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Issue 54, 2025

Easy, Educational, and Entertaining Automation

At AutomationDirect, the goal is to educate customers on the best industrial products for their applications. The mission is also about making industrial control easy — and sometimes even entertaining. In this issue of NOTEBOOK, we demonstrate how AutomationDirect delivers on these important objectives.

Here, we focus on modern PLC programming methods. Specifically, the transformative power of no code/low code and open-source platforms that are enabling more integration and innovation. Using visual interfaces and drag-and-drop programming to reduce coding requirements, these platforms can extend the reach of the controller to integrate Internet of Things (IoT) and other application programming interfaces (APIs).  The simplicity of the interface enables non-programmers to participate without having to learn an advanced programming language.

AutomationDirect is supporting the low-code and no-code programming movement with its CLICK PLUS PLC and the C2-NRED intelligent option module enabled.

Another benefit of modern PLCs is the accessibility to industrial data. As more manufacturers depend on data to improve quality control, equipment uptime, and operational responsiveness, they are finding ways to extract, aggregate, and analyze data. Find out how to mine this digital gold in the tech brief Unshackling Industrial Data Access. And do you know how manufacturers get all that digital data? Sensors. These little collection points are constantly capturing information on position, speed, proximity, etc. Choosing the right sensor for the job, however, can be overwhelming. We’re making it easy for you.

Now for the entertainment! We all know it’s hard to get young people interested in engineering when we are competing with social media content creators. But add some animatronics and special effects into the mix and the dynamic changes.

The team at Heemer Crafted is rooted in the “edu-tainment” industry by applying industrial automation to create interactive attractions that can be used across a variety of industries. In the article, Heemer Crafted founder Justin Hiemstra explains how AutomationDirect delivered the technologies needed to create interactive attractions in an agri-tourism environment. This is an interesting success story that is sure to make you smile!

Speaking of success stories, Mel-O-Cream Donuts International is incorporating automation into its operations to ensure product consistency and improve process efficiency. Find out how this 90-year-old company is baking in HMI, sensors, stack lights, and more to perfect the art of donut making.

Of course, there’s so much more to explore in the pages of NOTEBOOK.

In this issue of the Automation Notebook…

Issue 54 - 2025Notebook IssueProcess Sensing & ControlProduct

How to Choose a Sensor for the Production Environment 

By: Andrew Waugh Sensors play essential roles in the modern production environment, capturing data on position, speed, proximity, pressure, temperature, level, flow, current, voltage, and more. There is such a wide variety of sensors on the market that finding the right device for your application can seem overwhelming. It doesn’t have to be. The goal…
Issue 54 - 2025Notebook IssueProductProgrammable Control

How Low-Code and No-Code Visual Programming Tools Can Simplify and Accelerate Seamless Industrial IoT Connectivity

In this article, we explore the transformative impact of low-code/no-code PLC programming in industrial automation with Tim Shippy, a veteran AutomationDirect Product Engineer. With a wealth of experience spanning decades in industrial and enterprise software development, Tim has been at the forefront of integrating industrial systems with enterprise connectivity. His expertise in both traditional and…
Issue 54 - 2025Notebook IssueProductSafety

Six Tips to Help You Build a Better, Safer Machine

By: Joshua Draa and Larry Reynolds, Automation Direct Safety is an essential aspect of machine design and operation, protecting personnel, guarding against equipment damage, and maximizing productivity. The purpose of a safety system is to bring a machine to a known safe state as quickly as possible after a safety sensor detects a hazardous condition…
AutomationDirect SpotlightIssue 54 - 2025Notebook IssueStudent SpotlightStudent Spotlight

Cultivating Curiosity with Automated Edu-tainment

Crafting agricultural education experiences that are also fun is a specialty requiring a mix of creativity and technology. Byline: Justin Hiemstra, Heemer Crafted Capturing the interest of a young person today can be a tough task, especially considering the proliferation of mobile devices and the obsession with screen time. However, there are still important opportunities…
Application StoriesFood and BeverageHMIIndustryIssue 54 - 2025Operator InterfaceProduct

Recipe for Success: Automation Proves to Be a Key Ingredient

The right mix of automation elements is crucial for creating a consistent process yielding high-quality donuts and baked goods. By Roger Dyer, Mel-O-Cream Donuts International Mel-O-Cream, a commercial bakery in Springfield, IL, has been baking and perfecting donuts since 1932. From measuring precise ingredient amounts and maintaining a consistent mixing process, to ensuring uniform dough…
Issue 54 - 2025Notebook Issue

BrainTeasers - Issue 54, 2025

Application Complication The programmer for the gasket applicator robot at the puzzle factory noticed that there were a number of different tool paths that could be used to program the gasket path required for a new mechanical puzzle.  The complete pattern is shown below.  He must apply the gasket in a continuous bead along all…
Issue 54 - 2025Notebook IssueOperator InterfaceProductProgrammable Control

Unshackling Industrial Data Access

Modern PLCs and HMIs make it easy to implement extensive data connectivity and analytics. By: Damon Purvis, AutomationDirect Modern consumers are increasingly familiar with tailored experiences, abundant information, and generally getting things “their way.” Those working in the industrial manufacturing and automation sectors, on the other hand, have not always enjoyed such flexibility. Fortunately, hardware…
IdentificationIssue 54 - 2025Notebook Issue

Industrial Strength Identification is Essential for Manufacturing

Applying the right barcode, RFID, and vision technologies addresses the increasing demand for data-driven manufacturing, improved quality control, and compliance with track-and-trace requirements. By Larry Reynolds, AutomationDirect Automation systems routinely use a variety of sensors to detect the position, motion, weight, and many other physical characteristics of products and other targets. This type of monitoring…
Issue 54 - 2025NewsNotebook IssuePress ReleasesPress Releases

Advantech Gateways & Ziplink Connector from AutomationDirect

December 18, 2024 – AutomationDirect has added Advantech serial-to-Ethernet Modbus gateways allowing connections of isolated serial devices to the Internet for centralized machine communication management. Advantech Modbus gateways provide easy integration of Modbus TCP and Modbus RTU/ASCII networks and offer two 10/100 Mbps Ethernet ports for LAN redundancy. These gateways can be set up and…
Issue 54 - 2025NewsNotebook IssuePress ReleasesPress Releases

Endress+Hauser Soliphant® FTM20 Vibration Rod Level Switches from AutomationDirect

December 18, 2024 – AutomationDirect has added Endress+Hauser Soliphant vibration rod level switches to detect fine- or coarse-grained, non-fluidized bulk solids in silos, hoppers, and bins. They can even detect solids underwater, such as sediment buildup in a tank. These robust switches are insensitive to buildup, providing maintenance-free operation and easy setup with no calibration required….
Issue 54 - 2025NewsNotebook IssuePress ReleasesPress Releases

Lika Electronic Medium Duty Encoders and Encoder Linear Measuring Wheel Systems from AutomationDirect

December 18, 2024 – AutomationDirect has added four new series of Lika Electronic rotary encoders each with unique features or applications. Linear measuring wheel encoders are also now available. The new A41 series are compact (41mm diameter body) medium duty encoders with hollow or solid shafts and resolutions from 100 to 3600 PPR. A50 series…
Issue 54 - 2025NewsNotebook IssuePress ReleasesPress Releases

Murrelektronik EtherCAT® IO-Link Line Master Modules and Additional Io-Link Hubs from AutomationDirect

December 11, 2024 – AutomationDirect has added Murrelektronik Premium EtherCAT IO-Link master modules to their IO-Link product lineup. IO-Link masters provide standardized, point-to-point connections between smart devices and controllers. IO-Link functions similarly to traditional field I/O but adds the capability to collect diagnostic and operational data from IO-Link capable devices, helping pinpoint potential problems or…
Issue 54 - 2025NewsNotebook IssuePress Releases

More NIDEC US Motors ACCU-Torq Motors from AutomationDirect

December 4, 2024 – AutomationDirect has added more ACCU-Torq motors from Nidec U.S. Motors. The ACCU-Torq motors are high-performance inverter duty motors and are an excellent cost-effective solution for applications that require 100% torque down to zero speed. They are available in 230/460 VAC and are now offered in sizes up to 20 hp at…
Issue 54 - 2025NewsNotebook IssuePress ReleasesPress Releases

AchieVe FDM Series 12mm Tubular Photoelectric Sensors from AutomationDirect

November 13, 2024 – AutomationDirect has added AchieVe FDM series 12mm tubular photoelectric sensors that offer a rugged metal construction, high IP67 protection ratings, and sensing distances up to 4 meters. These photoelectric sensors feature selectable light-on/dark-on operation, a 10 to 30 VDC operating voltage range, potentiometer or teach-in button sensitivity adjustment, and a fast 1kHz…
Issue 54 - 2025NewsNotebook IssuePress ReleasesPress Releases

IronHorse ACG Drives from AutomationDirect

August 28, 2024 – AutomationDirect has added general-purpose AC drives to the IronHorse brand. These new VFDs support three control modes, including V/Hz, slip compensation, and sensorless vector, and come in various voltage and horsepower ratings at a very affordable price. The 230 VAC models can support AC motors up to 20hp with 230 VAC…