Image data in industrial applications: Ensuring reliability and performance during transmission
Optical sensors are the “eyes” of industrial systems, relying on robust peripherals for reliable image processing. As sensors grow more powerful, challenges like data management, mechanical stress, and thermal issues in compact designs demand innovative solutions.
Optical sensors are the “eyes” of systems in industrial applications. However, just as with humans, in industrial applications a powerful peripheral system must ensure that image processing permanently functions reliably, without errors, and at the required performance level.
As optical sensors become increasingly powerful, the number of applications in which they can be used is also increasing. Along with the associated quality management and documentation system, the monitoring and evaluation electronics in state-of-the art production and documentation systems produce a flood of data. This mass of data must be transmitted, collected, and processed reliably. The underlying technical structures of machine vision systems must remain fully functional even under demanding conditions, such as permanent mechanical stress due to shocks and vibrations. Data connectors in particular, which are important interfaces within the system, also have to meet these requirements so that there is no wear on the male and female contacts (cf. fretting corrosion). Otherwise, contact interruptions will lead to downtimes in production or process errors that require time-consuming and cost-intensive measures.
Increasingly compact systems in smaller spaces, following the trend of miniaturization, pose additional challenges for device developers of machine vision systems. These include electromagnetic interference pulses that can influence the functionality of the individual components. The reduced structures within the system architecture also jeopardize stable system integrity. The increasingly powerful components, installed increasingly closer together, also bring with them a thermal problem that may not only have an impact on the operation of the sensors, but may also make device approval more difficult. Miniaturized interfaces and device-integrated connection technology that provide secure shielding and data transmission are active solutions to these potential problems. The optimized positioning of components on the printed circuit board in accordance with electromagnetic and thermal considerations during device development also ensures reliability. Simulations of heat generation, signal integrity, and impedance are helpful, especially when non-standard components are used.
Standards for optimized image processing
There are numerous transmission standards, including Camera Link, CoaXPress, GigE Vision, and USB 3, to suit the respective machine vision applications and associated interfaces. All factors must be coordinated and work reliably together to ensure optimized image processing.
Phoenix Contact is synonymous with high quality in the field of industrial connection technology. The portfolio of the company, founded in 1923, includes tried and tested data connectors such as D-SUB, RJ45, USB, HDMI, coaxial, and fiber-optic connection technology.
With its commitment to quality and innovation, Phoenix Contact is also an expert partner for new components, such as the Single Pair Ethernet (SPE), RJ45 Industrial (RJ45-IND), and the connection system for shielded and unshielded Finepitch series board-to-board connectors.
RJ45 Industrial
The RJ45 Industrial (RJ45-IND) product family was developed especially for industrial applications. This powerful product family has been further developed and optimized based on a large amount of experience gained with the standard RJ45 products in cooperation with customers from different industries. With this development, Phoenix Contact has created a product range featuring an optimized 360° shielding concept, for example.
To counter electromagnetic interference, the housing shield springs and shield pins for the printed circuit board have been raised. This also improves the mechanical strength of the socket on the printed circuit board.
The connection between RJ45-IND connectors or patch cables and RJ45-IND female printed circuit board (PCB) connectors has been decisively optimized. Shocks and vibrations are now counteracted by the so-called “perfect match” of the connector system. The development also included optimizing the contact depth of the female PCB connector from 8.3 m to 9 mm, thus enlarging the contact zone of the connector system. There have also been decisive improvements in the tolerances in the connection of the socket and plug, meaning that their contact connection is even better matched. On the connector side, the contact pressure was increased further through the inclusion of a compression spring.
The temperature resistance of the female PCB connector has been improved through the use of a reinforced housing, now utilizing fiberglass technology. Temperatures from -40 up to +105 C are now possible without any problems.
The RJ45-IND patch cables, which are suitable for drag chain applications and robots, are also particularly robust. A major advantage and unique selling point of the Phoenix Contact solution is the IDC fast connection, which enables the one-piece connector to be assembled quickly and easily without the use of a special tool.
Single Pair Ethernet
The IEEE 802.3 task force has developed the transmission standards for Single Pair Ethernet (SPE), defining the standards 10Base-T1, 100Base-T1, 1000Base-T1, and MultiGigBASE-T1.
The SPE standards enable data rates of 10 Mbps up to 1 Gbps at distances of 15 to 1,000 m. The MultiGigBASE-T1 standard goes so far as to enable data rates of up to 10 Gbps at distances of up to 15 m. The power transmission for the SPE standards 100BASE-T1 and 1000BASE-T1 are defined by the IEEE 802.3 bu standard (PoDL – Power over Data Lines).
The load outputs of the end devices (power devices) are divided into 10 performance classes from 0.5 to 50 W.
With regard to industrial image processing, SPE is an exciting field of application not just because of the potential to transmit data and power. In particular, the SPE portfolio from Phoenix Contact plays to its strengths here with its compact and 50 W consistent design. For example, the SPE-IP20 socket saves about 50 percent of space compared to a standardized RJ45 jack.
Phoenix Contact also has a consistent SPE product portfolio in which all components have been matched and tested. This portfolio provides compact IP20 connectors (in accordance with IEC 63171-2) and IP67-protected M8 connectors (in accordance with IEC 63171-5). A brand new addition to the portfolio is the SPE-M12 hybrid connector from the Onepair series.
The advantages of the SPE connection technology include the uniform mating face and the possibility to achieve a high degree of common part usage. This means that adapters are no longer necessary and no additional costs are incurred.
Various SPE components are available for the developers of machine vision sensors. These include new semiconductors (SPE PHYs and PoDL controllers), SPE magnetics, connection technology in accordance with IEC 63171-2 and -5, and SPE-compatible cables in accordance with IEC 61156.
Tip: With a membership in the System Alliance (www.singlepairethernet.com/), it is possible to gain detailed information about Single Pair Ethernet and become familiar with specific solutions for industrial applications.
Board-to-board connectors
Contact systems are to be preferred over simply designed male and female strips, in particular in demanding applications – such as for industrial image processing, for example. They are sophisticated yet at the same time robust.
With its board-to-board connectors, the Finepitch product series from Phoenix Contact offers a professional contact system for space-saving PCB connections. Various numbers of positions as well as stack heights provide a great deal of flexibility for developers. The system features high-speed data transmission rates of up to 52 Gbps. The innovative ScaleX double contacts (FP 0,8) are designed as hermaphroditic, meaning that vibration-resistant connections can be created in very confined spaces.
The shielded version available as an option also prevents electromagnetic interferences.
As a valuable service offering, Phoenix Contact experts provide support during the entire design-in process as well as design-in support. This means that device developers of machine vision systems can quickly obtain preconfigured 2D/3D data for their CAD software.
Phoenix Contact also provides individual thermal and housing simulations based on the finite element method (FEM). Free simulations for data and signal integrity complete the comprehensive service offering. With this support, customers can realize stable communication right from the start and throughout the entire development process.
Phoenix Contact rounds off its services with a free sample service and reliable logistics.
Summary
The developers of modern machine vision systems must consider various important factors during the product development process to ensure that reliable and high-performance systems are ready for the market in the environment of high data transmission rates and miniaturization. The cost factor also plays a decisive role. Phoenix Contact is a reliable partner, providing both products and services. In addition to the proven data connectors and innovative product solutions – such as for SPE, for example – Phoenix Contact provides simulations that help to realize stable device communication and reliable systems with cost-efficiency. This creates a high-performance periphery for reliable industrial image processing.
Written by:
Dipl.-Ing. Verena Neuhaus, Product Management Data Connectors, Business Unit Field Device Connectors, Phoenix Contact GmbH & Co. KG, Blomberg, Germany
Thomas Schulze, M.Sc., Product Management Board-to-Board Connectors, Business Unit PCB Connectors, Phoenix Contact GmbH & Co. KG, Blomberg, Germany