Robotics cabling for automotive industry

Robotics cabling for automotive industry

PROFINET/AIDA robotics cabling A coherent platform for power, signals and data in automotive industry PushPull connectors and Weidmüller s junction boxes are the basis for this new cabling standard in the automotive industry. The new PushPull connectors are an integral part of Weidmüller s power-signal-data installation system for AIDA* (AIDA is the Automation Initiative of the German Domestic Automotive Industry). The cabling standard for PROFINET installations was established on this foundation and so it naturally includes all the benefits of STEADYTEC technology! Cable packet from the electrical cabinet to the robot base Hose packet from the robot base to axis 3 Hose packet from axis 3 to the robot head The installation system for the robotics cabling is comprehensive and complies with the PROFINET cabling directive. It cuts the effort needed for assembly in half. The system consists of custom-tuned individual pluggable components intended for wiring the hose packets. This is a complete solution since you can Plug & Play to join the three key elements of industrial automation: power, signals and data. A cable packet is used to establish the connection from the electrical cabinet to the robot base. Hose packet 1 connects the robot base with axis 3. Hose packet 2 then establishes the connection from axis 3 to the robot head. Weidmüller s innovative installation strategy offers major benefits for the user: there is less complexity during installation and quicker replacement of the hose packets during maintenance. PushPull connectors enable you to swap out power, signal and data cabling; the procedure is simple, quick and complete. The sturdy metal housing enclosing the connector ensures a long lifespan even when used for applications in harsh environments. * The Automation Initiative of German Domestic Automobile Manufacturers (AIDA): - this organisation defines the standards for automation in the automotive manufacturing branch. - Clearly acknowledges PROFINET. *AIDA = Volkswagen, Audi, Porsche, Daimler and BMW 2

It consist of PROFINET PushPull connectors with two different inserts for data and signals along with the PushPull power connector. The system is completed with a FreeCon doublejunction box for both power (24 V) and data (Ethernet), and also a FreeCon single-junction box for signals. The connectors and the FreeCon junction boxes are equipped with RJ45 modules. The use of RJ45 modules featuring STEADYTEC technology allows the number of plug-in ports within a single channel to be reduced. The PROFINET specification calls for the the number of plug-in ports to be limited to six. Each additional plug-in port along the channel increases the power loss and reduces the effectiveness of the entire transmission path. Weidmüller use Category-6 A RJ45 components. In comparison to Category-5 components, these feature a significantly higher system reserve when transferring data. This permits more plug-in ports to be used within a Cat.5 channel than the specification describes. The PushPull connector for the power lines is fitted with a 5-pole insert for 16 amps. The PushPull signal connector is fitted with a 10-pole hybrid insert. This provides a custom-tuned system for power, signals and data. A continuous cabling system can be used all the way from the electrical cabinet to the robotics (or to similar applications). Module transmission path (channel) with six plug-in ports Coupling Coupling Patch cord Patch Cord Patch cord Transmission path (channel) with four plug-in ports Patch cord RJ45 module RJ45 module Patch cord When using high-quality CAT.6 A components, the distance to the allowed limit value is increased. Thus the security of the transmission is improved. The graph below clearly shows this difference in relation to the red limit curve. 3

The PROFINET PushPull connectors and FreeCon junction boxes PushPull data connectors for Ethernet or PROFINET transmissions. Max. 8 x AWG22, Cat.6 A PushPull signal connectors: 10-pole for analogue signals, low-level voltages or Fieldbus. For crimp contacts with wire cross-sections from 0.08 to 0.75 mm². PushPull power connectors for 24 V/16 A connections of up to 5x 2.5 mm² cables FreeCon: combined 2-way junction box for PushPull power and PushPull data connectors. Installation options: frontal install on a installation panel or with a supplemental mounting foot. FreeCon: junction box for PushPull signal or PushPull data connectors. Installation options: frontal install on a installation panel or with a supplemental mounting foot. 4

Weidmüller s FreeCon junction boxes provide other mounting options so that you can always be sure of getting the optimal cable feed. There are two M4-threaded fittings on the bottom side which allow the FreeCon junction boxes to be screwed on to a floor panel. These threads can also be used for attaching the mounting foot. Thus allowing the connector to be positioned within a 120 angle range. Thus allowing the hose packet to be properly guided within the range of the robot s axis 3. It can also be mounted on the front using four M4 screws. Thus the cable packet can be guided through such things as a panel or a wall. A mount opening is required in such cases. This installation system is suitable not only for robotics cabling, but also for all applications which require a sturdy, reliable and pluggable cabling solution. FreeCon junction box with frontal attachment The advantages include: Quick installation and replacement Sturdy metal housing Excellent transmission security A variety of attachment methods PROFINET-compliant Complies with the AIDA specification CAT.6 A components 120 FreeCon junction box with mounting foot 5

Double coupling of power and data IE-CD-V14MRJ/VAPM24V-C-MA 52 41 68 80 62 General data Sheath diameter Power Sheath diameter data Power flange: material properties Seal material Contact material Contact carrier material Contact surface material Pollution severity Plugging cycles Power flange: electrical properties Rated current I N Rated voltage U N Number of poles Connection cross-section Sheath diameter Type of connection RJ45 module: material properties Housing surface RJ45 module: electrical properties Category Contact resistance Insulation resistance Dielectric strength Current carrying capacity Number of poles Standard Diameter Type of connection Textured stainless steel IP65 diecast nickel-plated zinc NBR Copper alloy PA Gold over nickel 2 IP65 16 A at 20 C 24 V 40 C 70 C 5 AWG 18 AWG 13 / 0.75 mm 2 2.5 mm 2 Tension clamp diecast zinc / PBT GV30 CUSnZn Cat. 6 A / Class E A (IEC 11801 PDAM 1.2.2007) < 20 mω > 500 MΩ 0 V, DC (Contact contact) 1500 V, DC (Contact shield) 1 A at 50 C -40 C 70 C 8 IEC 60603-7-5 Assemble on connector max. 120 max. 120 23 23 IE-CD-V14MRJ/VAPM24V-C-MA 1 1068820000 including pivoting housing foot 6

Double junction box for power and data IE-CD-V14MRJ/VAPM24V-FJ 52 41 68 80 103 General data Sheath diameter Power Sheath diameter data Power flange: material properties Seal material Contact material Contact carrier material Contact surface material Pollution severity Plugging cycles Power flange: electrical properties Rated current I N Rated voltage U N Number of poles Connection cross-section Sheath diameter Type of connection RJ45 module: material properties Housing surface RJ45 module: electrical properties Category Contact resistance Insulation resistance Dielectric strength Current carrying capacity Number of poles Standard Diameter Type of connection Textured stainless steel IP65 6-12 mm 5-10 mm diecast nickel-plated zinc NBR Copper alloy PA Gold over nickel 2 IP65 16 A at 20 C 24 V 40 C 70 C 5 AWG 18 AWG 13 / 0.75 mm 2 2.5 mm 2 Tension clamp diecast zinc / PBT GV30 CUSnZn Cat. 6 A / Class E A (IEC 11801 PDAM 1.2.2007) < 20 mω > 500 MΩ 0 V, DC (Contact contact) 1500 V, DC (Contact shield) 1 A at 50 C -40 C 70 C 8 IEC 60603-7-5 AWG 26 AWG 22 IDC terminal Assemble on connector max. 120 max. 120 23 23 IE-CD-V14MRJ/VAPM24V-FJ 1 1068830000 Please order the pivoting housing foot separately: IE-CD-MA 1099580000 7

Single junction box for signals IE-CD-V14MHYB-10P-FJ 52 41 29 41 103 General data Sheath diameter Power Connector: material properties Seal material Contact material Contact surface material Pollution severity Plugging cycles Connector: electrical properties Textured stainless steel IP65 6-12 mm PA 66 GV30 NBR CuSn Au 3 IP65 Assemble on connector 23 max. 120 Rated current I N Rated voltage U N Surge category Contact resistance Number of poles Connection cross-section 24 V III 5 mω 40 C 70 C 10 AWG 24 AWG 20 / 0.2 mm 2 0.5 mm 2 max. 120 23 Unengaged connector Contact, 300-piece spool Contact, 9000-piece spool IE-CD-V14MHYB-10P-FJ 1 1068850000 IE-BIC-HYB-P-0,5-300 1 1096150000 IE-BIC-HYB-P-0,5-9000 1 1096160000 Please order the pivoting housing foot separately: IE-CD-MA 1099580000 8

AIDA robotics cabling Simple junction box specifications IE-CD-V14MRJ-FJ 60 52 41 29 41 Assemble on connector General data Sheath diameter Power RJ45 module: material properties Housing surface RJ45 module: electrical properties Category Contact resistance Insulation resistance Dielectric strength Current carrying capacity No. of poles Standard Cross-section Type of connection Textured stainless steel IP65 6-12 mm diecast zinc / PBT GV30 CUSnZn Cat. 6 A / Class E A (IEC 11801 PDAM 1.2.2007) < 20 mω > 500 MΩ 0 V, DC (contact contact) 1500 V, DC (contact shield) 1 A at 50 C -40 C 70 C 8 IEC 60603-7-5 AWG 26 AWG 22 IDC terminal 23 max. 120 max. 120 23 IE-CD-V14MRJ-FJ 1 1068880000 9

120 AIDA robotics cabling Pivoting housing foot, including 2 fastening screws IE-CD-MA 112 110 ø 4.2 ø 23 ø 4.2 58 Material Stainless steel 1.4301 10 35 IE-CD-MA 1 1099580000 20 Protective cap flange RJ 45 IE-BP-V14P Material PA IP 67 40 C 70 C IE-BP-V14P 1 1058300 Protective cap flange IE-BP-VAPP Material PA IP 54 40 C 70 C IE-BP-VAPP 1 1068930000 10

Power connector with PushPull interlock IE-PS-VAPM-24V General data Cladding diameter Material properties Seal material Contact material Contact carrier material Contact surface material Pollution severity Plugging cycles Electrical properties Rated current I N Rated voltage U N Number of poles Connection cross-section Sheath diameter Type of connection 5 mm 8 mm IP67 diecast zinc / PBT GV30 NBR Copper alloy PA Gold over nickel 2 < 16 A at 20 C 24 V 40 C 70 C 5 AWG 18 AWG 13 0.75 mm 2 2.5 mm 2 9 mm 13 mm Tension clamp IE-PS-VAPM-24V 1 1068900 11

Power connector, metal flange with PushPull interlock IE-BSS-VAPM-24V General data Material properties Seal material Contact material Contact carrier material Contact surface material Pollution severity Plugging cycles Electrical properties Rated current I N Rated voltage U N Number of poles Connection cross-section Type of connection IP67 diecast nickel-plated zinc NBR Copper alloy PA Gold over nickel 2 < 16 A at 20 C 24 V 40 C 70 C 5 AWG 18 AWG 13 0.75 mm 2 2.5 mm 2 Tension clamp IE-BSS-VAPM-24V 1 1069030000 12

PushPull plug-in connector Housing variant: 14 metal IP 67 Ø 27.41 + 0.48 0.49 33 ± 0.1 22 ± 0.05 R1.25 12.56 + 0.21 0.22 M3 18.4 ± 0.05 Housing variant: 14 metal Application: The Weidmüller variant-14 housings are made up of a bottom part (flange) and a top part (plug housing). When plugged together, they achieve IP67 protection. The differences: Flange-mounted housing Standardized flange with RJ45 adapter Central screw flange with RJ45 adapter Device flange Plug housing With RJ45 adapter With RJ45 adapter and kink prevention With fibre-optic adapter With fibre-optic adapter and kink prevention Type Order No. IE-BHS-V14M-RJA 1011540000 IE-BHC-V14M-RJA 1047950000 IE-BHD-V14M 1047940000 IE-PH-V14M-RJ 1011560000 IE-PH-V14M-RJ-BP 1011570000 IE-PH-V14M-FO 1058000 IE-PH-V14M-FO-BP 1058100 on request 1011560000: plug housing with RJ45 adapter 1011570000: plug housing with RJ45 adapter and kink prevention 1058000: plug housing with fibre-optic adapter 1058100: plug housing with fibre-optic adapter and kink prevention 1058280000: plug housing: protective cap (PA) 1011540000: standardised flange with RJ45 adapter 1047940000: device flange 1047950000: central screw flange with RJ45 adapter 1058300: flange housing: protective cap (PA) The Weidmüller range of tools includes a selection of sheet metal punches for creating the cut-outs in electrical cabinet doors. We also offer a comprehensive range of markers for connectors and flanges. See also the chapter. Colour coding Type Order No. yellow IE-CR-IP67-WS20-YE 1963030000 blue IE-CR-IP67-WS20-BU 1963020000 orange IE-CR-IP67-WS20-OG 1963000 green IE-CR-IP67-WS20-GN 1963040000 grey IE-CR-IP67-WS20-GY 1963000000 white IE-CR-IP67-WS20-WH 1962990000 Dust cap Flange-mounted housing, protective cap IE-BP-V14P 1058300 Plug housing protective cap IE-PP-V14P 1058280000 IP 67 diecast zinc Variant Variant14 to IEC 61076-3-117 Cladding diameter 5 mm - 10 mm Configuration Connector housing with label retainer 9*11 mm; suitable for holding RJ45 and FO inserts, min. / max. -40 C / 70 C Plugging cycles 750 plugging cycles for plugs to IEC 60603-7 13

12,9 AIDA robotics cabling RJ45 inserts Cat.6A IP 20 9,45 13,19 40,22 15,6 32,51 13,19 40,1 15,6 RJ45 inserts Application: The inserts are designed for use in Weidmüller housings regardless of whether variant 1, variant 4 or variant 5. RJ45 tool-free connector insert Flange insert USB coupling, type A RJ45 coupling, Type C RJ45 AWG 22, EIA / TIA 586 A RJ45 AWG 22, EIA / TIA 586 B RJ45 AWG 22, PROFINET Plug insert RJ45 tool-free RJ45 crimp Type Order No. IE-BI-USB-A 1019570000 IE-BI-RJ45-C 1962840000 IE-BI-RJ45-FJ-A 1962850000 ie-bi-rj45-fj-b 1963840000 IE-BI-RJ45-FJ-P 1963830000 IE-PI-RJ45-FH 1962730000 IE-PI-RJ45-TH 1962720000 diecast zinc housing, black Litz conductor: AWG 26/7 to AWG 22/7 Solid conductor: AWG 26/1 to AWG 22/1 Sheath diameter: 5.5 to 8.5 mm Wire insulation diameter: up to 1.6 mm Colour coding on connector in TIA A/B/ProfiNet tools Pressing tool Type Order No. TT 8 RS MP 8 9202800000 See also the chapter. RJ45 crimp connector insert: Brass housing Litz conductor: AWG 27/7 to AWG 24/7 Solid conductor: AWG 27/1 to AWG 24/1 Sheath diameter: 5 to 7.3 mm Wire insulation diameter: 0.85 to 1.05 mm Category Cat. 6 A / Class E A (IEC 11801 PDAM Am 1.2 2007) IP 67 with housing Plugging cycles 750 plugging cycles for plugs to IEC 60603-7 Shielding 360 all-round enclosure Configuration Connector and flange insert for variant 1, 4, 5 and 14 housings RJ45 flange insert: diecast zinc housing Version for TIA A/B ProfiNet Litz conductor: AWG 26/7 to AWG 22/7 Solid conductor: AWG 26/1 to AWG 22/1 Sheath diameter: 5.5 to 10 mm Wire insulation diameter: up to 1.6 mm USB flange insert Housing made from thermoplastic (PBT) Type A acc. to IEC 61076-3-107 USB 2.0 compliant Rated for more than 1500 plugging cycles : 14

PushPull hybrid connector (Q10) 86.3 3.4" 22.3 0.9" 33 1.3" 42 1.65" 26.8 1.1" SW20 0.8" 22.2 0.87" approx. 56.5 2.2" PushPull hybrid connector (Q10) PushPull hybrid connector (Q10) V14 plug, in compliance with IEC 61076-3-117, hybrid insert, 10 poles Flange insert V14 standardised flange / Hybrid (Q10) (including insert) Insert (separate) Plug insert V14 plug / Hybrid (Q10) (including insert) Insert (separate) Type Order No. IE-BSS-V14M-HYB-10P-FJ 1072900000 IE-BI-HYB-10P 1069000 IE-PS-V14M-HYB-10P 1072900 IE-PI-HYB-10P 1068990000 V14 standardized flange V14 standardised flange, in compliance with IEC 61076-3-117, hybrid insert, 10 poles. Order crimp contacts separately. Crimp contacts, hybrid (Q10) Crimp contacts, socket for plug-insert hybrid (Q10) Crimp contact, AWG 24 20 / 0.2 0.5 mm² Crimp contacts, male for flange-insert hybrid (Q10) Crimp contact, AWG 24 20 / 0.2 0.5 mm² Crimp contacts / tools Type Order No. Crimp contacts, hybrid (Q10) - socket IE-PIC-HYB-S-0,5-300 1096180000 for connector insert (roll with 300 contacts) Crimp contact, hybrid (Q10) - male IE-BIC-HYB-P-0,5-300 1096150000 for flange inserts (roll with 300 contacts) Crimping tool for hybrid contacts (Q10) HTF HYB 1119580000 *Plugging cycles min 500 Type of connection crimp Connection cross-section mm 2 AWG 24-20 *Rated current [A] 3 *Volume resistivity per path [mohm] < 5 15

www.weidmueller.com Argentina Australia Austria Azerbaijan Bahrain Belarus Belgium Bosnia and Herzegovina Brazil Bulgaria Canada Chile China Colombia Costa Rica Croatia Czech Republic Denmark Ecuador Egypt Estonia Finland France Germany Great Britain Greece Hong Kong Hungary Iceland India Indonesia Iran Ireland Israel Italy Japan Jordan Kazakhstan Korea Kuwait Latvia Lebanon Lithuania Luxembourg Macedonia Malaysia Malta Mexico Moldova Netherlands New Zealand Norway Oman Pakistan Peru Philippines Poland Portugal Qatar Romania Russia Saudi Arabia Serbia Singapore Slovakia Slovenia South Africa Spain Sweden Switzerland Taiwan Thailand Tunisia Turkey Ukraine United Arab Emirates United States Uruguay Uzbekistan Venezuela Vietnam Weidmüller positions itself worldwide successfully on a sustained basis as the leading provider of solutions for electrical connectivity, transmission and conditioning of power, signal and data in industrial environments. The company develops, produces and sells products in the field of electrical connectivity and electronics all over the world. Via a global network of application specialists Weidmüller offers engineering services and develops application specific solutions. The complete product and service portfolio consistently assures both Weidmüller and its customers of competitive advantages and an increase in value. We cannot guarantee that there are no mistakes in the publications or software provided by us to the customer for the purpose of making orders. We try our best to quickly correct errors in our printed media. All orders are based on our general terms of delivery, which can be reviewed on the websites of our group companies where you place your order. On demand we can also send the general terms of delivery to you. Weidmüller Interface GmbH & Co. KG Postfach 3030 32720 Detmold Klingenbergstraße 16 32758 Detmold Phone +49 5231 14-0 Fax +49 5231 14-2083 info@weidmueller.de www.weidmueller.com Order number: 1210640000/05/2010/TMMD