Interconnection
Interconnectivity is the building block for automated warehouses
By Manuel Rüter, principal, TE Connectivity
are not equipped to take in more data or provide greater functionality. As facilities evolve to Industry 4.0 and operations want to take advantage of technologies like AI and machine learning, sensors must be capable of more than a simple react/ respond functionality. As a result, sensors are increasingly being integrated within the system itself; in essence, the sensor becomes part of the control network. Integrating sensors within the control network also unlocks additional field-level functionality that operations demand.
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ndustrial automation today relies on technologies such as robotics, the Internet of Things (IoT), and artificial intelligence (AI), putting interconnectivity at the heart of smart warehouses. Interconnectivity is vital for collecting and analyzing data, driving improvements, and enabling automated systems that help operations run efficiently. The automation possibilities in today’s warehouses are nearly endless — from autonomous mobile robots (AMRs) and automated guided vehicles (AGVs) to automatic storage and retrieval systems (ASRS) and management systems. Automated systems can handle material storage, make decisions on material placement and inventory rotation, and order fulfillment tasks.
Consider just one aspect of the industrial automation revolution: the increasing number of AMRs in warehouse automation and logistics as warehouse operators look for ways to improve efficiency and performance. The global AMR market size
60 September 2023
is expected to grow at a compound annual growth rate of 33.11 per cent from 2023 to 2030, according to Research Reports World. Those AMRs require connectivity with many other devices and sensors inside of their facilities to operate as programmed. As operations integrate more sensors within industrial Ethernet networks for these types of solutions, they are unlocking greater capabilities and boosting the intelligence and efficiency of their facility. Let us explore the trends in high-speed data and interconnectivity and the role that Ethernet sensors play in automation advances.
The importance of interconnectivity As warehouses become more automated, all the components within — from machines and software to edge sensors and the cloud — must be seamlessly interconnected. This requires reliable, high-speed data and power transmission across the entire warehouse system. In addition, connectivity solutions must be designed as platforms
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with finely orchestrated communication between touchpoints.
This offers substantial potential for automated warehouses. By bringing together data from all the different sensors on the floor and integrating it in the cloud, operators can access the information they need to make their operation more efficient and uncover opportunities for improvements. These insights can also make the facility nimbler and more responsive, allowing automated systems to react in real time as the situation requires.
What role do Ethernet sensors play? For decades, most industrial sensors provided a trigger function to machine builders. If something moved in front of the sensor, it would trigger an alert telling the system that something was there. The interface for those basic sensors is a simple on-off signal wired to an I/O module. The sensor would trigger an alert; then an on-off signal was sent to the control so it could respond. However, these simple trigger sensors
Making sensors a node in the Ethernet network allows the sensors to communicate in the control language of the industrial Ethernet protocol used so they can more effectively perform high-level tasks. Code readers, machine vision, and position encoders are all examples of where these Ethernet sensors are in place today. Because they are an integrated part of the network, they can communicate almost seamlessly — making edge computing and cloud connectivity possible. The use of Ethernet sensors has grown significantly as the industry takes advantage of these advancements and the benefits they provide.
Other trends in warehouse automation also impact the move toward using Ethernet sensors. For example, AGVs are built to be nimble and small, which means the components inside must be extremely compact. Manufacturers want high-signal, high-data, and high-power capabilities in the smallest possible package, driving the trend toward miniaturization. Further, the communication between the AGV (fleet control) requests a lot of information be given by the sensor. In this case, we are talking about a completely new application and sensor combination. Ethernet connectivity can deliver the performance and reliability required, helping to improve efficiency and streamline facilities.
Trends in Ethernet sensors In lower-end applications where it does not make financial sense to integrate a direct Ethernet connection, there is an uptick in the
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