Modern manufacturers are focused on streamlining production line operations and minimizing costly downtime. Engineers are seeking ways to improve product quality and performance, address safety and communication protocol challenges, and optimize space usage in assembly lines with limited design space. This article will introduce Single Pair Ethernet (SPE) technology, which addresses industrial automation connectivity issues, along with the related solutions and product features offered by Molex.
Single pair Ethernet technology breaks the physical space constraints of cable and connector technology
With the development of Industry 4.0 or the Industrial Internet of Things (IioT), the benefits of smart interconnected equipment have already been demonstrated. However, to fully realize the vision of seamless sensor-to-cloud Ethernet connectivity and harness the advantages of the industrial metaverse, significant infrastructure challenges must be addressed, and SPE technology is providing the solution.
Ethernet technology, based on TCP/IP, is typically used to connect the cloud, ERP, MES, production cell, and machine-level controls. However, at the sensor and actuator level of these systems (located at the edge of the ecosystem), many devices still cautiously connect to another fieldbus, which then bridges or gateways the data onto the Ethernet. As a result, end-users require additional programming and hardware to support these fieldbuses, leading to extra costs, which in some cases, becomes a practical barrier to adopting smart technologies. For this reason, it is fair to say that the industrial metaverse and IIoT face a "last meter" problem.
To help address these issues, the SPE Industrial Partner Network was established in 2019. The mission of this alliance is to unite the entire industry under a new network standard, and today, it has more than 50 member companies, making it a veritable who’s who for cabling and connector suppliers.
SPE stands for "Single Pair Ethernet," and as the name implies, its core innovation lies in reducing wiring, using just one twisted pair instead of two or four cables. Clearly, the advantage of this arrangement is that it significantly reduces the weight and diameter of cables, making them particularly flexible and easier to routing.
But SPE also addresses other major pain points in industrial networking: bandwidth, power, and reach. The technology supports transmission speeds of up to 1 Gbps, with cable lengths reaching 40 meters, and the power over data line (PoDL) capability can supply up to 50W over a single cable, allowing for the transmission of more data and power with fewer lines compared to older technologies.
Even more impressive is that SPE supports transmission at 10 Mbps over cable lengths of up to 1,000 meters, ten times the length of traditional industrial Ethernet. Moreover, the electronics associated with the receptacle have already undergone size optimization, making it easier to fit SPE ports into tight spaces. Supporting PoDL with fewer wires facilitates connector miniaturization, thereby addressing one of the main barriers to Ethernet networks being equipped with sensors—the physical space limitations inherent in previous cable and connector technologies.
T1 SPE connector system for high-speed data transmission and power over data lines
Until now, achieving high-speed data transmission required using two twin wires for Fast Ethernet (100 MB) or four twin wires for Gigabit Ethernet. Molex's T1 SPE Connector System and cable assemblies enable Ethernet data transmission using just two wires, while also delivering power to terminals through PoDL technology, with power levels up to 50W.
Manufacturers increasingly rely on the IoT and IIoT to operate their production facilities. To fully harness the advantages of IIoT, a cost-effective and reliable method of integrating sensors and actuators from the field to the cloud is crucial. The Molex T1 SPE Connector System and cable assemblies provide a barrier-free connectivity for equipment, sensor/actuator technologies, and more, through IP-based end-to-end communication.
As the number of smart devices in the factory floor increases, the sensors and other equipment required for IIoT shrink in size, necessitating smaller wiring and interfaces. Additionally, the proliferation of smart devices and sensors in industrial environments makes cable management more challenging. Molex's T1 SPE cable assemblies use only one twisted pair with a wire gauge as small as 26 AWG (T1 SPE IP20) and 22 AWG (M12 T1 SPE IP65/67). Customers can more easily install these small and flexible T1 SPE cable assemblies from Molex, which are lighter in weight and lower in cost due to the reduced copper required.
The Molex T1 SPE Connector System and cable assemblies support two circuits and a current density of 4.0A, offering faster data transmission rates. The single-pair Ethernet setup allows for Ethernet data transmission with just two wires while powering terminals via PoDL, delivering up to 50W. The ability to integrate Ethernet interfaces with simple sensors, cameras, reading/ID devices, or similar equipment makes it feasible to implement industrial and IIoT solutions.
T1 SPE uses TCP/IP-based end-to-end communication, with standardized T1 SPE connections enabling the deployment of smart technologies in the field level, and simplifying parameter settings, initialization, and programming. As a result, device set-up, operation, and maintenance become more efficient and cost-effective. T1 SPE also provides pre-assembled cable assemblies, reducing implementation time through plug-and-play connectivity, eliminating the need for source cable assembly, tool investment, and cable testing.
T1 SPE cable assemblies use only one twisted pair with a wire gauge as small as 26 AWG and 22 AWG, supporting miniaturization and allowing customers to more easily arrange the wiring of small, flexible cable assemblies. These cables are lighter in weight and lower in cost. The T1 SPE cable assemblies feature two contacts plus a shielded through-hole jack, supporting easy wire-to-board connections with shielding that ensures excellent signal integrity.
T1 SPE cable assemblies are halogen-free, oil-resistant, and flame-retardant, designed to withstand harsh industrial environments. Its TCP/IP-based end-to-end communication allows a barrier-free connectivity for equipment and sensor/actuator technologies. T1 SPE is available as IP20-rated plugs, jacks, and cable assemblies, offering protection against objects smaller than 12.00 mm and is touchproof.
Rugged and compact micro-change M12 sealed connectors
Molex has also introduced the Micro-Change M12 connectors, which are rugged and compact sealed connectors, designed for sensor/actuator connectivity in industrial control applications.
The Micro-Change M12 connectors feature a threaded locking mechanism, supporting IP67 NEMA ratings, in compliance with industry standards developed according to IEC specifications. These connectors are engineered with exceptional quality to withstand harsh industrial and environmental conditions, ensuring highly reliable connections for control components in automation equipment. These premium connectors allow for easy and fast replacement of sensors, encoders, switches, and other input/output devices in industrial machinery.
The comprehensive Micro-Change product range includes 2, 5, 8, and 12-pole IEC compliant configurations, designed with both single-keyway and dual-keyway options (available in straight and 90° plugs), providing a complete connectivity solution. Molex has expanded the applicability of M12 connectors by introducing Harsh Duty receptacles, allowing them to handle more challenging environmental conditions. The Brad Micro-Change M12 Harsh-Duty receptacle offers sealed connections with superior EMI/RFI shielding in high-vibration systems, making it particularly suitable for petrochemical and Class 2 commercial vehicle applications.
Micro-Change products feature Harsh-Duty receptacles, designed with a rugged die-cast construction and in compliance with IEC 61076-2-101 standards. The durable housing provides superior protection against electromagnetic interference (EMI) and radio frequency interference (RFI), and meets CE industrial requirements. Its water-tight panel mount design ensures the housing meets NEMA 6P and IP67 protection ratings.
The Micro-Change products are anti-vibration to prevent decoupling, maintaining a secure connection even in extreme vibration conditions. They utilize a gold-over-palladium/nickel plating design, offering durable and outstanding electrical contact performance. The M12 design adheres to IEC standards, making the industry-standard interface compatible with a wide variety of sensors and switches. Additionally, it offers a complete LED machine lighting solution, with the machine lights package including LED lights, mounting brackets, M12 cordsets, and connectors. The entire lighting system is streamlined into a single order number, simplifying the ordering process. With a rated voltage of 250V AC/DC and a current capacity of up to 4.0A, it is ideal for Class 2 power and network circuit applications.
Brad M12 power L-code connector system meets miniaturization needs
The development of Industry 4.0 demands better connectivity to support more connections/nodes and provide greater power. Ethernet on the factory floor is the trend for the future (i.e., digital manufacturing). As the power requirements of manufacturing plants increase, space continues to shrink. Molex's Brad M12 Power L-Code Connector System lays the foundation for new standard equipment connections, saving space and keeping pace with the miniaturization trend driving Industry 4.0.
The Brad M12 Power L-Code Connector System complies with PROFIBUS standards and PROFINET International (PI) standards for PROFINET systems, providing the power needed to drive Industry 4.0 equipment with a compact form factor and reliable performance. Molex’s WSOR (Weld Slag and Oil Resistant) cables offer protection for wiring assemblies and systems in harsh environments.
The Brad M12 Power L-Code Connector System supports two options: 63V at 16.0A with M12 size at 2.50mm², and 63V at 12.0A with M12 size at 1.50mm². The Brad M12 Power L-Code Connector conforms to the new PROFINET application standards, including IEC 61076-2-111, and is PNO certified/approved, making it fully compatible with competitors' M12 Power L-Code products.
By leveraging Molex's precise manufacturing processes, the pre-assembled system reduces wiring and assembly errors, saving valuable time. Additionally, the Flamar WSOR cable provides further protection to the entire wiring assembly and system, even in the harshest environments. The Brad M12 Power L-Code Connector offers a sealed IP67-rated interface, capable of withstanding harsh and wet industrial conditions, including dustproof connectors that can be submerged in water up to 1 meter for short periods. The L-Code mating interface prevents mis-mating with other M12 connectors used for input, output, signal, or industrial network connections.
The Brad M12 Power L-Code Connector System supports 63V AC/DC with up to 16.0A per pin, delivering four times the power of standard M12 connectors. It allows for longer installation distances and reduces voltage drops caused by thicker 2.50mm² wires. The pins are sealed within the contact carrier, eliminating the risk of electric shock from exposed pins, thus enhancing operator safety.
The Brad M12 Power L-Code Connector System, which complies with PI standards, can be immediately implemented into PROFINET applications, saving time and cost. The product is developed in accordance with IEC 61076-2-111 standards, designed to create open industrial connector standards that facilitate the acceptance of a broader range of platforms by manufacturers.
Conclusion
SPE technology breaks through the physical space limitations of cables and connectors, significantly reducing the weight and diameter of cables, making them particularly flexible and easy to route, while providing greater bandwidth, power, and coverage. This will be a key development direction for industrial automation applications. Molex has introduced several industrial-grade connector and cable solutions for industrial applications, featuring optimized performance and compact designs. These solutions offer a variety of circuit sizes, plating, mounting options, and mating heights to support customers' diverse dynamic requirements. They will ensure long-term reliability and safety for smart manufacturing. The space-saving design increases production line flexibility and reduces downtime, making it an ideal choice for industrial automation applications.