https://community.element14.com/learn/learning-center/the-tech-connection/Tech Connection Keep up on the latest tech trends with the element14 Tech Journal or learn about the most current technologies today in Tech Spotlights.en-USTelligent Community 12https://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/when-the-world-gets-tough-molex-connectors-get-tougher---rugged-and-reliable-connectors-built-for-extreme-environmentsTue, 09 Dec 2025 12:05:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:ee28abab-2316-464d-adcb-018b7791aebavivekvelusamyIntroduction: The rising demand for extreme environment solutions Rugged connectors are the unsung heroes of the modern world. They are present everywhere, from autonomous vehicles that navigate dusty, bumpy roads to smart factory floors where robots work in harsh, industrial environments. In such environments, even a small connection failure can halt a machine or disrupt a critical network. Yet, amid the chaos, rugged connectors quietly keep everything running, ensuring the reliable flow of power and data. Whether it's the vibration of an IC engine, the heat of a powertrain, or the moisture inside a dishwasher, connectors are the critical components ensuring reliable performance. This article explores how next-generation rugged connectors from Molex are engineered to survive and thrive in the world's most challenging applications. Defining high reliability and ruggedness for connectors and their importance Connectors should be rugged to perform flawlessly under mechanical stress, environmental hazards, and extreme temperatures. When engineers tackle waterproof connector challenges, they explore the boundaries of what connectivity can achieve in harsh environments. Picture a connector in a military drone, enduring 50G shocks during evasive maneuvers, or one in a submarine, sealed against corrosive saltwater while maintaining flawless signal flow. In terms of performance, the connector must thrive under vibration (up to 20G in vehicles), extreme temperatures swinging from -40°C to +150°C, and ingress protection that shrugs off dust storms or high-pressure washes. High-reliability means using features and systems to avoid failure in demanding applications. In space, aviation, and defense markets, high-reliability is essential in mission-critical equipment where human lives are at risk. Connectors for these markets meet specific standards for each application. They are robust, can withstand extreme environments, and are thoroughly tested and inspected. Although costly, these connectors make a safer choice. Now, what makes a connector "rugged"? It isn't just thicker plastic or tighter latches. True ruggedness is multi-dimensional: Performance under pressure: True ruggedness means maintaining consistent electrical performance and signal integrity across extreme conditions, ranging from Arctic installations where metals contract and become brittle to desert environments where thermal expansion of every joint and seal is the norm. Rugged connectors must withstand thermal shock, resist relentless vibration that would shake ordinary components apart, and maintain perfect seals against dust and high-pressure water jets (IP67 and beyond). Long-term signal fidelity through hundreds of thermal cycles and fluctuating currents separates rugged connectors from commodity designs, ensuring no surprises when the product meets real-world challenges. Materials innovation: Materials in harsh environments are relentlessly attacked through heat, salt spray, oils, and particulate matter. Rugged connectors employ advanced polymer science and engineering plastics that resist UV degradation, chemicals, and impact while maintaining flexibility at -40°C and resisting degradation at +150°C. Metal contacts undergo specialized treatments and use gold, silver, or tin plating to resist oxidation, fretting corrosion, and environmental contaminants. Specialized elastomers for seals and gaskets retain compliance after UV, oil, or coolant exposure, providing watertight barriers that maintain connection integrity over time. Construction and design: Reliability emerges from a distinct design philosophy that assumes failure modes rather than hoping to avoid them. This includes redundant sealing systems, robust locking mechanisms with audible clicks for secure mating confirmation, terminal position assurance (TPA) to prevent backing out under vibration, and strain relief to reduce mechanical stress. Error-proofing features such as color-coding, unique keying to prevent mis-mating, shrouded headers for pin protection, and generous lead-ins make good terminations routine and bad ones obvious. These features are critical for high-mix assembly and field service where precision engineering meets real-world conditions. Applications of Rugged and Reliable Connectors Molex presents a series of products for different applications: DuraClik: Conquering the fields of smart agriculture When a drone flies over farmland, it sprays nutrients while battling gusty winds and humidity. Molex DuraClik Connectors inside the drone keep the soil sensors and control units connected despite constant vibration and harsh outdoor conditions. DuraClik works perfectly here because it handles high-vibration environments like crop-monitoring drones, where an audible "click" and secure lock create a reliable connection. DuraClik is a 2.00 mm pitch, 3.0A rated wire-to-board system designed for modules exposed to high vibration. Terminal retention forces range from 9.8 N (standard) up to 100 N (robust variant), depending on configuration, giving engineers options based on application severity. Operating temperature spans -40 °C to +105/+125/+130 °C depending on the variant. Product advantages and features The compact design of DuraClik Connectors enables secure mating while saving space. The integrated positive lock gives an audible ‘click’ for mating confirmation. Its automotive-grade robustness can withstand harsh conditions with an operating range of -40 °C to +130 °C, satisfying LV214 (S2 vibration), ES91500-03, and SAE/USCAR-21 standards. The many variants of DuraClik can support pull forces up to 100 N with strong connector-to-PCB retention. The design is also flexible, supporting 2 to 15 circuits in vertical and horizontal configurations. Markets and applications Automotive systems: battery management, DC-DC converters, onboard chargers, vehicle connectivity, lighting, infotainment, and seat adjusters Industrial and energy: cranes, industrial machinery, energy storage systems, inverters, and power distribution units Consumer and appliances: white goods, induction cookers, vending/gaming machines Figure 1: Structure of DuraClik 2.00mm Wire-to-Board Connector System MX150: Automotive excellence in miniature form The modern car is a demanding environment for electrical connections. Take automotive sensor networks, for example: these components must handle extreme temperatures from -40°C to +150°C, resist water from high-pressure car washes, and keep working reliably through millions of vibration cycles over the car's lifetime. MX150 is a 3.50 mm pitch sealed connector system using mat-seal technology that reduces the need for individual wire seals. It is validated to USCAR-2 and GMW3191 vibration profiles: random vibration ~118.7 m/s² RMS and mechanical shock pulses of 343 m/s² (≈35 g). The current rating supports up to 22.0 A with silver-plated terminals and a voltage up to 60 V mid-voltage. Operating range: -40 °C to +125 °C (tin plating) and up to +150 °C (silver). Product advantages and features: The MX150 has a sealed connector design with mat seal (1.50 mm terminals) that reduces the need for individual wire seals. There is an option for two-ring seal/pass-through sealing for oil-resistant applications. The compact one-piece 3.50 mm pitch housing reduces assembly cost. The Connector Position Assurance (CPA) and Terminal Position Assurance (TPA) locking prevent mis-mating or loose terminals. The MX150 meets stringent automotive standards (USCAR-2, USCAR-21, GMW3191) for vibration, temperature, and sealing. It has a broad operating range (-40 °C to +125 °C, up to +150 °C for silver-plated) and exceptional mechanical retention (strong connector latch retention force, strong contact retention forces). The connector also supports a variety of circuit sizes (2 to 20 circuits), male/female, panel mount, headers, and twist-head sealed bulkheads. Markets and applications: Automotive: ICE and electric vehicles, lighting, braking system modules, battery controllers, power distribution boxes Commercial vehicles and off-highway: industrial vehicles, agricultural equipment, recreational vehicles, marine Electrical and Power systems: solar energy storage, home generators, industrial motors Industrial automation and robotics: machines, motors, machinery control systems Figure 2: Structure of DuraClik 2.00mm Wire-to-Board Connector System Mini50: Compact infotainment specialist In connector design, size and capability often have an inverse relationship. As vehicles add more advanced driver-assistance systems (ADAS), such as radar, LiDAR, and surround-view cameras, the real estate on sensor modules and within tight door panels becomes precious. Step into the cockpit of a self-driving car, where screens glow and sensors whisper directions. The Mini50 connectors in this environment weave a web of connections in the tight confines of infotainment hubs, cameras, and HVAC controls. Mini50 is the industry's only USCAR-050 approved unsealed interface. Using 0.50 mm terminals achieves up to 50% smaller frontal area compared to traditional 0.64 mm USCAR systems. Operating temperature is -40 °C to +100 °C, with housings capable of +260 °C reflow for soldering. Product advantages and features The Mini50 has a 50% smaller frontal area than the 0.64 mm USCAR unsealed connectors. It is the industry’s only USCAR 050-rated unsealed interface. The Independent Secondary Lock (ISL) molded in the housing ensures terminal retention with fewer parts, with the optional CPA (Connector Position Assurance) preventing accidental unmating. The Mini50 has multiple polarization options (mechanical/visual/color) which help prevent mis-mating. The housings made of high-temperature thermoplastic are compatible with IR/wave solder reflow up to +260 °C (per ES-40000-5013). Its orientation and board retention features, molded into the headers, assist alignment and help retain the header during soldering. The terminal compatibility ((0.13–0.35 mm²) of the CTX50 enables lighter wire gauges while retaining strength. Markets and applications In-vehicle electronics (interior modules): HVAC controls, instrument clusters, infotainment, lighting, switches Door/seat modules, mirror systems, sensor/actuator interfaces Modules in passenger compartments, glove boxes, and overhead consoles Any modules in dry interior zones where space is at a premium and connectors are unsealed Figure 3: Exploded view of Mini50 Unsealed Connector System MXP120: Safeguarding lives in critical moments When a car crashes, MXP120 connectors instantly trigger airbags with perfect accuracy, their bright yellow housings showing how critical they are for saving lives. Built for automotive safety systems like seatbelt pretensioners and side airbags, these compact sealed connectors work well in body electronics, keeping out water and dust even when mounted on the car's frame. MXP120 is a 4.00 mm pitch, 1.20 mm terminal sealed connector system delivering up to 13.0 A in compact safety and body-electronics applications. It employs Single Wire Seal (SWS) perimeter sealing rated to IPX8 (IPX9K under evaluation), with ISL and PLR features for secure terminal retention. Operating temperature is -40 °C to +125 °C. Product advantages and features: The MXP120 compact 4.00 mm pitch/1.20 mm terminals save space compared to 1.50 mm systems. It supports medium-power sealed applications up to 13 A, and strong terminal retention is provided by the ISL and Primary Lock Reinforcement (PLR). The available scoop-proof shrouds and audible locks deliver secure, reliable mating and prevent accidental unmating. The MXP120 is designed to meet AK and USCAR standards for global automotive compatibility. Markets and applications: Automotive: safety systems (airbags, seatbelt pretensioners, SRS, SIR), body electronics and exterior modules (door-lock mechanisms, lighting, turn signals), powertrain and engine zones (ignition coils, emission controls, fuel injection) Commercial vehicles: safety restraint and body electronics in harsher environments Industrial/consumer: medium-power sealed connectivity applications (up to 13 A) Figure 4: Exploded view of MXP120 Sealed Connector System Conclusion: As technology progresses, the choice of a connector is a fundamental engineering decision that dictates the system's reliability, safety, and longevity. By offering a portfolio of specialized solutions like the user-friendly DuraClik, the industrial-strength MX150, the miniaturized yet mighty Mini50, and the high-power MXP120, Molex provides the critical connective tissue that allows innovation to flourish anywhere on Earth. The future is being built, and it’s being built to last on a foundation of rugged and reliable connectivity. Specification comparison table: Connector Family Pitch Current Rating Temp Range Key Lock/Seal Features Primary Applications Buy Now DuraClik 2.00 mm 3.0 A –40 °C to +105/125/130 °C ISL, robust retention up to 100 N Seat sensors, HVAC, and lighting modules Click Here MX150 3.50 mm Up to 22.0 A –40 °C to +125/150 °C Mat-seal, CPA, TPA Under-hood modules, off-highway vehicles Click Here Mini50 2.00 mm (0.50 mm terminals) Up to 4A –40 °C to +100 °C USCAR-050, ISL, CPA optional Interior harnesses, infotainment, switches Click Here MXP120 4.00 mm (1.20 mm terminals) Up to 13.0 A –40 °C to +125 °C SWS perimeter seal, ISL, PLR, CPA Safety systems, door/exterior modules Click Here For more Rugged and Reliable tough connector from Molex Shop Now ABOUT THE SPONSOR At Molex, we believe in the transformative power of creating connections. Obstacles become opportunity through innovation , engineering expertise, collaborative customer experiences and industry-leading interconnect solutions. Alongside our customers, we’re bridging borders between patients and medical providers, creating safer and smarter industrial environments, turning mobile devices into hubs of on-demand information and enabling data centers to support it all. Together, we are Creating Connections for Life. For more information, click here.Rugged and Reliable Connectorstech spotlightMOLEX connectorsExtreme Environmentshttps://community.element14.com/learn/learning-center/the-tech-connection/f/forum/56458/solenoid/231970Thu, 20 Nov 2025 01:08:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:941714e3-df78-4627-a6cb-fc4c339aa3e9dougwHere is a circuit: The "Adjustable Delay Monostable Trigger Relay" cost between $1 and $2, available in a 12V version. The solenoid should be oriented such that gravity makes it return when off. It is good practice to put a snubber diode across the solenoid terminals. If you absolutely need a second solenoid to make it return, you would need a second time delay relay.https://community.element14.com/learn/learning-center/the-tech-connection/f/forum/56458/solenoid/231969Thu, 20 Nov 2025 00:11:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:6ea5e34d-a3af-4d31-9dc5-5ab2040e0910robogaryPlease check the solenoid nameplate for inrush and holding current. If you want to use conventional parts, then need a relay for pickup and drop out, and TDAE realy for your time delay. You'll need limit switches on the top and bottom to know when the solenoid reaches those positions and remove reverse polarity contacts. If you can change the solenoid, get one that returns to home position when power is off. It will save you alot of grief.https://community.element14.com/learn/learning-center/the-tech-connection/f/forum/56458/solenoidWed, 19 Nov 2025 22:52:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:e789094d-b9a1-48a9-a0c7-d366d25bca78Haydn66Hi i need some help with this solenoid project I need to press switch to send 12v solenoid to make it go up and when it gets to its full travel it needs to hold for about 10 to 15 seconds then change it's polarity so the solenoid pulls back in to its start position to do it over again It's for a electric go kart indicator arms like the old ford pop iam making my grandson for Christmas so if anyone can crack this and give me a parts list that will be great Thanks Haydn66https://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/accelerating-innovation-with-the-amd-kria-kr260-robotics-starter-kitTue, 18 Nov 2025 11:10:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:59a3506d-b430-45c8-a961-c2b0e8f9d082vivekvelusamyThe demand for robotics is growing across various sectors due to the increasing adoption of automation. Businesses are increasingly turning to automation to address labour shortages, enhance efficiency, and improve the quality and consistency of their operations. However, robots require specialised computing solutions because they process copious amounts of sensor data and perform precise movements simultaneously. Adaptive computing platforms are crucial, as they offer the low latency and determinism required for safe, real-time control of multi-axis robots. The AMD Kria ™ KR260 Robotics Starter Kit is the easiest way to develop ROS 2-based robots with the attributes of adaptive computing and in adjunct applications involving industrial vision, communications, and control. This article discusses the KR260 Robotics Starter Kit and how adaptive computing, Robotics Operating System 2 (ROS), and particularly AMD Kria SOMs are the perfect compute platforms for next-generation robotics. Robotic Starter Kit: A Comprehensive Development Platform for Robotics, Machine Vision, and Industrial Automation A robotics starter kit is a comprehensive development platform designed for beginners, engineers, and researchers to develop hardware-accelerated applications for robotics, machine vision, and industrial communication and control. It typically contains all the necessary components and instructions to assemble and program a basic robot. The main components of a robotics starter kit typically include a micro-controller or system-on-module (SOM), memory, boot, and security modules. It also includes a power solution, multiple Ethernet interfaces, SFP+ connectivity, sensor interfaces, a cooling fan, and a microSD card. There are robot kits that include power adaptors and cables for connectivity and assembly. Sensors, motors, and software (e.g., Robot Operating System, known as ROS) are often included to enable environmental interaction and programming. Robotic starter kits find their application across various fields, including education, industry, and research. In education, they help understand STEM (Science, Technology, Engineering, and Mathematics) subjects and offer a practical approach to learning complex concepts. In the industrial sector, robotics kits provide a cost-effective solution for prototyping and testing new technologies. They help engineers and designers to develop and refine their design or prototype before full-scale production. These kits also provide them with a platform to test ideas and identify potential issues during the early stages of product development. A robotics starter kit also benefits researchers by providing them with a flexible and adaptable platform for experimentation. These kits allow them to develop new algorithms, test artificial intelligence applications, and explore innovative solutions to complex problems. How AMD Kria ™ K26 SOM and Robotics Carrier Card Power the AMD Kria KR260 Robotics Starter Kit The KR260 Robotics Starter Kit is comprised of the AMD Kria K26 SOM (non-production) and a robotics application focused carrier card. The K26 SOM is featured in both the AMD Kria KV260 Vision AI and KR260 Robotics Starter Kits, customers can also design their own custom carrier card to target various applications. The K26 SOM is a compact module built using a custom AMD Zynq ™ UltraScale+ ™ MPSoC device. This adaptive SoC integrates Arm® processors (Processor System, PS) for running operating systems like Linux and high-level applications, and Programmable Logic (PL) / FPGA for custom hardware acceleration of demanding tasks such as AI inference or image processing. It also includes essential memory and power management. The carrier card acts as the "interface" and expansion hub. The K26 SOM plugs into it, gaining access to the external world. The carrier card breaks out the SOM's high-density connectors into accessible ports, including Ethernet, USB, and crucial camera interfaces (MIPI CSI-2) for vision-based use cases. It also provides power distribution and application-specific peripherals like motor control interfaces and additional sensor connections. Using Kria SOMs together with AMD development tools (such as AMD Vivado ™ Design Tools and AMD Vitis ™ Software Platforms) and open-source tools (such as the Linux Device Tree Generator/Compiler), developers can create and test their own custom applications and programmable logic (PL) functions. This modularity also allows them to leverage powerful, standardised SOM while customising the carrier card for diverse robotic applications, accelerating development and reducing technical risk. Figure 1: AMD Kria ™ KR260 Robotics Starter Kit Source: AMD Native ROS 2 Support Offering Improved Reliability and Flexibility to Robotics Developers ROS is an industry-standard software toolkit for developing robotics applications. It includes open-source software libraries (e.g., for motion planning and control) and tools (e.g., simulation, testing, and debugging) for building robotic applications. ROS 2 is the latest version of ROS, with advanced communication capabilities and better performance than its predecessor. It is the de facto framework for robot application development, including current debugging and visualisation tools, libraries, and communication frameworks. Most features are available for all supported operating systems (including Ubuntu, macOS, and Windows), the communication protocol - historically DDS with several implementations - and programming language client libraries (in C++ and Python). The KR260 Robotics Starter Kit adopts the ROS 2 Software Development Kit (SDK), enabling a ROS 2-centric development approach with its open-source Kria Robotics Stack. The Kria Robotics Stack is a superset of ROS 2 that combines modern C++ and High-Level Synthesis (HLS) to integrate the AMD infrastructure into the ROS architecture. Figure 2 represents a simplified view of the Kria Robotics Stack and how it encompasses a robust set of system layers to enable hardware-accelerated libraries. Figure 2: Simplified view of Kria Robotics Stack One of the important features of Kria Robotics Stack is its optimization of the ROS 2 performance via FPGA-based hardware acceleration of some elements within the layers, such as TSN connectivity or packages within the perception stack. The Kria Robotics Stack can also be used by developers who do not use ROS, since most components are agnostic to the framework and can be used within traditional FPGA design approaches. For robotics developers, the ROS 2 system has been upgraded with new tools like the ROS 2 build system (ament) and ROS 2 build tools (colcon), making it much easier to use hardware acceleration. This means the same simple commands and workflows they use for regular robot software development also work for building acceleration kernels. These improvements allow developers to quickly add powerful acceleration capabilities to their robots using ROS 2. How Do AMD Kria ™ SOMs and ROS 2 Drive Next-Gen Robotics Innovation? Adaptive System on Modules (SOMs) provide a ready-made, off-the-shelf solution for robotics by blending an adaptive SoC with industry-standard interfaces and components, allowing roboticists with little or no hardware expertise to use an adaptive platform immediately. Adaptive SOMs (like the K26 SOM) are ideal for next-generation robotics, integrating powerful SoCs with FPGAs, Arm processors, and standard interfaces to simplify system integration and meet high compute demands. The Kria Robotics Stack enhances ROS 2-centric development and enables rapid prototyping with the KR260 Robotics Starter Kit. This allows developers to launch applications like the ROS 2 Perception Node faster. This out-of-the-box solution leverages FPGA flexibility for real-time performance without requiring deep hardware expertise, democratizing robotics development. The KR260 Robotics Starter Kit pairs a K26 SOM with a carrier card that supports critical robotics connections. It offers a customisable foundation using familiar tools like Python, C++, or FPGA RTL. Transitioning to a production-ready K26 SOM provides validated designs, pre-built firmware, and ecosystem resources, reducing hardware complexity and enabling roboticists to focus on sensors and actuators. Adaptive SOMs accelerate design cycles for software and hardware developers by supporting deep-learning frameworks like TensorFlow and PyTorch and eliminating proprietary tools. Deterministic Communication Across the Robotics Internal Network The KR260 Robotics Starter Kit features multiple Ethernet connections supporting standard DDS-UDP communication protocols. It has built-in support for precise time synchronization across networks using IEEE 802.1AS standards and advanced Time-Sensitive Networking (TSN) capabilities. These are essential for real-time applications like motor control or sensor coordination. The kit's TSN subsystem ensures that all connected devices operate in perfect synchronization with minimal timing variations. The system includes two external network interfaces, allowing it to connect directly to larger networks without requiring additional specialized TSN switching equipment. Versatile Connectivity with Ample I/O Support With four Pmod 12-pin interfaces and a 26-pin Raspberry Pi HAT, the KR260 Robotics Starter Kit allows developers to connect peripherals like GPS sensors, IMUs, motor drivers, or actuators. The kit’s non-production K26 SOM, equipped with 240-pin connectors, supports robust interfaces: four RJ-45 Ethernet ports, a 10GigE SFP+ cage for high-speed networking, a 2-lane SLVS-EC RX interface for advanced vision sensors (e.g., Sony IMX547 5.1MP camera), four USB 3.0 ports for cameras or standalone use with a keyboard and mouse, and a DisplayPort 1.2a for 1080p monitor output. Conclusion The growing installation of robots is driving increased demand for accelerated high-performance computing at the edge. The AMD Kria ™ KR260 Robotics Starter Kit provides an excellent development platform for entry-level and experienced roboticists looking to create innovative ideas for ROS 2-based robotics and take them to production. It also helps developers, especially in small and medium enterprises, get to market faster with reduced total cost of ownership (TCO). AMD Kria ™ KR260 Robotics Starter Kit Buy Now Sony IMX547 Camera Kit Color Buy Now AMD Kria ™ K26 System-on-Module Buy Now Avnet Heat Sink for AMD Kria ™ K26 System-on-Module Buy Now AMD, and the AMD Arrow logo, Kria, UltraScale+, Vitis, Vivado, Zynq, and combinations thereof are trademarks of Advanced Micro Devices, Inc. Other product names used in this publication are for identification purposes only and may be trademarks of their respective owners. For more innovative products from AMD Shop Now About the Sponsor AMD is the high performance and adaptive computing leader, powering the products and services that help solve the world’s most important challenges. Our technologies advance the future of the data centre, embedded, gaming and PC markets. Founded in 1969 as a Silicon Valley start-up, the AMD journey began with dozens of employees who were passionate about creating leading-edge semiconductor products. AMD has grown into a global company setting the standard for modern computing, with many important industry firsts and major technological achievements along the way. For more information, click here .roboticsAMD Kria™ KR260somamdKR260 Robotics Starter Kithttps://community.element14.com/learn/learning-center/the-tech-connection/m/managed-videos/150719Sat, 15 Nov 2025 10:02:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:c79b80d2-fe19-432f-815f-7ed4d76542bfbeacon_daveIntroducing Ikan's Lyra PoE Q-SYS plugin! Available in Q-SYS Designer assets today. Q-SYS Partner: https://www.qsys.com/alliances-partnerships/ikan/ Q-SYS Plugin Press Release: https://ikancorp.com/ikan-international-llc-releases-a-new-technology-...https://community.element14.com/learn/learning-center/the-tech-connection/b/blog/posts/overcoming-the-challenges-of-interoperability-in-industrial-automationMon, 10 Nov 2025 16:17:00 GMT93d5dcb4-84c2-446f-b2cb-99731719e767:bf96c7b3-2e9f-4867-8650-ac6e27872bbfe14sbhargavIntroduction Industry 4.0, or IIoT, leverages resources such as robotics, smart instruments, and programmable systems to boost production efficiency and optimize costs. This achievement requires the acquisition and integration of large amounts of data from devices and systems, which helps in making informed production decisions. Acquiring data from these devices and connecting them to a network becomes challenging due to vendor-specific protocols, legacy devices unable to communicate with the network, mismatched data models, and security issues. These challenges can be solved by establishing uniform interoperability and connectivity to achieve full and smooth integration between industrial automation devices and networks. However, implementing interoperability solutions for each device introduces challenges such as process disruption, budget constraints, lack of expertise, and security concerns.This article discusses the concept of interoperability, its challenges, and how HMS has mitigated them in water/wastewater and other industries through its Anybus line of products. What is Interoperability? Interoperability in an industrial automation environment is the capacity of different devices, including sensors, controllers, gateways, cloud platforms, and enterprise systems, to communicate, connect, and exchange information effectively across production processes regardless of their manufacturers or architectures. It enables hardware and software to support each other, allowing partners such as customers, suppliers, and various departments to share and use information quickly and accurately. Interoperability in industrial automation operates across multiple layers. At the device level, sensors and actuators must communicate using compatible protocols such as PROFINET, EtherNet/IP, Modbus, and EtherCAT. Network interoperability ensures data can move across different network infrastructures, from fieldbus systems to wireless networks and cloud platforms. Data interoperability represents another critical dimension, requiring standardized formats and semantic models that allow different systems to correctly understand and process shared information. This includes establishing common data models, metadata standards, and APIs that enable applications to process data from various sources with minimal customization. What are the challenges of interoperability? Interoperability in industrial automation faces several challenges that can affect the implementation and effectiveness of integrated systems. Some of those challenges are: Non-homogeneous or vendor proprietary protocols: Most manufacturing facilities use a combination of different protocols, each optimized for various use cases. Protocols such as PROFINET, EtherNet/IP, and CC-Link ensure real-time communication in industrial automation systems. However, these solutions often incorporate additional mechanisms to guarantee latency, and each lacks standardization, making interoperability a significant challenge. Legacy system integration: Many organizations rely on outdated, proprietary systems that struggle to communicate with contemporary industrial automation platforms. This creates barriers to modern automation integration, as these legacy systems cannot transmit real-time data. In addition, legacy systems often store information in siloed databases with incompatible formats, requiring special expertise and resources to extract, analyze, and consolidate data into shared storage. Vendor lock-in or dependency: Manufacturers often use systems supplied by different vendors. These systems generally run on proprietary protocols and present challenges when connecting devices across multiple facilities. This results in fragmented ecosystems where devices struggle to communicate effectively, leaving manufacturers locked into specific ecosystems. Data standardization issues: Industrial automation devices and systems often operate on different frequencies and protocols, leading to inconsistent, incomplete, or inaccurate data transfers between systems. Data security concerns: The lack of uniform security protocols and standardized frameworks makes industrial automation networks vulnerable to cyber threats. Outdated security frameworks also create data silos, which limit the effectiveness of AI-driven threat detection and analytics because data remains fragmented across systems. Implementation challenges: Implementing interoperable systems brings numerous challenges related to connectivity, data processing, scalability, and system reliability. For example, OPC UA offers many advantages, but implementing and configuring it requires deep knowledge of its architecture and capabilities, making adoption difficult. Cloud automation: With industries shifting toward cloud automation for faster results and real-time analysis, interoperability becomes more complex. Cloud components such as distributed environments, data mobility, and network resilience increase the difficulty of seamless integration. Figure 1: Interoperability challenges in Industry 4.0 (Source: HMS-Networks ) How has interoperability been addressed in the past? Early proprietary protocols and initial standardization (1970s - 1980s): Industrial communication began with HP-IB in 1975 (also known as the General Purpose Interface Bus, or GPIB), which established itself as a standard for industrial control. In 1979, Modicon developed the Modbus protocol, originally designed for their PLCs, which became a widely adopted de facto standard. These developments marked the beginning of industrial communication and fieldbus technology, though most solutions remained proprietary and lacked true interoperability across vendors. Standardization through IEC 61158: Specified by IEC 61158, Fieldbus encompasses protocols such as EtherNet/IP, Modbus, PROFINET, PROFIBUS, CAN bus, and CANopen. Each protocol has unique features, meeting the requirements of different industrial applications. While IEC 61158 aimed to unify the fragmented fieldbus landscape, it became more of an umbrella standard, legitimizing multiple competing technologies rather than creating one universal protocol. Rise of collaborative standards and OPC Classic (1990s): In 1996, Microsoft developed OPC, based on its Object Linking and Embedding (OLE) technology. This client-server model revolutionized data access by enabling historians, HMIs, and SCADA systems to uniformly retrieve data from PLCs across Windows-based platforms. However, this Windows dependency limited cross-vendor integration, particularly as Linux systems gained industrial adoption. While this era marked a shift from isolation to cooperation, it also exposed critical security vulnerabilities and portability constraints. Transition to platform-independent architectures (2000s): The launch of OPC UA in 2008 represented a major breakthrough. Built on TCP/IP, OPC UA introduced a service-oriented, secure framework that operated independently of operating systems and hardware platforms. Its object-oriented modeling enabled real-time data exchange, alarm management, and historical access from field devices to cloud platforms. Collaboration with standards bodies like IEC reduced vendor lock-in while preserving specialized functionality. However, high implementation costs for retrofitting legacy systems remained a significant barrier. Open initiatives and semantic enhancements (2010s - present): The rise of IIoT drove broader frameworks such as ExxonMobil’s Open Process Automation Standard (O-PAS), which aimed to enable seamless integration of multivendor components. Service-oriented architectures combined with semantic technologies have created intelligent, self-describing systems that coordinate complex IIoT operations with minimal manual configuration. The Unified Namespace (UNS) provides a centralized, publish/subscribe database that integrates data from all levels of the automation pyramid, enabling both automated and manual data gathering in a compatible format. These modern initiatives emphasize modularity, advanced analytics, and plug-and-play integration, though adoption still faces barriers of cost, complexity, and entrenched infrastructure. Mitigating interoperability challenges using Anybus from HMS Networks Anybus provides comprehensive industrial interoperability through embedded interfaces, gateways, and protocol converters that connect any industrial device to major networks, including PROFINET, PROFIBUS, EtherNet/IP, DeviceNet, Modbus, EtherCAT, and BACnet/IP, eliminating communication barriers and automation silos. HMS Networks uses several integrated mechanisms to address connectivity challenges. Protocol bridging with Anybus X-gateways enables direct communication between PLCs from different vendors without middleware or code modifications, while maintaining performance and low latency. Legacy integration modernizes existing equipment by translating RS-232/485 or CAN protocols into Ethernet standards, allowing older components to connect to modern networks without hardware replacement. The CompactCom embedded modules enable OEMs to implement a single design across multiple networks using simple module swaps, accelerating deployment while minimizing development costs. Advanced security features, aligned with IEC 62443 standards, such as TPM chips, signed firmware, and secure boot help ensure cybersecurity while preserving flexibility. Real-world applications Wastewater solution - Valve integration over PROFIBUS Durapipe, a supplier of water treatment systems, needed electrically actuated valves to communicate over PROFIBUS without redesigning their RS-232-based actuators. HMS Networks provided the Anybus Communicator AB7000, which connects non-networked devices to PROFIBUS by integrating serial RS-232/422/485 devices without modifications. The solution performed intelligent protocol conversion, presenting serial data to the Master PLCs as easily processed I/O data. It was housed in a separate IP65-protected enclosure, requiring no actuator redesign. The configuration proved simple for basic open/close valve commands, with potential for future diagnostic capabilities to support status monitoring and maintenance. It minimized downtime and successfully enabled PROFIBUS connectivity for water treatment applications. Automated real-time monitoring of the assembly line Comstar, an automotive component manufacturer, faced monitoring challenges with manual processes that prevented accurate defect diagnosis and delayed alarm acknowledgment. Red Lion by HMS Networks implemented the E3 I/O Module, DA30D, and Graphite HMI solutions seamlessly without affecting existing systems. The E3 I/O Module captured events through connected sensors, the DA30D logged status and transmitted data via radio modem to the control room SCADA, and the Graphite HMI provided local visualization. The solution delivered remote monitoring, reduced product defects, enabled real-time fault resolution, and provided a cost-effective, future-ready automation system, transforming manual monitoring into an efficient automated process. Conclusion Interoperability is essential for predictive maintenance, closed-loop optimization, and data-driven operations in industrial automation. The biggest challenge lies in networking devices with diverse protocols, legacy equipment, mismatched data models, and varying security requirements without disrupting production. Anybus from HMS establishes reliable, high-speed communication between any industrial device or system and all major networks, whether wired or wireless. This practical approach allows industries to modernize operations gradually, without major disruptions or excessive costs. Featured Products DA10D0C000000000 D A10D IIoT Protocol Conversion with RS232 and RS485 Buy Now DA30D0F000000000 High Performance Protocol with Data Logger, Web Server and Virtual HMI Buy Now AB7671-F X-Gateway, Anybus, EtherNet/IP Scanner to PROFIBUS Slave Buy Now 023200-B Anybus CompactCom 40, starter Kit - Pluggable Brick Buy Now About the sponsor HMS stands for Hardware Meets Software ™ . By enabling industrial equipment (hardware) to communicate and share information with software and systems, our customers increase productivity and sustainability. HMS Networks was founded in 1988 in Halmstad, Sweden where you still find our head office. Today, millions of industrial devices all over the world use HMS products to get connected. Since April 2024, Red Lion Controls is a member of the HMS Group.e14 - HMSHMS-Networksethernetprofinethmsindustrial automationprofibus