Digi-Key Electronics - Experts & Thought Leaders

To connect portable or remote network end devices to the Internet of Things (IoT), or to control machines remotely using machine-to-machine communication (M2M), a mobile radio connection for data exchange via the cloud is a good option. However, this option presents hurdles for the developer, such as determining which wireless networks can support the required data throughput worldwide and which protocols the wireless modem must be able to handle. System scalability, data security, cost, time to market, and the acquisition and operating costs incurred by the user must also be considered. IoT and M2M applications This article briefly explains what LTE Cat 1 offers developers of IoT and M2M applications. It then introduces radio modules from u-blox's LARA-R6 series that provide universal connectivity and reliable performance. The article concludes by showing how developers can use an evaluation board (EVB) to configure and control the modules via AT commands and generate AT command strings via library functions. LTE Cat 1 compared to LTE Cat 1bis, LTE Cat M, and LTE Cat NB While LTE cellular radio now achieves gigabit transmission rates, low-power, wide-area (LPWA) protocols like LTE Cat 1, LTE Cat 1bis, LTE Cat M, and LTE Cat NB are designed to be particularly efficient in terms of energy consumption, network resources, and cost. This is critically important for IoT devices. Providing up to 20 megahertz (MHz) channel bandwidth in full duplex, LTE Cat 1 achieves download data rates of up to 10 megabits per second (Mbps) and upload data rates of up to 5 Mbps. Two antennas enable receiver (Rx) diversity for better performance (Table 1). LTE Cat 1bis uses a single antenna. LTE Cat 1 mobile radio for global availability These modules are an excellent solution for global/multi-regional coverage and come in a small LGA u-blox's LARA-R6 series is comprised of robust cellular radio modules designed for the radio access technology (RAT) LTE Cat 1 frequency division duplex (FDD) and time division duplex (TDD) standards. They support 3G UMTS/HSPA and 2G GSM/GPRS/EGPRS as a fallback solution. These modules are an excellent solution for global/multi-regional coverage and come in a small LGA form factor measuring 26 x 24 millimeters (mm). Features and Capabilities Equipped with versatile interfaces, a wide variety of features, and multiband and multimode capabilities, LARA-R6 modules are suitable for applications that require medium data speed, seamless connectivity, excellent coverage, and low latency. Such applications include asset tracking, telematics, remote monitoring, alarm centers, video surveillance, connected health, and point-of-sale terminals. Reliable performance Programmers can take advantage of the embedded IoT protocols and security features All modules support Rx diversity for reliable performance in difficult coverage conditions or when voice-over LTE (VoLTE) is required. Programmers can take advantage of the embedded IoT protocols (LwM2M, MQTT) and security features (TLS/DTLS, secure update, and secure boot) to implement various functions, including device management, remote device control, and secure firmware over-the-air (FOTA) updates. Three regional variants The LARA-R6 series supports LTE Cat 1 according to 3GPP Release 10 and achieves global coverage with three regional variants: The LARA-R6001-00B (data and voice) and LARA-R6001D-00B (data only) modules support 18 LTE FDD/TDD frequency bands plus 3G/2G fallback for global connectivity. The LARA-R6401-00B (data and voice) and LARA-R6401D-00B (data only) modules provide an ideal LTE Cat 1 solution for North America, supporting LTE bands from AT&T, FirstNet, Verizon, and T-Mobile. The LARA-R6801-00B (data and voice) and LARA-R6801D-01B (data only) modules are designed for deployments in the following regions: Europe and the Middle East (EMEA), Asia Pacific (APAC), Japan (JP), and Latin America (LATAM) (Figure 1). LARA-R6 special features at a glance LARA-R6 modules integrate a cellular baseband processor with external interfaces, an RF transceiver with amplifiers and filters, memory, and a power management unit (Figure 2). The RF transceiver operates in the frequency bands 700 MHz, 800 MHz, 850 MHz, 900 MHz, 1.7 GHz, 1.8 GHz, 1.9 GHz, 2.1 GHz, and 2.6 GHz. All data transfer protocols of the cellular baseband processor can be controlled and configured via AT commands using the external UART and USB interfaces. Protocols Dual stack IPv4 and IPv6 Embedded TCP/IP, UDP/IP, FTP, and HTTP Embedded MQTT and MQTT-SN Embedded LwM2M eSIM and Bearer Independent Protocol (BIP) Peak transmission powers An excellent antenna sensitivity of less than -100 dBm, corresponding to signal powers of less than 0.1 pW LARA-R6 modules require a supply voltage of 3.1 to 4.5 volts and have an idle current consumption of around 1.1 milliamperes (mA). In 2G operation, individual TDMA time slots can reach peak transmission powers of over 33 decibels referenced to 1 milliwatt (mW) (dBm) (> 2.0 watts), and all other RAT reach levels of over 24 dBm (> 0.25 watts). An excellent antenna sensitivity of less than -100 dBm, corresponding to signal powers of less than 0.1 picowatts (pW), enables stable radio connections at the edge of the mobile network. Evaluating and programming The quickest way to start evaluating and programming a LARA-R6 module is to use an R6 EVB (EVK-R6) and a plug-in LARA-R6 adapter board (ADP-R6) for the corresponding region. For example, the EVK-R6001-00B for global applications includes the plug-in adapter board ADP-R6001-00B (voice + data) and a GNSS adapter board (Figure 3). Voice and data transmission EVK-R6801-00B for EMEA/APAC/JP/LATAM includes the ADP-R6801-00B adapter The EVK-R6401-00B variant for North America includes the ADP-R6401-00B adapter, while the EVK-R6801-00B for EMEA/APAC/JP/LATAM includes the ADP-R6801-00B adapter. The three adapter boards already mentioned for voice and data transmission are also available separately, as are versions for data transmission only, including the ADP-R6401D-00B (North America) and ADP-R6001D-00B (global). R6 adapter board The R6 adapter board extends the LARA-R6 module with two antennas and two MiniUSB connectors. The R6 EVB adds a GNSS module, a SIM card slot, additional plug-in connections, jumpers, switches, and a power supply to the module peripherals (Figure 4). Each kit contains one EVB with an attached LTE Cat 1 LARA-R6 adapter board and a GNSS module from u-blox, one USB cable, two LTE mobile radio antennas, a GPS/GLONASS antenna, and a power supply unit. Commissioning of the EVK The EVK-R6 kit from u-blox simplifies the evaluation of multimode LTE Cat 1 / 3G / 2G cellular modules The easy-to-use, powerful EVK-R6 kit from u-blox simplifies the evaluation of multimode LTE Cat 1 / 3G / 2G cellular modules. A Windows PC with the LARA-R6 USB driver installed controls the LARA-R6 modem via the USB connector and simplifies the connection setup via the system settings. To get started, the developer needs to: 1) Insert the SIM card and connect both cellular antennas and the GNSS antenna. 2) Carefully configure the jumpers and switches of the EVK. 3) Apply the supply voltage and turn on the main switch SW400 on the EVB. 4a) For operation as a low data rate modem via the “Main UART” interface, connect the PC to the MiniUSB jack J501 or RS232 jack J500 on the EVK. b) For operation as a low data rate modem via “Two UARTs”, connect the PC to the cellular USB jack J201 interface on the ADP. c) For operation as a high data rate modem via “Native Cellular USB”, connect the PC to the MiniUSB jack J105 on the ADP. 5) Press the Cellular Power-On button SW302 on the EVB. 6) Run a terminal application software (such as m-center), go to the COM port setup menu, choose the AT port corresponding to 4a, 4b, or 4c, and set these values: Data rate: 115,200 bps; Data bits: 8; Parity: N; Stop bits: 1. For more details, refer to the EVK-R6_UserGuide_UBX-21035387. The m-center tool helps evaluate, configure, and test u-blox cellular products, and it includes an AT command terminal. Simple Internet connection using a Windows PC By connecting a Windows PC to the EVK, the user can establish a wireless Internet connection in two ways: A low-speed packet data connection: This uses the TCP/IP stack of the Windows PC via the UART interface of the LARA-R6 module. The PC and EVK are connected according to method 4a. The developer must select Phone and Modem > Modems > Add using the Windows Control Panel. The next step is to pick the “Don’t detect my modem” checkbox, select “Standard 33.6 kbps Modem”, and allocate a COM port. If necessary, the developer can add Properties > Advanced > Extra initialization commands. A high-speed packet data connection: This accesses the Internet using the TCP/IP stack of the Windows PC via the cellular native USB interface of the LARA-R6 module. The PC and EVK are connected according to method 4c. The developer must select Network and Sharing Center > Set up a new connection or network via the Windows Control Panel and click “Connect to the Internet”. The next step is to select “Dial-up” and one of the AT USB Ports. The final step is to enter dial-up parameters (Dial-in number, provider name, user ID, and password). Registering the SIM card with the mobile operator Once the SIM card and MNO parameter are configured, the cellular module automatically registers itself on the cellular network after power-on. If there is a problem, the registration can be checked manually using the AT commands shown in Table 2. Communication to the remote HTTP server via AT command Sixteen application examples, including ping tests, registration, packet switch, SMS, GNSS, and IoT cloud The GitHub repository “Firechip_u-blox_LARA-R6_Arduino_Library” contains an extensive library of AT commands for the LARA-R6 modules, written in C++ for Arduino controllers.  Sixteen application examples, including ping tests, registration, packet switch, SMS, GNSS, and IoT cloud, provide suggestions for custom code structures. ThingSpeak AT commands can also send requests to a remote HTTP server during an active connection, receive the server response, and store that response transparently in the local file system. The supported methods are HEAD, GET, DELETE, PUT, POST file, and POST data. The Lara_R6_Example9 sends random temperatures to the RemoteHTTP-Server ThingSpeak.com using HTTP POST or GET. ThingSpeak is an IoT analytics platform service by MathWorks that helps to aggregate, visualize, and analyze live data streams in the cloud. Table 3 shows the syntax of the HTTP command “POST data.” This example can be programmed on an Arduino host controller, which controls the LARA-R6 module on an EVK board via AT commands. Additionally, a configured SIM card is required. Random temperature measurement The C++ main program generates a random temperature value, forms the cloud-specific data string The programmer must create a ThingSpeak user account and set field 1 for the random temperature measurement value via the menu item Channels > My Channels > New Channel. The corresponding "Write API Key" is entered in the main program. The C++ main program generates a random temperature value, forms the cloud-specific data string, and calls the library function every 20 seconds. Generate the AT command string calling library functions The library header “Firechip_u-blox_LARA-R6_Arduino_Library.h” forwards the function call sendHTTPPOSTdata to the library procedure “Firechip_u-blox_LARA-R6_Arduino_Library.cpp”, where the fully formatted AT command string is generated and sent. The library procedure uses the passed parameters of the function and additionally declared variables from the library header to generate the complete HTTP command string according to Table 3. Finally, the LARA-R6 modem sends the resulting AT command string to the ThingSpeak remote HTTP server. Conclusion For the global networking of low-power IoT and M2M applications, LTE Cat 1 multi-mode radio modules from the LARA-R6 series are efficient and cost-effective. As shown, developers have ready access to all interfaces using the EVK and can easily configure and control the protocols and functions of the module via AT commands. This provides simple options for operating as a PC modem, sending data to the cloud, and generating AT command strings via library functions.

PCB connectors are modular, insulated devices that facilitate electrical connectivity to circuit boards. As the demand for compact and efficient electronic devices increases, so does the need for reliable, easy-to-use connectors. Phoenix Contact, an industrial automation, interconnection, and interface solutions manufacturer, has introduced its LPC 2,5 PCB connectors for electronic applications. With a rich history and a commitment to innovation, Phoenix has established itself as a trusted partner for designers and engineers seeking quality, reliability, and performance. Establishing electrical connections Note that these connectors are designed to be mated to Phoenix Contact’s CCA 2,5 base strips with the matching number of positions. The primary focus of this article is on the LPC 2,5 PCB connectors. Therefore, the base strips will not be examined further. Connectors play a crucial role in establishing electrical connections within printed circuit boards Connectors play a crucial role in establishing electrical connections within printed circuit boards. These components enable the seamless transmission of signals between different components, such as integrated circuits and other electronic devices. One significant function of connectors is facilitating the easy and secure insertion and removal of electronic components during assembly and maintenance. In such scenarios, the quality of the connectors used directly impacts the PCB’s overall performance and lifespan; using inferior-quality products can lead to issues such as poor signal transmission, increased resistance, and even premature failure of the PCB. Delivering enhanced protection There are various types of PCB connectors, each with its own unique advantages. For instance, lever connectors provide a robust locking mechanism for a secure and reliable connection and are useful in applications where shock, heavy vibration, or frequent movements are a concern. On the other hand, connectors like the SPC series and the DMC series deliver enhanced protection and forceless ejection, which are essential for safety and ease of use. Integrating connectors into PCBs, while seemingly straightforward, requires meticulous attention to detail. By understanding the challenges of integration and seeking optimized PCB connector solutions, engineers can ensure the production of reliable and efficient electronic devices. Other potential hazards Safety concerns - A critical concern with the use of connectors is the potential loss of continuity across contacts. A break in continuity can have severe consequences in applications, including the following: Electric vehicles (EVs): A loss of continuity in PCB connectors can lead to the failure of critical systems such as steering and braking. Household appliances: Faulty connectors can result in short circuits, leading to fires and other potential hazards. Maintaining signal integrity Significant signal degradation can lead to data loss, corruption, or transmission errors Space constraints - The ongoing trend in electronics is evident – smaller and lighter – and this trend directly impacts PCB design, where every millimeter of space is valuable. Moreover, adequate spacing between connectors is vital to prevent electrical interference, known as crosstalk. When connectors are placed too close to each other, the risk of signals from one connector interfering with another rises, leading to electrical noise. Signal integrity - With the advent of high-speed data transfer, maintaining signal integrity is critical. Significant signal degradation can lead to data loss, corruption, or transmission errors. High-frequency signals are susceptible to transmission issues like reflection, attenuation, and interference. The choice of the connector and its precise placement on the PCB can impact the signal quality. High-frequency signals Durability and wear - Connectors are mechanical components, and like all mechanical parts, they are susceptible to wear and tear, especially when subjected to repeated insertions and removals. Connectors must be made from durable materials and designed to withstand the rigors of regular use. Moreover, the construction of a connector, including its locking mechanism, can significantly impact its longevity. Before integrating a PCB connector, designers must thoroughly review its specifications Compatibility issues - With a plethora of connectors on the market, ensuring compatibility with electronic components is crucial. Mismatched connectors can result in poor performance or damage to the PCB. Before integrating a PCB connector, designers must thoroughly review its specifications, ensuring the product is compatible with the intended application. Ensuring optimal performance Making the right selection of connectors is not just about ensuring a fit; it is also about ensuring optimal performance, reliability, and longevity of the PCB. Phoenix Contact’s LPC 2,5 PCB connectors are a standout in the industry due to their tool-free lever-actuated design, making them suitable for quick on-site device connections. The lever mechanism enables easy conductor connection, with or without ferrules. Another key benefit is the ability to prevent inadvertent terminal point opening, reducing the chances of wiring errors. This ensures high safety, especially when making quick connections. Specific project requirements Additionally, the LPC 2,5 PCB connectors feature a variety of accessories and product ranges Additionally, the LPC 2,5 PCB connectors feature a variety of accessories and product ranges, allowing for flexibility and customization based on specific project requirements. The connectors are offered in different numbers of rows and positions, nominal cross-sections, and socket types, ensuring compatibility with various applications and designs. The push-in spring is a unique feature of the LPC 2,5 connector, which supports conductors with cross-sections of up to 16 mm². Key benefits of this connection method include the following: Efficiency: The tool-free operation significantly reduces the time required to connect and release conductors. The LPC 2,5 incorporates a special spring contour, allowing users to insert rigid conductors or ferrules, and a dedicated cable entry funnel prevents individual Litz wires from splicing. Intuitive operation: The color-coded actuation lever of the LPC 2,5 provides a visual cue for intuitive operation, allowing users to identify misalignment in the clamping space, which could lead to connection errors. This lever also reduces the chances of connection errors, which is crucial for safe operation in high-power systems. Reliability: The defined contact force of the product ensures a reliable wire termination with long-term performance. Also, the lever mechanism helps to avoid inadvertent terminal point opening and short circuits, ensuring reliable connections and enhancing system safety. Versatility: Offering a voltage range of up to 300 V, the LPC 2,5 series is suitable for use in a wide variety of applications. Wide range of electronics LPC 2,5 connectors play a role in ensuring these systems operate efficiently As noted above, the unique design and features of Phoenix Contact’s LPC 2,5 PCB pluggable terminal blocks make them suitable for a wide range of electronics. The following are some key applications: Energy storage systems - Energy storage systems are vital for ensuring a consistent power supply, especially in renewable energy systems where energy production is often intermittent. With a voltage range of up to 300 V, these connectors can be used in various energy storage systems, from small-scale residential setups to large-scale installations. Photovoltaics - Solar energy systems utilizing photovoltaic (PV) technology are at the forefront of the renewable energy revolution. LPC 2,5 connectors play a role in ensuring these systems operate efficiently. In large-scale solar installations operating at higher voltages, the LPC 2,5's design helps prevent inadvertent terminal point opening. Leveraging sophisticated electronics Electric vehicle charging systems - The outdoor usage of EV charging stations necessitates robust connectors for reliable electrical connectivity. The LPC 2,5 series offers reliable wire termination, ensuring long-term performance even in challenging environments. Transportation systems - Transport systems, like high-speed trains and automated metro systems, leverage sophisticated electronics for control, communications, and safety. Establishing reliable electrical connections throughout these vehicles is vital for operational safety. Industrial machines - Maintaining reliable connections is crucial in industrial machines where precision is paramount. LPC 2,5 connectors can prevent disruptions or errors during operation. With their secure release and accidental terminal point opening prevention, these connectors ensure that machinery operates without issues. Establishing electrical connections Connectors play a crucial role in establishing electrical connections to printed circuit boards. Phoenix Contact’s LPC 2,5 PCB pluggable terminal blocks are engineered to establish versatile and reliable electrical connectors in a wide range of applications. Their unique design features, such as the lever-actuated mechanism and push-in spring connection, make them a standout in the industry. As technology rapidly evolves, the demand for reliable connectors will grow, making products like the LPC 2,5 indispensable.

The shift to smart manufacturing leverages advanced technologies to enhance yield, productivity, agility, efficiency, and safety while simultaneously reducing costs. Intelligent motion control is pivotal in this transformation. It often necessitates updating older factories by replacing fixed-speed motors and controls with superior motion control devices. These devices rely on advanced sensing for precise motion and power control. To achieve optimal workflow and production agility, designers must also implement real-time connectivity between production machinery and manufacturing execution systems. High-speed network interfaces Many advanced technologies and system-level solutions are available to enable the migration to intelligent motion control, yet designers are often left on their own to piece the system together. These include components for isolated current sensing and position feedback for multi-axis control This situation is changing, with comprehensive solution sets now available to help kickstart a motion control design. These include components for isolated current sensing and position feedback for multi-axis control of a motor’s speed and torque, as well as sensors for machine health monitoring to reduce unplanned downtime. High-speed network interfaces are also included, facilitating data sharing between machines and higher-level control and management networks. Industrial motion control This article briefly discusses the importance of improved motor control. It then introduces solutions from Analog Devices for intelligent motion control, including power, sensing, and networking components, and discusses how they are applied. Electric motors are foundational to industrial motion control, accounting for as much as 70% of the power used in industry. This percentage of industrial power represents about 50% of worldwide electrical power consumption. This is why so much effort has been placed into improving motion control efficiency, with intelligent motor control bringing many benefits. Servo-motor robotic actuators This inverter-driven motor enables significant reduction in energy consumption Early motion control relied on basic power-grid-connected motors, and this has evolved into sophisticated multi-axis servo-motor robotic actuators. This evolutionary development has tracked the increasing complexity needed to deliver the higher levels of efficiency, performance, reliability, and self-sufficiency required in smart manufacturing. The various types of motor control include: Fixed speed: The oldest and most basic motion controls are based on grid-connected 3-phase AC motors operating at a fixed speed. Switchgear provides on/off control and protection circuitry. Any required reduction in output is achieved mechanically. Inverter-driven motor: The addition of a rectifier, DC bus, and 3-phase inverter stage creates a variable frequency and variable voltage source that is applied to the motor to enable variable speed control. This inverter-driven motor enables significant reduction in energy consumption by running the motor at the optimum speed for the load and application. Variable speed drive (VSD): Used for applications needing additional precision for control of motor velocity, position, and torque, VSD achieves this control by adding current and position measurement sensors into the basic voltage-regulated inverter drive. Servo-driven system: Multiple VSDs can be synchronized into multi-axis servo-driven systems to accomplish even more complex motion for applications such as computer numerical control (CNC) machine tools where extremely accurate position feedback is needed. CNC machining commonly coordinates five axes and may use as many as twelve axes of coordinated motion. Multi-axis motion control At each stage in the development of motion control systems, the complexity has increased Industrial robots combine multi-axis motion control with mechanical integration and advanced control software to enable three-dimensional positioning along six axes, typically. Collaborative robots, or cobots, are intended to operate safely alongside humans. They are built on industrial robotic platforms by adding safety sensing, as well as power and force-limiting capabilities to supply a functionally safe robotic workmate. Likewise, mobile robots use functionally safe machine control, but they add localization sensing, route control, and collision avoidance to the robotic capabilities. At each stage in the development of motion control systems, the complexity has increased, often significantly. There are four key factors driving intelligent motion systems: Reduced energy consumption Agile production Digital transformation Reduced downtime to ensure maximum asset utilization High-efficiency motors Digital transformation involves the capacity to network motion control and extensive sensor data The adoption of high-efficiency motors and lower-loss VSDs, as well as the addition of intelligence to motion control applications, are key factors in achieving significant energy efficiency through smart manufacturing. Agile production hinges on rapidly reconfigurable production lines. This flexibility is needed to respond to fluctuating consumer demand for a diverse range of products in smaller quantities, requiring a more adaptable production setup. Industrial robots play a pivotal role in executing complex and repetitive operations, thereby increasing throughput and productivity.  Digital transformation involves the capacity to network motion control and extensive sensor data from the entire production facility and share this data in real time. Such connectivity enables cloud-based computing and artificial intelligence (AI) algorithms to optimize manufacturing workflows and enhance asset utilization. Initial installation costs Asset utilization serves as the foundation for various new business models and focuses on the productivity of factory assets, not just the initial installation costs. System suppliers are increasingly interested in billing for services based on the uptime or productivity of these assets. Analog Devices offers multiple devices in each area for designers to consider when updating older designs This approach leverages predictive maintenance services, which rely on real-time monitoring of each machine asset to boost productivity and minimize unplanned downtime. The key areas that designers must prioritize are power electronics, motion control, current sensing, position sensing, network interfacing, and machine health monitoring. Analog Devices offers multiple devices in each area for designers to consider when updating older designs or starting anew. Monolithic transformer technology Power electronics facilitate the power conversion from DC to pulse width modulated (PWM) power inputs in a motor drive system. The power conversion in a motor drive system begins with a high-voltage DC source, typically derived from the AC power mains. As illustrated in Figure 2, the power electronics section is configured using a three-phase half-bridge topology with MOSFETs. The gates of the upper MOSFETs are floating relative to ground and require an isolated driver. A suitable option is Analog Devices’ ADUM4122CRIZ. This is an isolated gate driver that provides up to 5 kilovolts (kV) root mean square (rms) isolation. The high level of isolation is achieved by combining high-speed complementary metal-oxide semiconductor (CMOS) and monolithic transformer technology. This gate driver features adjustable slew rate control, which minimizes switching power loss and electromagnetic interference (EMI). This is particularly important if gallium nitride (GaN) or silicon carbide (SiC) devices are used, given their faster switching speeds. Half-bridge switching devices The output stages of both the low-side and high-side drivers are floating and not connected to ground The lower MOSFETs have their source elements referenced to ground and can use Analog Devices’ LTC7060IMSE#WTRPBF, a 100 volt half-bridge driver with floating grounds.  The output stages of both the low-side and high-side drivers are floating and not connected to ground. This unique double-floating architecture makes the gate driver outputs robust and less sensitive to ground noise. Additionally, the devices incorporate adaptive shoot-through protection with programmable dead time to prevent both half-bridge switching devices from turning on simultaneously. Motion control system The motion controller serves as the brain of the motion control system. Acting as the central processor, it generates the PWM signals that drive the power electronics. These signals are based on commands from a central control center and feedback from the motor, such as current, position, and temperature. The controller dictates the motor's speed, direction, and torque based on this data. Often located remotely and implemented through an FPGA or a dedicated processor, the controller requires isolated communication links. The controller dictates the motor's speed, direction, and torque based on this data For this purpose, a serial data link like Analog Devices’ ADM3067ETRZ-EP can be used. This is an electrostatic discharge (ESD) protected, full-duplex, 50 megabit per second (Mbps) RS485 transceiver. It is configured to provide high-bandwidth serial communications from the position feedback sensors back to the motion controller. This serial line is protected from ESD up to ±12 kV and can operate over a temperature range of -55 to +125°C. Primary feedback parameter Current feedback from the motor is the primary feedback parameter for control. As current feedback determines the overall control bandwidth and dynamic response of the motion control system, the feedback mechanism must be highly accurate and have high bandwidth to ensure precise motion control. There are two commonly used current measurement techniques: Shunt-based measurements require the insertion of a low-value resistor or shunt in series with the conductor being measured. The differential voltage drop across the shunt is then measured, usually with the help of a high-resolution analog-to-digital converter (ADC). Shunt current measurements are limited by the voltage drop and power dissipation in the shunt resistor and are confined to low-to-medium current applications. Magnetic current sensing measures the current by evaluating the magnetic field in the vicinity of the conductor using contactless anisotropic magnetoresistance (AMR) measurements. The resistance of the AMR device, which varies with the magnetic field and hence the current, is measured using a resistance bridge. High current measurements The measurement is also electrically isolated from the measured conductor Magnetic current measurement eliminates the voltage drop and subsequent power loss in shunt resistors, making it better suited for high current measurements. The measurement is also electrically isolated from the measured conductor. For isolated current measurements, the Analog Devices’ ADUM7701-8BRIZ-RL can be used. This is a high-performance, 16-bit second-order sigma-delta ADC that converts an analog input signal, from a current sense voltage drop across a sense resistor, into a high-speed, single-bit digitally isolated data stream. Current measurement device An alternate current measurement device is the AD8410AWBRZ high-bandwidth current sense amplifier. This is a differential amplifier with a gain of 20, a bandwidth of 2.2 megahertz (MHz), and low offset drift (~1 microvolts per degree Celsius (μV/°C)). With a DC common mode rejection ratio (CMRR) of 123 decibels (dB), it can handle bidirectional current measurement with common mode inputs of up to 100 volts. An alternate current measurement device is the AD8410AWBRZ high-bandwidth current sense amplifier Rotational position sensing based on AMR magnetic position sensors offers a more cost-effective alternative to optical encoders. These sensors have the added benefit of being robust in industrial environments, where they are often exposed to dust and vibrations. Feedback on the motor shaft angle can be used for direct position control in servo systems or for determining rotational speed. Surrounding magnetic field The ADA4571BRZ-RL is a magnetoresistive angle sensor that uses dual temperature-compensated AMR sensors to detect shaft angle over a range of 180° (±90°) with an accuracy of <0.1° error (<0.5° over life/temperature). This device produces both sine and cosine single-ended analog outputs that indicate the angular position of the surrounding magnetic field. The device can operate in magnetically harsh environments and does not suffer degradation of angular readout error with wide air gaps. The outputs of the angle sensor can be connected to the Analog Devices’ AD7380BCPZ-RL7, a dual, 16-bit input, successive approximation register (SAR) ADC. This ADC samples simultaneously on both differential input channels at up to 4 megasamples per sec (MSPS). An internal oversampling function improves performance. Slower operating conditions Oversampling is a common technique employed to increase ADC accuracy Oversampling is a common technique employed to increase ADC accuracy. By capturing and averaging multiple samples of the analog input, this function reduces noise, using either normal average or rolling average oversampling modes. Oversampling can also help achieve higher accuracy under slower operating conditions. Smart manufacturing relies upon a network of intelligent motion applications that share data between the machines on the factory floor and the central control and management network. This sharing requires robust connectivity. For this, designers can use Analog Devices’ low-power and low-latency Ethernet physical layers (PHYs), including the ADIN1300CCPZ Ethernet PHY transceiver. Operating at data rates of 10, 100, or 1000 megabits per second (Mbits/s), the ADIN1300CCPZ is designed to operate in harsh industrial environments, including ambient temperatures up to 105°C. Reducing unplanned downtime Switches are used to route Ethernet connections. Analog Devices offers an industrial Ethernet Layer 2 embedded dual-port switch, the FIDO5200BBCZ. The switch complies with IEEE 802.3 at 10 and 100 Mbits/s, and it supports both half and full-duplex modes to support PROFINET, Ethernet/IP, EtherCAT, Modbus TCP, and Ethernet POWERLINK industrial Ethernet protocols. Machine health monitoring employs sensors to measure physical parameters such as vibration Machine health monitoring employs sensors to measure physical parameters such as vibration, shock, and temperature, providing real-time insights into a machine's condition. By logging this data during standard motion control operations and analyzing it over time, it becomes possible to accurately assess the machine's mechanical health. This data-driven approach allows for predictive maintenance schedules, which not only prolong the machine's operational life but also significantly reduce unplanned downtime. Intelligent motion control Applying machine health requires, vibration and shock sensors be installed into the motor. The ADXL1001BCPZ-RL ±100 g microelectromechanical systems (MEMS) accelerometer is an example of a low-noise sensor with a -3 dB bandwidth of 11 kilohertz (kHz). It is a high bandwidth and lower-power alternative to piezoelectric sensors. For applications that require measurement along three axes, the ADXL371 can be a suitable choice. Intelligent motion control is critical to enable smart factories, and it requires carefully chosen electronic components to be implemented effectively. As shown, many of these components are already curated to kickstart a design. They include power electronics to drive the motor, current and position sensors to provide accurate feedback data for precise and accurate motion control, industrial network connectivity to provide system-level insights to optimize manufacturing flow, and vibration and shock sensors to enable machine health monitoring to reduce unplanned downtime and extend the operational life of assets.