AUTOMATION & CONTROL /// CASE STUDY ARISO CONTACTLESS CONNECTIVITY

Preventing Cable Breaks in Pick-and-place Applications

ARISO Contactless Connectivity makes it possible for designers and engineers to change the way they design connections. Enabling increased reliability with the unlimited flexibility of a contactless solution, ARISO allows for freedom of movement. This case study shows the disadvantage of cables (in new or installed applications) compared to a contactless solution.

A fully automated production line produces a few hundred solar boxes per hour. One of its workstations includes a pick-and-place transfer from a conveyor belt to a workpiece holder. The original set-up included cables to connect the sensors of the movable gripper to the control—as is common in traditional production lines. The team operating the machine identified significant problems that caused line stops. “With the machine running 24 hours a day, 7 days a week, 365 days a year, this led to a reduction of output and high maintenance efforts.”

The operation teams replaced the old cable-based installation with a contactless solution that significantly lowered the maintenance cost and increased the uptime of the machine from an average of 1 to 2 machine-stops per week to virtually no machine-stops caused by these type of cable breaks.

Industries & Applications Industrial Automation and Machinery:• Conveyor belts & assembly systems• Filling & packaging machines• Intelligent tools & work piece holders

Any application where traditional connectors, slip rings, or cable assemblies reach their limits due to movement, rotation, or maintenance.

Challenges • Preventing cable breaks due to movements in high-speed automated production

TE Products used in this Application • ARISO Contactless Connectivity• M8/M12 Customer Benefits • Significant maintenance cost saving• Increased uptime• Increased production output

Featured

CASE STUDY:ARISO CONTACTLESS CONNECTIVITY

A fullly automated production line for solar distribution boxes

PAGE 2AUTOMATION & CONTROL /// CASE STUDY ARISO CONTACTLESS CONNECTIVITY

ARISO Contactless Connectivity: Preventing Cable Breaks

A fully automated solar box production line produces a few hundred fully assembled junction boxes per hour. For each of the sensors of the junction box transfer station, several signal and power cables are moving and bending once every few seconds.

Over time, this perpetual movement causes wear and damage to the cables. To repair a damaged cable, the line has to shut down for about one hour, resulting in a loss of production and maintenance costs.

Traditional ApproachIn a pick-and-place transfer station, the junction box is moved from a conveyor belt to a holder. To get process information, several cables connect the position sensors of the transfer station to the machine control.

The cables are led by drag chains. The gripper is pneumatic. The damage inflicted over time by moving and bending the cables causes wear and malfunction. The consequential breaks cause unplanned downtime, in addition to the frequent maintenance cycles.

BEFORE ARISO CONTACTLESS CONNECTIVITY

Cable Assemblies

Benefits • Easy to install • Low one-time material costs Disadvantages • Failures due to repeated bending • Lifetime material costs Cost of Today’s Solution (TCO) Material costs + Installation costs + Maintenance/replacements costs per month + Lost output due to unplanned stops

1 HOUR DOWNTIME

The gripper is moving from the left to the right. The drag chains connect the sensors of the gripper. The cables inside are getting bent continuously.

PAGE 3AUTOMATION & CONTROL /// CASE STUDY ARISO CONTACTLESS CONNECTIVITY

ARISO Contactless Connectivity replaced the cables, resulting in less maintenance cost, a significant reduction in downtime, and an increase in production output.

ARISO proved to be not only a valuable technological innovation but also a notable efficiency and cost improvement for these automated systems.

TE’s ARISO Contactless Connectivity approachAfter identifying the problem, ARISO couplers were installed. They supply power to the sensors and feed the data back to the control system. The Transmitters are placed at the gripper’s end positions and are connected to the Programmable Logic Control (PLC). The ARISO receiver is mounted on the movable gripper, where the sensors are connected to ARISO through an M8 distribution box. The couplers are facing each other at the end points - exactly where the sensor information is needed to pick & place the work piece. At this moment the sensors are powered up and send their data back via ARISO without contact: the so-called ‘on the fly connection’. The adaptation from cable to ARISO was truly plug-and-play. Aside from the ARISO couplers, no changes to the set-up or additional equipment was required. The operation team calculated annual savings of several thousand dollars, and the return on investment (ROI) was reached in the first months —without downtime.

“WE WERE EAGER TO IMPLEMENT ARISO. THE MOVING CABLES ALWAYS WERE THE WEAKEST

LINK IN OUR PROCESS. BUT WE WERE NOT AWARE THAT POWER AND DATA TRANSMISSION

WITHOUT CONTACT WAS POSSIBLE. WITH ARISO, THAT CHANGED SO WE MADE THE IMPOSSIBLE

POSSIBLE WITH ARISO, AND WE BENEFIT!” — TOMAS EHRENBERGER, PRODUCTION MANAGER

AFTERARISO CONTACTLESS CONNECTIVITY

ARISO Contactless Connectivity

Benefits • Easy to install, • Connect on the fly, • No wear and tear Disadvantages • Higher initial investment Cost of Today’s Solution (TCO) Material costs + Installation costs Total Cost of Ownership (TCO) comparison: payback time of few months

PLUG AND PLAY REPLACEMENT WITH ARISO ZERO DOWNTIME

Left/middle: the ARISO couplers replaced the drag chains & cables.Right: in the moment the couplers are face to face to each other the link is established.

CASE STUDY

TE Connectivity Automation & Control

Pfnorstr. 1 D-64293 Darmstadt Germany

+49 6151 607 1999

te.com

AUTOMATION & CONTROL /// CASE STUDY ARISO CONTACTLESS CONNECTIVITY

te.comARISO, TE Connectivity, TE Connectivity (logo) and Every Connection Counts are trademarks. All other logos, products and/or company names referred to herein might be trademarks of their respective owners.

While TE has made every reasonable effort to ensure the accuracy of the information in this brochure, TE does not guarantee that it is error-free, nor does TE make any other representation, warranty, or guarantee that the information is accurate, correct, reliable, or current. TE reserves the right to make any adjustments to the information contained herein at any time without notice. TE expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications.

© 2015 TE Connectivity Ltd. family of companies All Rights Reserved.

1-1773868-7  10/2015   Original: TS

Contactless Connectivity – A Definition ARISO Contactless Connectivity is a hybrid interconnection system, based on both contactless power and contactless data technology, which can easily connect over a short distance without mechanical contact.

How you can benefit

ARISO Contactless Connectivity has many uses to various challenges. Use it in applications where traditional connectors cannot match the mating cycles or harsh environment. Use it in complex harness constructions, which reach their limit due to bending or where slip rings or spring cables cannot meet the demand for maintenance-free, high-speed rotation. Profit from endless flexibility in new applications. Connect through walls and materials or build it into machines or equipment. Customize the ARISO design to fit almost any purpose. Reach out to your TE contact to learn more or visit us at: TE.com.

BENEFITS

Freedom of movement that includes tilt, angle and misalignment.

Design flexibility and cost savings by transfer of power and signal through fluids and walls.

Easy, on-the-fly connections for example connecting remote IOs or sensors on moving machine parts.

Rotational freedom that enables faster rotation with more than 360°.

Unlimited mating cycles in wet & dusty environments for reduced maintenance costs.

Safe & reliable connections in harsh environments through vibration resistance and fully sealed couplers.

PN Description Power level Number of Outputs - Connector

Size (w/o Cable) [mm]

Operation freedom

Specifications Features

2287598-1 ARISO TxM030S012PNP2a; Transmitter, 12W, 2PNP

12 Watt• Operating voltage: 24 VDC• Output current: 500 mA

2 PNP Signals - M12, male a-coded, 4 pos.

Ø 30x80.4 Air Gap: max. 7 mmMis-allignment: max. 5 mmAngle: max 300C

• IP67• Ambient temp.: -20°C to 55°C• Storage temp.: -25°C-100°C• Housing material: Ni-Plated Brass• Switching frequency f : 500Hz• CE, UL, RoHS

• Power input reverse polarity protection• Power output short circuit protection/ Data output short circuit protection • Data input / output reverse polarity protection• Over-temperature protection• Foreign Object Protection• Dynamic Pairing• In operating range / Status OK Indication (12 Pos. versions)

2287598-2 ARISO RxM030S012PNP2a; Receivever, 12W, 2PNP

2 PNP Signals - M12, female a-coded, 4 pos.

Ø 30x80.4

2287598-3 ARISO TxM030S012PNP8a; Transmitter , 12W, 8PNP

8 PNP Signals, Status OK/In Operating range Output - M12, male, 12 pos

Ø 30x80.4

2287598-4 ARISO RxM030S012PNP8a; Receiver, 12W, 8PNP

8 PNP Signals, Status OK/In Operating range Output - M12, female, 12 pos

Ø 30x80.4

2287598-5 ARISO RxM030S012PNP8b; Receiver, 12W, 8PNP

8 PNP Signals, Status OK/In Operating range Output - M12, female, 12 pos

Ø 30x80.4

Additional variants incl. power & data and form factor upon request