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New Challenges in Industrial Robot Controller Design
The industrial robot controller is a cornerstone of any efficient manufacturing environment, playing a big role in ensuring its security, performance and safety. Minimizing latency systemwide is a key objective to achieve real-time robot movement control, as any delay in processing sensor data and executing commands can undermine performance. With cyberattacks posing severe threats to the data integrity of the industrial robot, potentially disrupting the entire manufacturing process, security must be top priority. At the same time, designers need to integrate protocols for safe and efficient interactions between human operators and robots to prevent accidents.
To address these issues, engineers need control unit solutions that enhance real-time processing and boost data speed, supplying sufficient bandwidth to manage the high-volume data streams from multiple sensors without lags in robot response. For cybersecurity protection, control units must be integrated with system communication protocols to maintain data integrity. Furthermore, designing for safety on the factory floor requires adhering to relevant standards and conducting rigorous testing and validation.
Molex offers a range of solutions to meet these challenges. As an early entrant into single-pair Ethernet (SPE) technology, Molex provides proven high-speed data transmission capabilities throughout industrial settings, making seamless end-to-end IP-based communication possible for robotic control units, sensors and actuators. Expertise in Network Interface Security Cards helps customers implement secure and stable communication protocols for industrial automation applications. Additionally, Molex’s proficiency in CIP Safety and PROFIsafe compliance guarantees reliable industrial automation connector performance across various environments, supporting safe and efficient robotic systems.
Featured Products
Control Module Communication and Connectivity Solutions
Achieving high performance in robotic equipment, while ensuring cybersecurity standards are met — whether measured in terms of efficiency, precision or reliability — is a delicate balance of speed and security. Factories are turning to Molex to help ensure rapid data transmission and secure network communications for industrial robots.
Control Modules
Robot Functional Safety Protocol Interfaces | Hardware Compatibility | Code Footprint (approx.) | Industrial Certification Standards | Supported Operating System (OS) | |
---|---|---|---|---|---|
SDKs for Functional Safety | CIP Safety EtherNet/IP |
32- or 64-bit microprocessors (SDK is independent of hardware) |
200 kB (adapter), 400 kB (scanner) |
CIP Safety 2.22, CT20ES, IEC 61508, TÜV Certified, Pre-certified ANSI C source code |
No OS required (SDK is independent of OS) |
Managed / Unmanaged | Ports | Input Voltage | Data Speeds | Network Protocols | IP Rating | |
---|---|---|---|---|---|---|
Industrial Ethernet Switches | Managed or unmanaged | 5, 8 | Up to 57V | 10, 100, 1,000 Mbps | EtherNet/IP, PROFINET | IP20, IP67 |
Configuration | Circuits | Voltage | Current (Max per Contact) | |
---|---|---|---|---|
CRC Connectors | I/O Connectors | 4 to 50 | 250V AC (RMS)/DC | 1.0 to 15.0A |
Terminal Blocks and Barrier Strips | PCB Terminal Block Connectors | Up to 600V | 5.0 to 115.0A |
Industrial Ethernet Connectivity
Coding | Poles | IP Rating | Field Attachables | Shielded | Cable Material | Cable Length | |
---|---|---|---|---|---|---|---|
Micro-Change M12 | X‑Code, D‑Code |
4, 8 | IP67, IP68 | x | Shielded or unshielded | PUR, PVC, weld-slag oil-resistant (WSOR) TPE |
Up to 100m |
Single-Pair Ethernet (SPE) | T1 | IP20, IP65, IP67 | x | Shielded | PUR and TPE | Up to 40m |
Power Supply Connectors
With a growing number of devices making up smart factory systems, design engineers must optimize power consumption while reliably maintaining the functionality of multiple features. Molex industrial automation solutions provide low-loss and energy-efficient interconnects with modularity built into the design, ensuring fast and easy installation. These power components are rated IP66 / IP67 / IP68 / IP69K to seal against high-pressure water, dust and moisture.
Circuits | Voltage | IP Rating | Current (Max per Contact) | Field Attachables | Shielded | |
---|---|---|---|---|---|---|
GWConnect Heavy-Duty Connectors | 2 to 216 | 250V 10.0/16.0A, 230/400V 16.0A, 500V 16.0A, 830V 35.0/80.0A, 460/690 +250V 4x 4.0A + 2x 10.0A |
IP66, IP69 | Up to 100.0A | x | Shielded |
BradPower Connectors | 3 to 4 | 600V | IP67, IP68, IP69k | Up to 32.0A | x | Shielded or unshielded |
Mini-Change Connectors | 2 to 12, 14, 19 | Up to 600V | Up to 10.0A | x | Shielded or unshielded |
Voltage | Current (Max per Contact) | Wire Sizes | |
---|---|---|---|
High-Current Universal Clamps (HCUC) | Up to 1,000V | 120.0 to 380.0A | 6 AWG to 500 MCM (16.00 to 240.00mm² nominal) |
Teaching Pendant Interface Module Connectors
In an automated factory, teaching pendent components need to be durable and robust enough to survive long-term, allowing human operators to program, control and monitor robotic systems without fail. Rugged, compact connectors from Molex are designed to comply with IEC 61076-2-101 standards with heavy-duty die-cast construction, offering excellent protection against electromagnetic Interference (EMI), radio frequency interference (RFI) and environmental ingress.
Circuits | Current | Data Speed | Voltage (Max) | Operating Temperature | |
---|---|---|---|---|---|
USB Connectors | Up to 24 | 3.0, 5.0 and 6.0A | Up to 40Gbps | 48V | -40 to +85°C |
Poles | IP Rating | Field Attachables | Shielded | Cable Material | Cable Length | |
---|---|---|---|---|---|---|
Micro-Change M12 | 4, 8 | IP67, IP68 | x | Shielded or unshielded | PUR, PVC, weld-slag oil-resistant (WSOR) TPE |
Up to 100m |