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Industrial Robot Control Unit

When designing industrial control units, engineers look to ensure responsive monitoring and control, safety in human-to-machine interactions and protection against cybersecurity threats.  Industrial-grade connectivity and communication solutions from Molex elevate the design of robot control units with safe, high-performance, low-latency communications and connectivity solutions that are focused on security for today’s smart factories.

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.

Industrial Automation Control Unit

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

Flexible Printed Circuits

With their ability to handle compact, high-performance designs, Flexible Printed Circuits (FPCs) are frequently used in industrial control modules. Their flexibility makes them ideal for tight spaces and dynamic operations, which are often required for applications such as automation systems, control panels and other industrial equipment.

User Interface Solutions

Industrial control module operators use Human-Machine Interfaces (HMIs) to interact with systems, creating the need for User Interface Solutions like touchscreens, keypads and other interface designs. Their durability, shock and vibration resistance and customizable dashboards make them ideal for control module applications. 

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.

Power Connectors from Control Unit to Industrial Robot

Power Supply
  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

Power Connectors Inside the Control Unit

Internal Power Supply
  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