“We are integrating condition monitoring directly into connectivity.”

You're putting a Bluetooth transmitter in the connector—what's the idea behind this approach?

Andreas Ix: Our new M12Plus connectors are the result of a technology-driven development. The underlying idea is to integrate condition monitoring for heavily loaded cables directly into the connector technology. To achieve this, we have integrated the necessary voltage and current monitoring electronics into the connector, along with a Bluetooth chip. This allows the measured voltage and current values to be transmitted wirelessly to a control system on a continuous basis—currently once per second—or, depending on the application, to trigger an alarm.

What happens to the measured values obtained in automation, and how are they used for analysis, visualization, or IIoT applications?

The information collected is available directly and easily at the automation level, for example, via the Bluetooth connection to our IP67-rated TBEN-PLC controller. There, it can not only be individually preprocessed, evaluated, and visualized, but also exchanged with all other devices via multiprotocol. What’s more, the TBEN-PLC also enables, upon request, the transmission of cable status data directly to the cloud, which supports IIoT applications. At the same time, the Cable Monitor app can be used within our TURCK Automation Suite (TAS). By comparing input and output values, problems such as cable kinks, cable breaks, or a lack of power supply are detected early on, greatly simplifying the implementation of condition monitoring and predictive maintenance for the cables. This is a major advantage, especially in applications with drag chains or in robotics.

Can individual cables also be uniquely identified via the connectors?

Yes, because in most cases several cables will be used. To do this, we can parameterize the connectors and assign a unique ID to each cable. This offers a number of benefits: The user can identify in advance any cable that is at risk of failure via the individual MAC address of each connector and replace it immediately. A QR code on the connector will make maintenance even easier.

So the condition of the cables can be monitored – has monitoring of the connected actuators also been considered? For example, via the current and voltage values of a connected motor?

Our main focus is currently on monitoring the cables – but in principle it is possible to extend this to the connected devices. An application has already been implemented for preventing the unintentional shutdown of a conveyor system. The M12Plus cables with integrated condition monitoring detect increasing current consumption of stopper motors and report this to the PLC via Bluetooth. The stoppers are designed to prevent material jams. However, the drives get dirty quickly and then no longer work correctly, resulting in the motor drawing more current. If a threshold value is exceeded, the safe shutdown of the conveyor system is triggered and maintenance can rectify the problem. This example illustrates the advantage of our technology-driven approach: Although the focus is initially on the cable and its condition, a variety of other applications can be implemented. We are always open to exciting new ideas.

Compared to a standard sensor-actuator cable: How much more expensive is the variant with the M12Plus connectors compared to the standard cable?

Of course, the smart connectors have to be more expensive, but the user still benefits because their use can prevent machine downtime, for example. The costs incurred in the event of an unplanned production shutdown would be much more relevant here. The following must also be taken into account: As the saying goes, contacts are the end of electrical engineering. In fact, the most common causes of faults are poor plug connections or a faulty cable. Both – including the quality of the plug connection – can now be monitored, as products such as M12Plus and the TBEN portfolio complement each other perfectly. This is a particular benefit with regard to IP67 technology. It offers immense advantages, but a major disadvantage is the time-consuming troubleshooting. While the voltage can be easily measured at a terminal in the control cabinet, this has so far involved considerable effort in the plug connector. This is now much easier with our solution.

What goals is TURCK generally pursuing in the field of connection technology?

We are constantly expanding our extensive portfolio in this area – which includes couplings and connectors, flanges and bushings, connecting cables and fieldbus cables and distributors in numerous designs. Self-assembly plug connectors are also available. The range also includes inductive couplers – for example, the contactless inductive couplers in the NIC series transmit up to 16 switching signals via IO-Link and up to 18 W of power if required.