Passive components are the foundation for achieving high performance and high reliability in industrial automation

Passive components play a critical role in the performance, safety, and stability of industrial systems

There are many types of passive components. They may seem insignificant in industrial automation applications, but they play a critical role in the performance, safety, and stability of industrial systems. In the field of industrial automation, polymer capacitors are the cornerstone of voltage stabilization for high-performance power supplies. Due to their excellent electrical performance, polymer capacitors have become key components for ensuring stable and clean power. Polymer capacitors are renowned for their extremely low equivalent series resistance (ESR). Compared with traditional capacitors, they generate less heat and need to feature high-temperature resistance, high ripple current capability, miniaturization, and long life, while also handling larger ripple currents to ensure voltage stability in high-load scenarios such as servo drive DC-Link, robot joint power decoupling, PLC power filtering, and motor drive smoothing. Their performance at high frequencies is also particularly outstanding, as they can effectively filter out high-frequency noise and protect sensitive circuits from interference.
 
In addition, power inductors are the core of high-efficiency power conversion. They often work closely with capacitors to jointly build efficient and stable power systems, and are one of the cores of modern power management technology. As the core of DC-DC converters, power inductors are responsible for storing energy when the switch diode is conducting and releasing energy when it is turned off, thereby achieving voltage step-up, step-down, and stable output. Advanced power inductors use low-loss alloy powder cores and flat wire coils, significantly reducing DC resistance (DCR) and greatly improving conversion efficiency. Their magnetic shielding structure can also effectively suppress electromagnetic interference (EMI), ensuring system electromagnetic compatibility.
 
The primary task of industrial power supplies is to be stable and reliable, capable of continuously outputting clean power even in harsh industrial environments with severe temperature changes, high humidity, high dust, and vibration. In addition, high power density design enables them to provide greater power within a smaller space, meeting the compactness requirements of equipment. More importantly, modern industrial power supplies are no longer isolated power supply devices, but intelligent nodes integrating communication functions such as EtherCAT and IO-Link, capable of proactively providing real-time operating data such as voltage, current, and temperature to support remote monitoring and predictive maintenance.
 
The core of Industry 4.0 is data, and wired communication devices are the key to building the data highway and the neural network of smart industry. In industrial sites full of strong interference sources such as motors and inverters, wired communication devices ensure reliable, real-time data transmission. Due to the severe electromagnetic interference in industrial environments, wired communication devices must possess strong anti-interference capabilities.

Polymer capacitors are the core components for achieving efficient, compact, and reliable designs

KEMET polymer capacitors, with their ultra-low equivalent series resistance (ESR), high ripple current handling capability, and high reliability in harsh environments, are widely used in various industrial automation equipment. They are core components for achieving efficient, compact, and reliable designs.
 
KEMET, targeting the core needs of the industrial automation field, primarily focuses on the following two technology routes of capacitor series: Hybrid Aluminum Polymer Capacitors and KO-CAP® Organic Polymer Tantalum Capacitors. Hybrid Aluminum Polymer Capacitors are "all-rounders" that balance performance and self-recovery, combining the advantages of high-conductivity polymer and liquid electrolyte to achieve a perfect balance between performance and reliability. The A780 and A782 series, as representatives of KEMET hybrid capacitors, are compact surface-mount devices offering operating voltages up to 63V and capacitance up to 680µF. They support a wide operating temperature range from -55°C to +135°C and offer vibration-resistant models capable of withstanding up to 30g vibration, making them ideal for high-vibration environments such as servo drives and robot joints. The PHA225 and PHH225 series feature axial and radial leaded packaging and can operate up to 140°C. They have extremely high ripple current capability and excellent self-recovery characteristics, commonly used in high-power scenarios such as DC-Link for 48V inverters.
 
KO-CAP® Organic Polymer Tantalum Capacitors are "performance champions" for miniaturization and low ESR. The core advantage of the KO-CAP series is that it combines, in one package, the low ESR of multilayer ceramic capacitors (MLCCs), the high capacitance of aluminum electrolytic capacitors, and the high volumetric efficiency of tantalum capacitors. This series features ESR as low as 4 mΩ, capacitance as high as 1500 µF, and can handle higher ripple current. Its broad product series meet various design needs, from general-purpose power filtering to automotive-grade high reliability. The T52X offers the widest range of voltage options from 2Vr to 75Vr, as well as a choice of capacitance and case sizes, and is optimized for input stage applications with power rails from 1V to 12V, 24V, and 48V. The T59X is automotive grade, while the T54X is the high-reliability HRA series, offering additional screening options suitable for mission-critical applications.

Power inductors achieve differentiated positioning in current capability, size, and cost

Pulse's BPXX, BMCA, BWVF, and BWVS series power inductors achieve differentiated positioning in current capability, size, and cost by employing different technologies such as magnetic glue shielding and molding. The BPXX series is a cost-optimized general-purpose power choke. It is a magnetic glue shielded wire-wound inductor designed to balance performance and cost, suitable for a wide range of general industrial scenarios. It effectively reduces electromagnetic interference (EMI), improves system stability, and offers a wide range of electrical specifications, with inductance covering 0.3µH to 1mH to meet various circuit requirements.
 
The BMCA series is an ultra-high-performance molded power inductor. It uses molded one-piece molding technology and is designed for demanding applications requiring extremely high current and very low losses. Its core advantages are ultra-high current and extremely low DCR. For example, a 1.5µH model has a saturation current (Isat) of up to 18A and a DCR of only 15mΩ; a 4.7µH model has an Isat of 10A and a DCR of 40mΩ. It features a one-piece molded structure. This closed magnetic circuit design not only achieves excellent shielding effects but also brings the characteristic of ultra-low audible noise, enhancing product experience, and supports a wide operating temperature range from -55°C to +125°C, offering strong applicability.
 
The BWVF series is a small-sized magnetic shield inductor that balances performance. It is a wire-wound inductor with magnetic shielding function, achieving a good balance between performance, size, and cost. The product has excellent magnetic shielding performance, effectively limiting magnetic flux leakage and reducing interference with surrounding sensitive circuits. It features a miniaturized design, available in various compact packages from 2520 to 4040, such as the 2520 (2.5mm x 2.0mm) package, suitable for high-density circuit boards, and supports an operating temperature range of -55°C to +125°C.
 
The BWVS series is a high-cost-performance molded power inductor. It is another molded one-piece inductor, positioned to provide a compact solution with high saturation current and low DCR. The product features high saturation current. Compared with wire-wound inductors of the same size, BWVS offers higher saturation current. For example, a 1.5µH model has an Isat of up to 7.1A. It also features a low DCR design; lower DC resistance helps reduce losses. For example, a 1.5µH model has a DCR of only 16mΩ. It is available in various flat packages such as 4040, 6060, and 8080, where the height of the 6060 package (6.00mm x 6.00mm) is only 3.00mm.

Power solutions provide a complete set of high-reliability guarantees for industrial automation equipment

The core advantage of YAGEO's power solutions lies in providing industrial automation equipment with a complete set of high-reliability guarantees from the "heart" to the "neural network," mainly covering four product categories: capacitors, inductors/transformers, power modules, and communication isolation components.
 
Aluminum electrolytic capacitors are the stable cornerstone of industrial power supplies. In industrial automation, 48V systems are becoming increasingly common. YAGEO's PEx227 and PEx228 series aluminum electrolytic capacitors specifically introduce an 80V voltage rating option for this purpose, filling the gap between 63V and 100V. They feature high capacitance (up to 10,500µF), low ESR, high ripple current capability, and stable operation in harsh environments up to 150°C. These characteristics make them ideal choices for DC-Link capacitors and bus filtering in servo drives, inverters, and motor control units.
 
As the core of power conversion, YAGEO provides a variety of magnetic components for efficient power supply design. For example, in a 4kW GaN power supply reference design, YAGEO's Flyback transformer and LLC inductor support operating frequencies up to 500kHz and currents up to 80A, achieving high efficiency and high power density in a compact volume. Additionally, for the driving needs of IGBTs and SiC MOSFETs, YAGEO also offers high-isolation SMT flyback gate drive transformers to ensure safety and reliability in high-voltage, high-frequency switching environments.
 
YAGEO also offers various modular isolated power supply solutions, making it easy for engineers to quickly build safe "energy islands." For example, the SA1 series DC-DC converter module provides 1W of power and up to 3kV isolation, covering a wide input and output voltage range from 3.3V to 24V, making it ideal for providing isolated on-board power for PLCs or industrial communication interfaces. For more complex or higher power requirements, YAGEO's HXE20xxHL series reinforced isolation transformer modules support operating voltages up to 1500Vdc and isolation up to 6000Vdc, designed for critical applications such as daisy-chain communication in high-voltage battery packs.
 
Due to the complex electromagnetic environment in industrial sites, YAGEO offers a rich selection for building stable and reliable communication networks. For example, the PH9085 series isolation transformers provide up to 2.5kVrms of isolation for fieldbus interfaces such as RS-485, CAN, and Modbus, effectively blocking interference. For industrial Ethernet applications, the HB/HXB series discrete LAN transformers support data rates up to 10Gbps and 90W PoE power delivery, providing at least 1500Vrms of isolation to meet the demands of Industry 4.0 for high-bandwidth, high-reliability networks.

Providing complete solutions for industrial automation wired communication

YAGEO's wired communication products in the industrial automation field primarily focus on physical layer isolation, signal integrity, and power over Ethernet (PoE) for industrial Ethernet communication, offering a complete solution from discrete magnetic components to integrated RJ45 connectors (PulseJack®).
 
In industrial automation, OT (Operational Technology) layer device (such as PLCs, servo drives, HMIs, industrial robots, sensors, etc.) demands extremely high real-time performance, reliability, and anti-interference capability for communication. YAGEO's wired communication products primarily address physical layer signal isolation (isolating the digital domain from analog/chassis ground), common-mode rejection and EMC performance improvement, supporting PoE (Power over Ethernet) power delivery, and adapting to harsh industrial environments (temperature, vibration, EMI).
 
YAGEO's discrete LAN transformer modules are suitable for industrial equipment requiring flexible layout or customized design. They are compatible with standard packages (e.g., 12.7 x 9.5mm, 17.6 x 15.9mm), easy to replace and upgrade, support wide temperatures (-40~85°C, some up to 105°C), and offer optional PoE levels to simplify power supply design.
 
Integrated RJ45 connectors (PulseJack® Integrated Connector Modules, ICM) integrate magnetic components + RJ45 socket + common mode choke + LED into one module, significantly saving PCB area and improving reliability. They save PCB area, reducing it by more than 30% compared to discrete solutions, simplify BOM and assembly by replacing multiple magnetic components and connectors with a single component, enhance EMC performance with internal shielding and common-mode design, support -40~85°C industrial temperatures, and feature high insertion cycle durability with 30µinch gold plating, exceeding 750 insertions.
 
PulseChip™ High-Power PoE Technology: For 90W PoE (4-pair power delivery) applications, Pulse introduces the new PulseChip™ drum coil structure (e.g., TCxG001P), replacing traditional toroidal coil solutions. It offers lower temperature rise, suitable for sealed or high-density industrial equipment; smaller footprint, supporting miniaturized design; higher current capability, supporting 90W PoE; and a non-polarized design, simplifying layout.

Conclusion

Although not as eye-catching as processors or sensors, passive components are precisely the physical foundation for achieving high performance, high reliability, and intelligence in industrial automation equipment. From the ultra-low ESR and high ripple rejection of polymer capacitors to the high-efficiency energy storage and magnetic shielding characteristics of power inductors; from the wide-temperature stable power supply of integrated power modules to the signal isolation and anti-interference transmission of wired communication components - each type of passive component silently supports the precise operation of the system from its respective "behind-the-scenes" role. The passive components launched by YAGEO for industrial automation applications will play a critical role in the journey of Industry 4.0 and smart manufacturing towards higher bandwidth, higher power density, and enhanced adaptability to harsher environments.