In the smart factory, seamless communication from the “shop floor to the top floor” is the name of the game. This demands reliable, high speed networks when connecting, for example, brownfield as well as new machine and production environments, the so-called operational technologies (OT), with the IT and ERP systems. Real-time data captured by numerous machine sensors must be securely communicated to the cloud, people and machines throughout the organization and the supply chain.

The key to the success of these networks is the connectors that carry power, data and signals. These connectors must ensure high data rates and be able to withstand harsh production environments. However, being frequently plugged in and unplugged means they are at constant risk of a limited lifetime brought about by the contacts being damaged or worn prematurely.

CONTACTLESS DATA AND POWER TRANSMISSION

In response to these challenges, Rosenberger’s RoProxCon designers have developed an innovative contactless connector system that provides transmission that is not restricted by physical limits. Such freedom is achieved through a specially developed antenna concept. The focus is on simultaneous and bidirectional data and power transmission without having to compromise on mechanical flexibility.

Power transmission is based on resonant inductive coupling and data transmission is based on 60 GHz radio waves. This allows for a wear-free connection and these techniques can be used by a variety of different media. In this way, data in the Gbit/s range can be transmitted across an air gap regardless of the rotation angle. Moreover, the RoProxCon solution allows an angle deviation and a radial offset.

Typically, in industrial applications, there is no power supply on either side of a communication application. Therefore, in addition to high data rates, sufficient power must be provided for devices like proximity sensors and actuators. Rosenberger is working on a solution called the RoProxCon - Hybrid that can transmit up to 30 W of power while keeping the modules as compact as possible to enable the optimum usage of the installation space. Rosenberger also supports implementation in a particular customer application. Ethernet-based transmissions such as PROFINET, EtherCAT or EtherNet/IP can be easily integrated and implemented using suitable adaptor circuits. In addition, proprietary IO signals or fieldbuses can be utilized. The RoProxCon - Hybrid also offers safety features such as foreign object detection and active receiver detection.

PORTFOLIO OUTLOOK AND VISION

The RoProxCon portfolio from Rosenberger comprehensively addresses the typical limitations of conventional connection solutions in industrial environments. This reflects the company’s in-depth market- and customer-oriented product development ethos, combined with more than 60 years of company experience in connector technology. This heritage allows Rosenberger to provide maximum flexibility for easy integration of new application possibilities, which is another important requirement.

With these requirements in mind, Rosenberger offers the RoProxCon System-on-Module (SoM). It can be easily customized to suit individual customer transmission needs, from board to board or device to device. The specially designed antenna that is integrated into the SoM enables new solutions for a range of applications where the use of conventional systems would usually require performance or price compromises. In contrast to conventional systems, a user can twist and rotate this system in any direction.

The SoM is based on the ST60A2 from STMicroelectronics. The ST60A2 is a radio transceiver chip that can transmit data at 60 GHz with speeds up to 6.25 Gbps. This IC allows solutions with very low power consumption and latencies as low as 7 ns to be implemented into networks. These performance levels have become very important for real-time industrial applications. The partnership between STMicroelectronics and Rosenberger makes it possible to integrate the knowledge and strengths of both companies into the product development process.

The results of this collaboration are a portfolio of cost-optimized products with maximum functionality for the customer. In addition to solutions for new applications, a cost-effective retrofit solution for a straightforward plug and play upgrade of existing systems can be achieved by using various RoProxCon adaptors and cable connections. This allows existing factory plants and systems to be upgraded with minimal technical and regulatory effort, directly benefiting customer total cost of ownership.

CONCLUSION

Thanks to its innovative mechanical decoupling design and the resulting flexibility, combined with uncomplicated integration, Rosenberger’s RoProxCon transmission system offers significant advantages for networking the factory of the future. The new connection system allows endless rotation and opens completely new applications and perspectives for developers. The RoProxCon product portfolio addresses data and power in a hybrid solution and Rosenberger believes that it will become the choice for maximum performance with maximum flexibility.

Rosenberger is one of the world’s leading manufacturers of impedance-controlled and optical interconnect solutions. The portfolio includes solutions in high frequency, high voltage and fiber-optic technology for mobile communication networks, data centers, industrial measurement technology, automotive electronics and high voltage contact systems, medical electronics and aerospace applications.

Rosenberger
Hochfrequenztechnik GmbH & Co. KG
Fridolfing, Germany
www.rosenberger.com