial Internet of Things (IIoT) applications to access available power that runs reliably and uninterrupted. The first basic step a facility can take toward becoming fully connected and integrated is to install networking and communications capabilities, including effective and efficient power delivery. 

IOT is the backbone of Industrial Ethernet, which can use Cat5e/Cat6 cables and standard networking hardware for up to 1 Gbps transmission rates. However, this too has limitations, such as the maximum covered space capping at a length of 100 meters. Industrial Ethernet typically uses M8 or M12 connectors, which seem large for some applications such as connections to sensors. There are repeaters, or an implementation could be run over fiber optic media, but these options are more expensive and harder to maintain and repair. Present cable versions support Power over Ethernet (PoE) at 15.4 or 30 watts per port using 4-pair cables for gigabit Ethernet. 

Single Pair Ethernet (SPE), a relatively new option for Industrial Internet of Things (IIoT) applications, is a superior solution. Rather than using 2-pair or 4-pair cables, one twisted pair does all the work to support 1 Gbps transmission rates and offers Power over Data Line (PoDL) up to 50 watts. Under the IEEE 802.3ch standard, transmission rates of up to 10 Gbps should be possible.

The reduced wire count enables miniaturization of connectors and electronics associated with the receptacle that are size-optimized — making it easier to squeeze SPE ports into tight spaces. In addition, SPE is compatible with existing Ethernet infrastructure, and single connectors providing both power and signal while simplifying design, reducing size and managing cost.

The next step is monitoring what is happening on the factory floor. Are products the right size and shape? Are there delays in the output of a machine? Maybe the factory wants to control automation or robotics in addition to collecting data.

With the right communications network in place, it is possible to add significant capabilities into the existing factory. Ethernet-compatible equipment can be made to work with SPE, so existing equipment can be connected to the network.  

Adding sensors and equipment to increase capability becomes relatively simple with this approach. For example, one of these boxes with a sensor that can register vibration can be placed on a machine to measure the vibration level. If the vibration measurement starts to increase, it could be a signal of an unbalanced load on a motor, a loose part or something that potentially signals a range of other malfunctions. Alternatively, a small video sensor can be added to measure infrared light to determine if a piece of produce passing on a conveyor belt displays hidden bruising. It can then signal a device to divert the damaged goods for separate processing.

Another solution to the signaling challenge is 5G communications, which brings with it the particularly attractive feature of handling high data rates using next-to-no cabling. 5G technology requires antenna arrays in individual devices throughout the factory to capture short-range transmissions. 

Molex has a long history of expertise and capability making assemblies, parts, connectors and cables small enough to accommodate all requirements, with a broad product line that addresses a multitude of industry needs. As an early entrant in SPE technology, Molex has a large team of experienced engineers that can help expand capabilities and intelligence by adding miniaturized connectors, wiring, sensors, or other technologies for smarter, more agile factories. The bottom line? Your factory doesn’t have to grow with the changing requirements of modern technology. In fact, it may even get smaller with the right approach.