Ever since the first programmable logic controller (PLC) was developed in the late 1960s, pundits have been predicting when the fourth industrial revolution would occur. This long-anticipated milestone, dubbed Industry 4.0, is now upon us—and it carries the promise of integrated, real-time data accessibility that can control costs and curtail downtime.

While the third industrial revolution enhanced assembly line operations with greater automation and Computerised control, the fourth actually builds on those capabilities by incorporating internet-driven connectivity. Consequently, in many respects, this new phase may actually represent something of an evolution. Smart factories essentially combine operational technology (OT) like software-defined assembly line equipment with advanced information technology (IT) like cloud computing and artificial intelligence (AI) to bring high-speed, low-latency responsiveness to the factory floor.

In the Industry 4.0 ecosystem, the underlying objective is capturing and analyzing information to reduce bottlenecks, optimise throughput, enact preventive maintenance and avoid delays—thereby unlocking supply chain and operational efficiencies that create competitive advantage. Fully embracing this new frontier means leveraging machine learning (ML) and robotic process automation across the Industrial Internet of Things (IIoT) to design smart factories that can self-regulate in real time for more informed, autonomous decision-making.

Succinct as that may sound, however, the actual Industry 4.0 implementation roadmap isn’t necessarily simple to navigate. Because so many of the systems underpinning these applications are proprietary, integrating new technology that fuels smart manufacturing can be daunting. At the same time, engineering more intelligent equipment introduces hurdles that can’t be realistically resolved by expanding physical space or rebuilding existing facilities. More autonomous operation also introduces unique safety and cybersecurity concerns.

All this means that flexibility, awareness, and persistence are imperative for Organisations hoping to maximise the possibilities of Industry 4.0. A clear understanding of evolving trends can lead to coordinated strategies that identify future-proof approaches, address potential pain points and encourage multi-level business buy-in.

As an array of comprehensive advances converge to revolutionise capabilities across the value chain, here are three unfolding Industry 4.0 technology trends to watch.

Trend 1: Smarter machines are transforming system-wide communication

Achieving the full potential of Industry 4.0 means making relevant data available in ways that enable timely decision-making and utilize next-generation technologies. Today’s industrial automation (IA) supply chain is already incorporating these next-generation technologies in smart machines that feature augmented computational capabilities to perform more advanced analytics.

Unfortunately, engineers are encountering existing IA command structures that are often outdated or unwieldy. Successfully addressing this challenge can directly support streamlined flexibility and smarter connectivity across a robust, scalable and integrated manufacturing platform. One way to achieve this flexibility increase is by incorporating dedicated machine logic that eliminates the PLC altogether.

Eliminating the PLC can considerably reduce cabinet size while improving overall cost structures, PLC elimination also boosts the efficiency of advanced robotics by applying logic locally, on a machine-to-machine (M2M) basis instead of top-down. M2M communication thereby facilitates automatic production and assembly line adjustments without episodic equipment resetting or human intervention.

Because Industry 4.0 advances add considerable systemic complexity, it’s equally crucial to help these smart machines identify issues and communicate meaningfully with elements and operators across the entire distributed network. This is where innovative sensor functionality helps today’s manufacturers maximise smart machine capabilities and optimise real-time data access. It’s not enough for sensor solutions to simply identify a wide variety of objects and properties—they also need to withstand harsh industrial conditions while fitting into size-constrained areas.

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Molex offers specialised sensors that are engineered to enable smarter, more agile factories. Our self-contained Contrinex Inductive and Photoelectric Sensors, for instance, offer the following advantages:

• Single-piece metal housings that make them virtually impervious to shock, vibration or rough handling, which could cause signal interference
• Full compliance with IP67, 68, 69K and Ecolab standards to withstand debris ingress and external hazards
• Compact size and extensive sensing range, making them ideal for limited-space environments comprised of numerous integrated components
• Integrated I/O link, which continuously monitors process-related input for uninterrupted assessment of operational status and more robust communication
• Application-specific integrated circuit (ASIC) technology, which helps ensure long life and dependable performance
• Patented ultraviolet (UV) technology is integrated into the photoelectric option, which detects thin or transparent objects at distances of up to 1200mm

Sensors serve as a vital link that can make smart machines more self-aware, so Molex is equipping customers with ruggedized innovations that reflect 80+ years of industrial communications and miniaturisation expertise.

Trend 2: Power demands are expanding substantially

Engineering professionals who responded to the latest Molex 'State of Power' survey indicate that industrial power management is their number-one concern by a whopping 40% margin. This is likely because self-monitoring assembly lines are governed by sophisticated ML modules that inspect products, analyse information, calculate appropriate adjustments and course-correct as issues arise. That degree of integrated functionality represents an extensive information network—one that consists of sizeable machines, specialised wiring and numerous interconnected devices like cameras, actuators, control units and sensors.

All these advanced capabilities introduce a higher demand for electrical power and potential electrical upgrades such as transformers, switchgear and power distribution panels. Those signal and power elements need to be engineered for extremely unforgiving and often space-constrained operating conditions while delivering high current carrying capacity and uninterrupted performance. Under these exacting circumstances, safe and reliable connectivity is a critical priority.

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Recognizing this vital need, Molex offers several solutions designed to help advanced industrial environments optimise efficient power management.

Sentrality High-Current Pin and Socket Interconnects are one example. They incorporate several advantageous features, including:

• The patented Molex COEUR socket design, a conical shape that creates multiple contact beams to provide added surface area at the contact interface—fostering very low contact resistance
• Extremely low voltage drop across the contact interface, resulting in minimal heat generation and higher current-carrying capacity compared to other contact designs
• Proprietary OmniGlide technology from Molex, which enables an industry-leading radial self-alignment of up to 1.00mm—avoiding tolerance stack-up issues while minimizing potential connector and contact beam damage during mating
• Multiple connectivity options to address a diverse range of industrial needs—including board-to-board, busbar-to-board and busbar-to-busbar

The Molex Brad M12 Power L-Code Connector System is another offering that’s optimised for Industry 4.0 demands. This compact yet high-capacity solution:

• Adheres to PROFIBUS and PROFINET International (PI) standards for PROFINET systems, making it fully compatible with existing infrastructure
• Delivers up to four times the power of standard M12 connectors
• Is engineered to mitigate wiring and assembly errors
• Offers added ingress protection and peace of mind in harsh industrial environments, thanks to Molex Flamar weld-slag and oil-resistant (WSOR) cabling and an IP67-sealed interface

Industry 4.0 equipment requires leading-edge power solutions that can endure the rigours of automated smart factory environments. Molex is helping customers enhance the value chain with intelligent and robust power management innovations.

Trend 3: Safety initiatives are an even higher priority

Particularly in light of the high-current power demands, integrated systems running largely unsupervised need active safety protocols. This is especially true given the humidity, shock, vibration, harsh chemicals and temperature extremes typically present on factory floors. Machinery in constant motion also creates its own inherent safety concerns.

Additionally, despite the autonomous foundation of Industry 4.0, a genuine 'lights-off' factory floor isn’t necessarily attainable because while numerous aspects of production can be addressed by intelligent automation, some level of human oversight will always be required. Personnel will still need to access the factory floor for maintenance or troubleshooting, for example. These human operators require safe conditions to carry out their various roles.

Cybersecurity is another key aspect of safety when it comes to Industry 4.0. This is because interconnected devices sharing information via the internet can introduce potential information vulnerabilities as various OT and IT elements converge—and interception tactics are constantly evolving.

All these issues underscore the need for dependable interconnectivity options that support safe operation, rapid communication and timely mitigation should hazardous concerns arise. In addition to facilitating rigorous external awareness, connectivity solutions also need to accommodate the broad range of distributed control protocols currently employed by industrial manufacturing networks—thereby supporting the implementation of both physical safety and cybersecurity measures.

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This is why Molex offers machine-mountable Harsh I/O Modules that serve as simple yet reliable solutions for connecting industrial controllers to I/O devices in unpredictable factory environments. Harsh I/O Modules offer:

• Full compliance with all major fieldbus standards, including CANopen, EtherNet/IP, CIP Safety and PROFINET, to optimise flexibility
• Diagnostic LEDs that enable ongoing visual awareness of network, I/O and power status for safe, consistent productivity

As Industry 4.0 continues to evolve, sustained safety is imperative for smooth, efficient equipment operation. Molex supports customers with rugged yet adaptable interconnect solutions that perform reliably in hazardous environments while aligning with current communication and security protocols at every level.

Industry 4.0 illustrates that steadfast connections are key

The interconnected systems that comprise Industry 4.0—including robots, ML and machine-to-machine communications—are enabling smarter factories that improve real-time responsiveness while measurably enhancing efficiency. Updating and evolving existing systems creates an array of unique challenges that include integrated M2M communication, power management, operational safety and more. To successfully address these complex issues, Organisations can align themselves with experienced industry allies who are able to provide trend-related insights and deliver targeted solutions. If there’s one crucial long-term takeaway from Industry 4.0, it’s the enduring importance of dependable connections.

CONCLUSION

As Molex continues to establish new standards in industrial automation, Farnell is expanding its product range to offer you the latest innovations and essential connectivity solutions that have been integral to our portfolio for generations. Explore the newest innovations from Molex. Click here