In an automation system, interface products that connect various elements play a very important part. Interface products in automation play the same role that is played by infrastructure in development of a nation.

Katlax Interface Products Group (IPG) manufactures various connectors, connectors with cables and such interface products which help in connecting various types of sensors to different types of cable trees or amplifier and controller units which make automation systems. Some of the common and standard products are available off the shelf and various others that need to be developed are also taken up to meet special needs.

With an in-house development cell which has die design, machining and pilot extrusion machine for quick development this group caters to various demands of its clients with tailored quality products. The test facilities include micro ohm meter, insulation and high voltage tester as well as routine automatic tester for mass production needs. With an ERP system and programmable length cable cutting machine customized cable lengths which help in reducing waste can also be supplied by this group.

Why Interface Products

Normally field devices are mounted in harsher environments near equipment but the central controls are located at central locations. The signal from field devices needs to be taken to controllers via cables. If there are environmental problems like fluctuating voltage, spikes, physical abuse or accidental breakages, the devices fails more often than the connecting path consisting of cable and interconnections. Earlier the devices used to have their own cables and one had to change device as well as cable. It means increased downtime and consequent production loss. With interface products, one need only replace the device and quickly restart the system. Various advantages of this system are given below:

• Time saving of reconnecting device at machine
• No skilled electrician is needed to change a device. The device becomes as versatile as a PCB and can be replaced by anyone
• With newer technologies one can substitute device and improve performance
• One becomes free on choice of sensing device
• The interconnection quality does not depend on electrician skill but is assured by interconnection system components
• It is environment friendly and reduces carbon footprint by preventing scrapping of cables
• It is automation friendly and can be better used for higher levels of control, and
• After replacement the wiring does not become worse as it is not affected. In the old system, due to lack of proper dressing components wiring after such replacement becomes shabby and unreliable.

Katlax Interface Product Group (IPG) has developed innovated and indigenously various types of connectors and cable assemblies for sensors:

• Screw type straight
• M-12 plastic (M & F) connector
• M-8 (M & F) straight
• Quick connect series connector
• M-8 female right angle
• M-12 female right angle
• M12 female straight
• M-12-5 pin male (up to 8 pin), and
• M-12-4 in male connector.

Application

When sensors are used in automation or any high efficient machine, machine or process down time is critical when sensors are provided with molded cable, which is part of cable harness assembly. To avoid cable removal when sensor is defective, connector is solution with plug forming part of sensor and socket with cable.

Key Features

• Conductor color identifications comply with European Standards
• Katlax sensors, for all size, i.e., M8 to M36 or box type, we use M12 connectors both male and female
• Right angle cable socket, with integrally molded lead, self-securing lock nut
• Screw locking, metal coupling nut and self-assembly
• Connector assembly also available without cable, and
• All the combinations also available with shielded type cable.

These connectors can be supplied in mounting diameters of M8, M10 and M12 and Euro, M & F, F and F, 3 core and 4 core types to serve various applications. Likewise, the male and female contacts are available in 3 poles, 4 poles and 5 poles. Female connectors can be supplied with or without LED. The designs include hydraulics and pneumatics controls and I/p - O/p devices.

Sensor connectors have been so designed that they are user friendly and facilitate the implementation of wiring jobs in the automation projects. The connectors' I/O wires can all be crimped at once and hence, they simplify the wiring. The connector and cable assemblies provide substantial new application flexibility to production lines and associated OEM production machinery design. They reduce wiring to a great extent. Besides, as Actuator-Sensor interfaces (AS-i) they speeded up maintenance when required. They detect short circuits to prevent system from going down. They locate faults quickly. In short, they simplify the troubleshooting process. All these save precious time and money for the users and ensure maximum uptime.

The connectors allow for fast and easy replacement of sensors, switches and control components. They provide mechanical safeguard against vibrations. In conjunction with the sensors the use with bus-bars (CAN-bus, PROFI-bus, INTRA-bus) circular connection with extruded insulation cable cuts costs and work, substantially during the system installation.

Connectors come with nickel plated couplers and provide IP67/IP68 protection. They are mechanically keyed for miss-mating.

Connectors consist of male and female plugs, straight and 90? configuration with polyurethane body and PVC jacketed cables. Teflon body and cables can also be offered for special applications.

Connector and cable assemblies are designed for international standards. Some of the products are tested and certified by CE compliance and UL (American) and cUL (Canadian) listed by Underwriters' Laboratory. The cables used are UL approved and are characterized by very high mechanical and chemical stability. The connectors are factory moulded to the cable for durability.

The cables can be made available with varied lengths of wire or different cable material depending on user's exact application needs.

Connectors can be offered without cable also, connector and cable assemblies can be used with sensors in conveyors, automated machinery, material handling equipment, packaging machinery, textile machinery, plastic moulding machinery, printing machinery, pharmaceutical machinery, etc. They ensure better handling of automation and improve efficiency of diagnostics. On request special type connectors with union nuts of high quality nickel chrome plating for food applications and the chemical industry are available.

(Katlax Enterprises Pvt Ltd (Interface Product Group), Pune. Telefax: 91-20-27110224. Mobile: 096897-83922. Email: sales@katlax.com)