Automation & Control Products

Omron’s 4-pole relay fits on a PCB to reduce the heat generated in three-phase power electric vehicle wallboxes during high-power charging. More people are transitioning from internal combustion engine to electric vehicles to reduce carbon emissions. As EV numbers increase, more reliable and high-speed EV supply equipment and chargers are needed.

Charging speeds have improved, but higher charging currents require higher-rated electronic components that generate more heat in the EV wallbox charger. This heat generation limits many home chargers’ useful lives, but Omron has developed a high-power PCB relay—the G9KC—to promote faster charging without the extra heat.

High Temperatures Challenge EV Wallboxes

An EV wallbox is installed in people’s driveways and garages to allow charging at any time. Wallboxes vary in charging speeds, depending on access to single or three-phase power. Three-phase power is an AC circuit with three wires, with each wire’s voltage phase-shifted by 120 degrees relative to the other wires. Three-phase power can accommodate higher loads, allowing higher-powered charging points.

The usual charging speeds for home wallboxes range from 3 kW to 7.4 kW for single-phase power. Wallboxes with much higher charging speeds can be installed for homes with three-phase power, but the specific values range by geographical location. For example, in Europe, three-phase power wallboxes range from 11 kW up to 22 kW, whereas in the U.S., they range from 9.6 kW to 19 kW. 

Naturally, higher-powered circuits give off more heat as an operational byproduct of the components. High heat is typically generated from the relays within the wallbox because these components have a high contact resistance, which helps generate a larger current and more heat. The result increases the wallbox’s internal temperature.

Wallbox heat generation. Image used courtesy of Omron

However, high temperatures significantly impact the wallbox’s charging performance and efficiency and can cause temporary power limitations. The heat suppresses the charging current, leading to longer charging times. Increasing the number of elevated heat cycles the wallbox experiences often causes the internal components to degrade and fail prematurely.

Because higher power systems produce more heat, it’s difficult for EV infrastructure designers to balance the heat generated with the need to provide a high charging power. Current wallbox designs have reduced size and are often enclosed in completely sealed units to prevent water from entering. Smaller units are even more susceptible to internal heat spikes.

Taking Away the Heat

Omron has developed and released its G9KC relay with a mechanically coupled, double-break contact design for three-phase high-charging wallboxes. The relay can reduce the operating temperature in wallboxes up to 22 kW while improving the charging process’ efficiency and speed.

Diagram of 3-phase EV charger. Image used courtesy of Omron

The relay uses a 4-pole structure to replace the traditional, larger multipole contractors in wallboxes. The relay has an initial contact resistance of less than 6 mΩ, which reduces the chance of localized hotspots forming within the wallbox to prevent component deterioration and wallbox failure. The G9KC also has a low operation temperature, which decreases the number of charge cycles that reach the charging current throttling thresholds.

The G9KC is also small. Contractors are bulky units, but the G9KC relay can be used on a printed circuit board (PCB) to create smaller, lighter designs. The G9KC has received approval from various certification bodies, including UL/C-UL, TUV, and CQC. It has been designed to meet the specifications of IEC 62955—Residual direct current detecting device (short circuit capability) and IEC 61851-1—Electric vehicle conductive charging systems.

Benefits Beyond Thermal Dissipation

While thermal dissipation is a key challenge with EV wallboxes, the G9KC also has several other advantages for wallboxes. It can reduce charging time because heat suppresses the charging current, decreasing the chance of overheating. The G9KC also enables smaller and slimmer wallboxes. 

While the relay has been designed for EV wallboxes, it is a versatile component that can be used to perform input/output switching operations in many other devices, including photovoltaic inverters, industrial inverters, energy storage systems, DC quick chargers, and uninterruptible power supplies.

IDEC introduced its ez-Wheel Assist Wheel Drive (AWD) EW1A Series, a solution providing electrical motion assistance for industrial manual material handling equipment.

As per a press statement from IDEC, with the help of an EW1A, workers can safely move heavy loads, increasing productivity and efficiency. The EW1A reportedly addresses safety issues with an integrated electric motorized wheel solution that is retrofitted onto existing trollies or designed into new equipment.

The EW1A system consists of a few modular components, with numerous options to satisfy new equipment designs, or aftermarket retrofits by maintenance personnel. The main drive unit is available with 150mm or 160mm resilient polyurethane wheels, and the ability to support a vertical working load up to 400kg, and to transfer loads up to 1000kg. A suspension bracket provides an adaptable way to add the main drive unit to upgrade any equipment.

All models can accept internal batteries, which are recharged with a specific cable and charger. However, for greater capacity designers can alternately choose to use an external battery pack by means of an adapter cable. Batteries operate at a nominal 24V DC, with capacities ranging from 3Ah to 15Ah, depending on the model. The wheels operate at about 0 to 5km/hr (0 to 3mph) in both directions and are available with adjustable braking modes and an option parking brake. The wheels are rated for indoor use, in non-freezing temperatures and up to 40°C.

Two controller options are available. The standard controller is a compact panel, much like a pendant control but fixed-mounted, with an on/off button, forward/reverse speed control thumbwheel, and a lighted or unlighted emergency stop button. A two-handle-type controller is also available with the same functionality implemented into a pair of handles, which can be oriented vertically or horizontally as needed. The handle-type controller is available with or without a battery charge status LED indicator. ez-Config software running on a PC and connected using a standard USB cable lets users configure operating parameters, such as forward/reverse speed, acceleration time, deceleration mode, assist time limit, time to sleep mode, and more.

The IDEC ez-Wheel Assist Wheel Drive EW1A Series can reportedly be retrofitted on any existing moving equipment as an aftermarket solution, to upgrade and update working capabilities.

Remote control is a risky business for industrial automation, but the ability to remotely monitor, asses failures, and clear faults has been expanded from robotics to PLC systems by Olis Robotics.

Olis Robotics, the champion of remote troubleshooting, diagnostics, and fault elimination, has recently expanded the system scope to include PLC-connected I/O devices, in addition to robotic arms, providing exceptional downtime elimination control throughout an entire production system.
 
Remote Monitoring

Robotic cell control and programming is nothing new, even with the advent of collaborative robots (cobots). Similarly, PLC wiring and programming is a well-established field of study. Modern advancements in such systems must now revolve around the elimination of the unknowns: those rare anomalies that cause faults and costly downtime. Identifying and removing these problematic scenarios is an ongoing challenge.


Olis Connect is now available for PLCs. Image used courtesy of Olis Robotics

Olis Robotics is a pioneer in the field of diagnostic fault recovery and elimination, providing a literal view into the process to both diagnose the fault and recover operations to working condition remotely. Until now, this system has been specialized for industrial robotic cells, but recently, the scope of Olis coverage now includes the PLCs that drive the process beyond the robot.
 
PLC Diagnostics

Understanding robot faults has been an excellent first step in Olis' strategy to detect and solve problems. However, the challenges associated with robots alone only present a portion of the true root cause analysis. The PLC is responsible for collecting the I/O signals and sending motion commands to simple conveyance or precise multi-axis systems. It’s critical to understand how each of these systems is operating around the robot before a cause can be firmly established.


Olis hardware consists of processing (IPC), networking (secure industry-standard hardware), and visual verification (camera systems). Image used courtesy of Olis Robotics

In the end, safely jogging the robot and restarting the cycle may be the immediate solution, as identified by Olis in the past, but being able to expand the scope of inspection to the PLC allows much deeper diagnostic analysis.
 
Data From the PLC System

As of now, the Olis system is compatible with PLCs from Rockwell Automation, a leader in the North American PLC market, but upcoming plans predict expansion to many other brands. In the beginning, a similar strategy progressed Olis beyond the initial robot product offering to allow compatibility with Universal Robots, FANUC, and Kawasaki brands.


Olis Connect is now able to diagnose faults in both robotic and PLC systems. Image used courtesy of Olis Robotics

In true PLC form, the data visibility can provide insights from local and field I/O, motor/motion control tags, and memory registers, creating a comprehensive look into virtually any important data point within the PLC system. Any data point that might indicate a fault or alert can trigger a response from a remote engineer and return the system to faster operation, saving countless dollars of costly downtime.

As with the robotic solutions, the goal is primarily to remove faults and restore working condition, not necessarily to provide an easy ‘remote control’ access. Remote access introduces security risks for the safety of the process and Olis has taken extreme measures to ensure that any jogging or cycle starting from any motion platform (including robots) is only performed under verified safe conditions.

Similarly, with cyber security, the Olis team takes measures to update and deploy measures to prevent unauthorized access, as would be desired with any network connection to an industrial automation cell.

Littelfuse built the new solid-state relay family to meet the rigorous reliability requirements of commercial and industrial machinery.Littelfuse has released the SRP1 solid-state relays (SSRs) family to meet customer demand for more reliable switching performance that reduces downtime in industrial and commercial machinery.

Traditional mechanical relays are often prone to failure when subject to prolonged use in challenging environments. The solid-state architecture of the SRP1 family addresses these limitations and is engineered for durability over extended periods of use in harsh environments. 

According to Littelfuse, the key to the new relays' performance is a proprietary power component that is resistant to heat degradation and designed for high-frequency switching over extended periods of time. This results in fewer field failures and less costly equipment downtime.  

The SRP1 SSRs are available in five configurations for easy installation and design flexibility across various applications, including industrial automation machinery, HVAC, and food and beverage equipment.

The Basics of the New Solid-State Relay's Operation

The SRP1 SSRs quickly block or pass AC line power to downstream equipment loads, such as cooking ovens, hot drink dispensers, traffic lighting control, HVAC equipment, plastic and packaging machinery, industrial ovens, and electronics production equipment.

At the heart of the SRP1 SSRs are power diodes and optical isolation circuitry (rated to 4000 V_rms) that consists of light-emitting diodes (LEDs) and photodetectors (PDs). The diode IP comes from the IXYS power semiconductor portfolio, including a range of rectifiers, fast-recovery diodes, and other diode types. The IXYS power circuitry within the SRP1 can support AC load currents up to 90 A at low or high voltages (up to 660 V, 50–60 Hz).

SRP1 functional block diagram. 

The relay is controlled by either an AC or DC signal (depending on the model type) applied to its input terminals, which is passed across the optical isolation boundary to open or close the relay and control AC power to the output load.  

The SRP1 series operates with either instantaneous (random turn-on) or zero cross-switching. For instantaneous switching, the relay turns on immediately regardless of the AC output cycle, while zero cross-switching coordinates the switching with the zero crossing of the AC load signal. The latter helps mitigate the generation of interfering signals from switching under load.   

SRP1 switching properties.

According to Littelfuse, with no moving parts subject to wear and tear over repeated use, the SSRs offer two to three times more life endurance cycles than conventional relays. In many cases, solid-state relays can also open and close faster than their electromechanical counterparts.   

Key Capabilities of the SRP1

Littelfuse engineered the new SRP1 relays to minimize operational disruptions due to equipment failure or maintenance, allowing customers to focus on efficient operations. Equipment uptime is critical to cost-efficient operations, making the SRP1's specified endurance the headline feature of the SSRs. Littelfuse designed the SRP1 series to support up to 750,000 life cycles, more than twice that of standard SSRs.

SRP1 lifecycles.

The SRP-1 series incorporates IP20 finger-safe protection and overvoltage protection to help with safe installation and is compliant with UL and IEC international standards governing safety and electromagnetic compatibility. 

All images used courtesy of Littelfuse.

Nexperia has introduced a new series of 4- and 8-channel analog switches designed to monitor and protect 1.8V electronic systems. This series of multiplexers includes AEC-Q100 qualified variants as well as standard versions. The control pins in the NMUX1308 and NMUX1309 switches operate independently of their power supply voltage range, negating the need to use additional components. Fail-safe logic and a power-off protection feature permits control and analog pins to be biased prior to system power-up and remain biased even after the system has powered down. These devices integrate injection current control circuitry, limiting output voltage shifts on the active channel to less than 5 mV when an overvoltage event happens on disabled signal channels. Standard (-40°C to +85°C) and automotive-qualified (-40°C to +125°C) versions are available in leaded and leadless options, including a leadless package which supports automated optical inspection for automotive applications.

Werock Technologies has introduced the Rocksmart RSC622. This model has a 21.5-in. display with up to 1200 cd/m2 brightness and complements the existing RSC610, RSC612 and RSC616 models. The Rocksmart RSC622 features an aluminum housing with IP65 front panel protection for optimal use in harsh indoor and outdoor environments. The Rocksmart RSC622 weighs only 5.6 kg and is equipped with passive cooling and a wide operating temperature range to support in-machine and free-standing installation with VESA mounting points. It also features a gesture-enabled multi-touch screen and pressure-sensitive single-touch screen. Like all models in the Rocksmart RSC600 series, the latest model is based on thE Intel Elkhart Lake Celeron 4-core processor with 10 nm lithography. An optional AI processor is available as well as communication for fieldbus, while real-time Ethernet protocols can be optionally supported as master or slave.

Epson Robots expanded its 6-Axis robot lineup with its new C-B Series powered by the RC700E controller with integrated SafeSenseTM technology. The series includes the C4B, C4LB, C8LB, C8XLB, and C12XLB.

The C-B Series reportedly offers performance and flexibility in a compact footprint. It features advanced GYROPLUS vibration reduction technology for fast production speeds and smooth motion control.

The C-B Series offers multiple arm configurations with a reach of up to 1,400 mm. The products support payloads of up to 12 kg while maintaining a small form factor. The RC700E controller, featuring SafeSense technology, reportedly allows for safe human-robot interaction through safety-rated speed and position monitoring combined with a proper risk analysis.

Combined with no-code Epson RC+ Express software, users can create industrial collaborative solutions with speed and repeatability.

WAGO launched a new Remote IO campaign on Aug 5. The message from the campaign focuses on WAGO’s Remote IO as the winning hand in industrial automation.

The company shares that its 750/753 Series Remote I/O system provides the confidence to go all-in on your automation application. It features 16 fieldbus options and interoperability with higher-level PLCs. These modules reportedly offer a flexible, modular, and compact platform for stand-alone or distributed automation.

Customers have the option to choose from over 500 simple and complex modules that allow for easy data acquisition from almost any signal. Cost-effective system upgrades can reportedly be made for energy monitoring, IO-Link masters, and proportional valve control, to name a few.

WAGO explains in a press statement that whether it’s a need for digital or analog, it ensures that customers will get only the I/O needed for their application within a small, compact footprint. The company’s patented CAGE CLAMP technology, and its extensive range of marking systems, allow these modules to be wired easily and also provide for a vibration-proof, maintenance-free connection.

Binder has launched an M8 12-pin circular connector. This product complements the existing M8 series and sets new standards for applications in industrial sensor technology, measurement, and control, technology, camera technology, and robotics. The circular connector offers significant advantages, particularly in terms of miniaturization, flexibility, and performance.

Modern machines and automation systems are becoming smaller and more powerful. To design devices efficiently, all components, including connectors, must take up as little space as possible. Several factors drive the industry's demand for compact connectors, including space savings, higher packing density, flexibility, modularity, cost efficiency, improved performance and reliability, user-friendliness, and ergonomics.

Space-saving and Continuous Plug Compatibility

"The future of automation lies, among other things, in miniaturization, for which we are already very well positioned with our portfolio of smaller sizes such as M5 and M8. One of the advantages of M8 is that it requires 20 percent less space for adjacent connectors compared to the next larger series," explains Guido Werner, product manager at binder.

The new edition of the design specification for M8 circular connectors with screw or snap-in locking DIN EN 61076-2-104 also includes the C-coding. "This lays the foundation for continuous plug compatibility in the connector market. New possibilities in signal transmission arise for M8," says Guido Werner.

Despite the high number of contacts, the M8 12-pin circular connector remains compact, making it ideal for applications with limited space. The high contact density allows for versatile use in a wide range of industrial applications. With IP67 protection, it is well-suited for harsh industrial environments. The support of C-coding and adaptability to future standards and requirements make it a future-proof solution.

Customer Demand was the Initial Spark – and Challenge

Specific customer requirements initiated the development of the M8 12-pin circular connector. A major customer demanded a new generation of length measurement systems that could transmit more than eight signals without increasing the compact size of the M8 circular connector.

"The development of the M8 12-pin connector posed several technical challenges for our design and development team. One of the biggest tasks was to fit 12 pins on the compact M8 connector face. This was achieved through a symmetrical arrangement of the contacts and the introduction of five small coding steps. This solution enables secure polarization and protects the sensitive contacts from damage. In production, manual pre-assembly requires a delicate touch. Ultimately, we successfully mastered all challenges through trained personnel and the use of color templates for precise placement of the wires," explains Guido Werner.

Already Successfully Used in Various Applications

The M8 12-pin circular connector is now a logical addition to the binder standard product portfolio. Leading manufacturers already use M8 12-pin connectors in length measurement systems and laboratory automation for environmental analytics. M8 12-pin connectors are also integrated into industrial cameras from well-known manufacturers.

About binder USA, LP

binder USA, LP, is a subsidiary of binder Group, a leading global manufacturer of circular connectors, custom cordsets, and LED lights. binder USA products are used worldwide in industrial environments for factory automation, process control, and medical technology applications. Defined by technical innovation and traditional values, the binder name is synonymous with the highest standards of quality and reliability. The company’s quality management system is ISO 9001 and 14001 certified, but it is a solution-focused approach to customer applications and commitment to superior service that truly differentiates binder from the competition. 

For more information, visit www.binder-usa.com, email This email address is being protected from spambots. You need JavaScript enabled to view it., or call 805.437.9925.

Premier Tech launches the next generation of its popular CHRONOS OMR Series Robotic bagging machine, previously known as the PTH and PTW Series. This automated solution, ideal for packaging free-flowing products such as animal feed, sugar, nuts, seeds, grains, and more, is designed to empower businesses to start their automation journey or tackle workforce challenges.

One of the most notable upgrades is the enhanced robotic system, which features a 30% increase in payload capacity. This enhancement results in higher throughput and ensures a 98% uptime for reliable operation. The new user-friendly HMI enables operators with minimal technical knowledge to easily create new recipes and efficiently manage the machine.

The CHRONOS OMR Series excels in consistent production. This bagging machine offers some of the best rates in the entry-level category–up to 20 bags per minute! It adapts to frequent recipe and bag size changes, reducing repetitive manual labor tasks. These improvements make it reliable for stabilizing production and maintaining high throughput, even with high workforce turnover.

Finally, the Premier Tech CHRONOS OMR Series delicately handles both products and their bags. The filling process preserves the quality of high-value products while reducing dust emissions. Advanced gusset control features maintain the bag's position throughout the process, ensuring proper filling and sealing.

By introducing these enhancements for a simple, reliable, and low-maintenance packaging process, Premier Tech continues to lead the industry in innovative robotic solutions that enhance productivity and quality while maintaining low worker intervention.