The development of connectors is influenced by three trends: digitalization, decentralization and miniaturization. With decentralization, more and more functions in the industrial environment are moving to the device and field level, which means that there will be an increasing need for continuous connections between devices along the horizontal and vertical axis of the automation pyramid. This also includes the addition of intelligent functions. The integration of sensor and diagnostic functions directly into the connector opens up new fields of application and eliminates the need for additional sensors. Measured variables such as current, voltage, power and temperature can be recorded and saved and evaluated via an app, an ERP/Scada system or a cloud. Weidmüller is presenting such an intelligent connector at the Hannover Messe. The smart connector was developed as part of the "Intelligent electrical connectors and connection technology with electronic signal processing (ISA)" funding project of the BMBF (Federal Ministry of Education and Research).

Smart connectors in practice

Connectors and electrical connection technologies play a central role in the networking of tomorrow's production. They are the main interface between machines, control systems and data processing systems and therefore form the basis for the functions, ease of use and reliability of automation technology. The smart connector can be located in the connecting cables of production systems, modules or islands. It is used for power supply as well as signal and data connection to the SCADA or ERP level.

Current, voltage and power are recorded as measured variables in the smart infrastructure connector. The maximum current is 3 × 72 A. The voltage is measured directly at L1-L3 without galvanic isolation. Temperature detection is also integrated. The plug connector is also designed for industrial environments. Its temperature range is between -40 and 125 °C, the permissible voltage is 3 × 230 V AC at a signal frequency of 50 or 60 Hz. The current is measured using Hall sensors, i.e. without interrupting the circuit.

Plug-in cycle counter for safe operation

The number of mating cycles determines, among other things, the function and wear of a connector. Weidmüller therefore implements a counting function with an energy-autonomous piezo-based miniature system. This works as follows: The force applied during the mating cycle generates an energy to supply the downstream electronic system with power. The energy converter is located in the force flow of the mating system - in or on the connector. The energy supply activates the electronic counter. Plausibility criteria are used to validate whether the plugging process has been carried out safely. If validation is successful, the counter is incremented by one. The absolute value is saved in a non-volatile memory. When the specified maximum number of plugging cycles is reached, a visual mark is made on the measuring system. The meter reading can be read contactlessly via an RFID interface. The system is supplied with power via the RFID interface during the reading process.

With the functions of the intelligent infrastructure connector, Weidmüller enables an increase in efficiency during installation and commissioning as well as in the reliable operation of machines and systems. The smart connector from the ISA project therefore helps to improve production.