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How to Choose a Sensor for the Production Environment 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…

April 23, 2025 – AutomationDirect has added GC Valves 71 series 2-port water valves, which are constructed of durable lead-free brass. They are certified to NSF/ANSI 61 and have NSF-approved EPDM diaphragms. They are a great choice for drinking water applications and are ported for the most popular NPT sizes (up to 2”) with a…

Node-RED is a visual programming tool for connecting physical hardware devices, APIs, and online services together as part of the Internet of Things. It was originally developed by the IBM Emerging Technology Services team and is now a part of the OpenJS Foundation. Node-RED’s low-code, drag-and-drop interface makes it easy to create complex data flows…

April 9, 2025 – AutomationDirect has added ICON Process Controls Truflo® TKM series paddle wheel liquid flow meters that provide reliable, full-pipe liquid flow measurement with exceptional long-term performance. These rugged, highly repeatable sensors deliver outstanding value with no scheduled maintenance required. Built with a chemically resistant PVC body, they are ideal for corrosive liquid…

Lika Electronic specializes in encoders and position measuring systems, including incremental and absolute, optical and magnetic, rotary and linear encoders, incremental & absolute magnetic measurement systems, rotary actuators, displays, signal converters and encoder interfaces. Starting in 1982 as a family-owned business, Lika Electronic has grown to become a forward thinking innovative, global company. Over the…

The C-more CM5-RHMI headless HMI offers all the features of the traditional touchscreen C-more line, but in a compact and connectable low-cost form factor. AutomationDirect’s C-more CM5-RHMI has been nominated for Control Engineering’s Product of the Year program in the human-machine interface (HMI) category. Help us bring home the gold by visiting https://survey.alchemer.com/s3/8206433/f8132b621423 and casting…

Complex high-frequency signaling challenges, for both existing and new applications, can be solved using signal conditioners. Frequency signal conditioners—designed to handle high-frequency pulse signals from sensors and convert them into other useful automation signals—are an important industrial automation design component for both new and retrofit applications. High-frequency pulses may be generated from a proximity sensor…

Six Tips to Help You Build a Better, Safer Machine 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…

March 26, 2025 – AutomationDirect has added Datasensing SH4 series 14mm finger and 30mm hand safety light curtains that are available in basic models with automatic restart or standard models, which include external device monitoring (EDM) and an optional manual restart. Body protection models in 300 or 400mm resolution are available only in the standard…

March 26, 2025 – AutomationDirect has added Wenglor OPT25 series laser measurement sensors that offer best-in-class distance sensing for ranges within 1 meter. These sensors are IO-Link v1.1 compatible, employ a Class 1 red or Class 2 blue laser, use triangulation to measure distances with extreme accuracy, and can reliably detect tiny objects with a…

March 26, 2025 – AutomationDirect has added Autonics BTF, BTS, and BPS series miniature photoelectric sensors featuring ultra-compact slim or narrow housings that are easy to install in tight spaces. The lineup includes:        These miniature sensors offer sensing distances up to 3m, durable PBT thermoplastic housings, and an IP67 protection rating. They…

March 19, 2025 – AutomationDirect has added ProSense linear potentiometers that offer reliable and consistent position measurement while delivering exceptional value and performance. These position sensors measure linear displacement by converting mechanical movement into a resistive output. Typically, they require a signal conditioner or a 10 VDC supply to provide an analog signal for a…

March 19, 2025 – AutomationDirect has added IronHorse worm gearboxes with IEC inputs that offer all the same features and advantages as our existing aluminum models, including 30mm to 75mm frame sizes, 10:1 to 100:1 ratios in most sizes, and maintenance free operation.  They are factory filled with synthetic oil and their double lip oil…

March 12, 2025 – AutomationDirect has added METEcon multi-wire connectors that feature quality and cost-effective inserts and housings. Inserts are available in multiple pole configurations from 2 poles plus ground up to 108 poles plus ground, with screw or crimp termination types and sizes ranging from 26 to 12 AWG, 10 to 80 Amps. METEcon…

Headquartered in Racine, WI, Master Appliance has been a leader in heat tool innovation since the 1950s. The company introduced the first portable industrial heat gun to North America, coining the term “heat gun” and revolutionizing how industries apply heat for tasks such as heat shrink packaging, drying parts, shrinking plastics, paint stripping and shaping…

February 26, 2025 – AutomationDirect has added new specialty modules for the CLICK PLC family. CLICK PLUS CPUs offer the utmost versatility with up to two option slots for custom I/O configurations. These option slots also allow for specialty modules, including the C2-DCM serial communication module and the new C2-NRED and C2-OPCUA modules. The C2-NRED…

February 26, 2025 – AutomationDirect has added the new Titanio series of stepper drives from Ever Motion Solutions®. These drives offer peak performance, a rich feature set, and work seamlessly with AutomationDirect SureStep® stepper motors.  Three new drives are available with two open-loop (no encoder feedback) models and one open/closed-loop version (a motor-mounted encoder provides…

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…

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…

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…

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…

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…

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…

Unshackling Industrial Data Access 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 and software advancements mean that access to valuable industrial sourced data is easier, more…

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…

At the London International Exhibition in 1862, Alexander Parkes introduced the world’s first man-made plastic. His creation launched the beginning of the plastics industry, which would grow exponentially during the next 100 years to serve both manufacturers and consumers in many ways. In 1965, Horst Wieder founded CITO Products, Inc. as a toolmaking, machining, and…

Build Better Machines Faster Using Today’s Enhanced Motion Controllers and PLCs High-performance servo motion is now more affordable and accessible than ever due to integrated controllers, making the technology viable even for applications which could not formerly support the cost or complexity of traditional implementations. Learn more The Master Controller of Motors Everyone knows that…

February 12, 2025 – AutomationDirect has added BLOCK CT and USTE series open core control transformers to provide a flexible solution for stepping down a wide range of voltages from 208 to 600 VAC. The BLOCK CT series is made in the USA and offers a rugged design specifically engineered for isolation, lighting, or signaling…

February 12, 2025 – AutomationDirect has added Murrplastik MP10 series cable/hose drag chains and chain brackets to their growing selection of wire and cable management products. Drag chains route cables/hoses to moving components and help to extend cable/hose life, provide protection for personnel, and reduce equipment downtime and repair costs. The MP10 series is built…

This award, sponsored by AutomationDirect, celebrates the art of digital animation and its close relationship to STEAM (Science, Technology, Engineering, Art, and Mathematics). The 2025 Digital Animation Award is offered to help encourage students to cultivate skills in design and creation of animation including, but not limited to, storytelling, creativity, use of computer software, and…

February 5, 2025 – AutomationDirect has added WAGO splicing connectors to their selection of wiring solutions. The 221 series LEVER-NUTS® are equipped with WAGO’s CAGE CLAMP® spring technology, allowing quick and easy connection of all conductor types of different cross sections using two-, three-, and five-wire connectors without soldering or using tools. The 221 series…

February 5, 2025 – AutomationDirect has added general-purpose WEG CFW320 AC drives and full-featured SSW900 soft starters. The CFW320 series VFDs offer all the features of the existing CFW300, including a compact size, a built-in operator interface (HMI), and an embedded SoftPLC, but provide support for 460 VAC and Ethernet communications. These drives support 230 VAC 3-phase…

February 5, 2025 – AutomationDirect has added more Murrplastik frames and grommets to their current offering of cable entry systems. Cable entry frames used in conjunction with the required grommets provide easy cable installation through an enclosure and strain relief while maintaining environmental ratings. This expansion adds more frame sizes to our existing KDL/D and…

January 29, 2025 – AutomationDirect has added Gladiator GPB1 and GPB2 series enclosed-style terminal blocks to provide a safe and reliable way to connect multiple electrical circuits to a single power source. The GPB1 series terminal blocks are ultra-compact, offering time-saving multiple wire connection options for a variety of control panel applications. Push-in spring connections…

January 29, 2025 – AutomationDirect has added additional Zener barriers from STAHL to isolate various control signal types from hazardous environments. For automated systems installed in potentially explosive atmospheres (ex., oil and gas production), extra precautions must be taken to ensure the electrical circuits do not become ignition sources. Properly grounded Zener barriers isolate the…

January 22, 2025 – AutomationDirect has added configurable and programmable safety relays from Schmersal. Many safety systems require more than one specialty safety relay but do not justify the need for a safety controller. Schmersal PROTECT SRB-E configurable relays are easy to set up and reduce the number of safety relays required for a machine…

January 22, 2025 – AutomationDirect has added Dold VARIMETER series voltage and phase monitoring relays to safeguard electrical equipment and prevent costly downtime by evaluating voltage levels and phase sequences. These relays provide early detection and response to abnormalities such as undervoltage, overvoltage, phase loss, phase reversal, and phase imbalance. The VARIMETER series monitoring relays…

January 22, 2025 – AutomationDirect has added seven new sizes of PBC linear guide tracks with slides in lengths up to 2000mm.  The guide tracks are ceramic-coated 6061-T6 aluminum, paired with a self-lubricating slide. The slides have a proprietary PTFE (FrelonGOLD®) plain bearing bonded to the mating surface. These guide tracks and slides are rated…

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…

January 15, 2024 – AutomationDirect has added ProSense FLG series detecting light grids that offer a cost-effective solution for object detection and feature a simple setup with no programming required. They have no dead zone on the full detection height and are perfect for a variety of applications, such as material handling, counting, and warehousing….

January 15, 2024 – AutomationDirect has added Southwire flexible metal conduit to their growing selection of electrical conduit and wiring solutions. Southwire’s Alflex™ type RWA (Reduced Wall Aluminum) and Galflex™ type RWS (Reduced Wall Steel) conduits are built using a metal strip that is helically formed into a continuously interlocked flexible metal conduit which can…

January 15, 2025 – AutomationDirect has added Penn-Union compression lugs to provide a secure method of terminating electrical cables, especially high-power or large-diameter cables, to electrical equipment. Unlike mechanical lugs, that are screwed/clamped in place, these connectors are crimped onto the cable using the appropriate crimping tool for a permanent installation. These connectors are rated…

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…

Servo motors and drives use feedback to provide accurate position, speed, and acceleration control, making them ideal for demanding machinery and robotics applications. By Chip McDaniel, AutomationDirect Servo motor systems are a high-performance motion control technology, able to execute complex motion profiles while delivering high torque output, beyond the capabilities of typical direct current (DC)…

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…

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….

December 18, 2024 – AutomationDirect has added more Captron capacitive pushbuttons that utilize touch control and are activated without pressure when a hand or body part nears the device’s surface. They feature a robust IP69K design, wear-free operation, resistance to water, oil, and harsh environments, and are available in various mounting/operator sizes. Caneo Series10 additions…

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…

Simplified Motion Control High-performance servo motion is now more affordable and accessible than ever due to integrated controllers, making the technology viable even for applications which could not formerly support the cost or complexity of traditional implementations. Learn more Turning Up the Heat on a Balky Boiler Applying commercial off-the-shelf automation products can provide the…

3-Axis Motion Made Simple in 3 Ways using CLICK PLUS PLCs | White Paper AutomationDirect CLICK PLUS PLCs, when combined with stepper motors, make advanced motion control and edge integration simple for smaller systems. Electric motors provide the motive force for many types of machinery and equipment. Sometimes standard AC and DC motors are operated…

December 11, 2024 – AutomationDirect has added Teknokol Eco series HMI enclosures and suspension arm systems which are designed to work together to provide customized, adjustable HMI panels using a selection of components and cut-to-length arm profiles. These suspension systems allow the HMI to be relocated as needed for better HMI visibility and operator comfort. …

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…

Variable Frequency Drives (VFDs) are a crucial component in industrial automation, providing precise control over a motor’s speed and torque. Numerous built-in protections and fault indications are provided with modern VFDs, including the commonly seen DC Bus Overvoltage Fault. This fault has several possible causes and this whitepaper explores each one, offering solutions to ensure…

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…

December 4, 2024 – AutomationDirect has added high quality Helukabel unshielded “extra hard use” 600V SOOW and 300V SJOOW portable cord. Portable cord (also called service cord) is cable with multiple conductors used for electrical power connections that are not intended to be permanent. Applications for these cables often involve portable equipment such as power tools…

Everyone knows that motors are the workhorses of industry. They move machinery, fans, pumps, compressors, conveyors, elevators, etc. How are they controlled? The simple way is by using across-the-line control and turning them on and off. This works great in most cases, but what if you need to vary the speed of the motor? Control…

November 20, 2024 – AutomationDirect has added Schneider Electric Easy TeSys series manual motor protectors, contactors, thermal overload relays, and accessories to their lineup of motor control products.  Schneider Electric Easy TeSys series IEC manual motor protectors are compact, easy to use, and cover the functions of disconnect, controller, thermal overload relay, and branch circuit…

November 20, 2024 – AutomationDirect has added FTG enclosed-style power distribution and terminal blocks to provide a convenient central location to connect several wires and distribute power from a single source to multiple loads. The enclosed power distribution blocks feature a modular design for easy multi-pole assembly and an IP20 finger-safe protection rating. They are…

Welcome to the fall issue of AutomationDirect’s NOTEBOOK, your guide to practical products, technologies, and applications! This fall season has been difficult for many of us in the direct path of Hurricanes Helene and Milton. Our thoughts are with everyone personally impacted. From a business standpoint, AutomationDirect is paying close attention to the supply chain…

Process-enabled motion controllers and motion-enabled PLCs give OEMs the flexibility to optimize design and performance. By: Kevin McClelion and Joe Scoccimaro, AutomationDirect There was a time when designing machines that included motion control followed a standard architecture. The PLC handled basic machine control and a dedicated motion controller managed the motion axes. Today, the trend…

Industrial automation products are useful for much more than traditional applications, as PLCs and HMIs can be used in all sorts of unique commercial markets. Byline: Mark McHenry, Systems & Controls Other than being large and generally rectangular-shaped, a modern custom bus—the type frequented by touring music stars, mobile multi-millionaires, and campaigning politicians—bears little resemblance…

The EtherCAT protocol is a high-performance and cost-effective Ethernet networking technology, providing a versatile solution when EtherNet/IP and PROFINET simply aren’t fast enough. By Joe Kimbrell, AutomationDirect Ethernet rapidly expanded into and throughout commercial information technology (IT) networking connectivity environments beginning in the 1980s, and it has experienced rapid performance advancements and adoption since then…

By Chip McDaniel, Automation Expert & Education Specialist, AutomationDirect Human resources departments call the phenomenon the “grey tsunami.” They’re referencing an historic U.S. retirement surge of 4.1 million Americans a year. Manufacturing, in particular, is taking a big hit as industrial engineers, equipment operators, maintenance and repair technicians, plant managers, and others in supporting roles…

The SIDirect program connects end users of all sizes with systems integrators ready to support their automation needs, spanning a variety of technologies and processes. By: Jeff Payne, AutomationDirect Every manufacturing business must make choices about supporting their machines, production processes, and personnel. Careful application of the right automation technologies and skillsets in each of…

Industrial-grade products provide a path for this student organization to develop a space-capable rocket. Byline: Oleg Khalimonov, Space Concordia Many are familiar with the phrase “it isn’t rocket science.” But today more than ever, sometimes it is rocket science. SpaceX and other organizations have made rocket launches and space exploration commercially viable and almost commonplace,…

For determining the precise motion of industrial machinery and equipment elements, or servo motors, encoders provide a high-performance solution—but only if they are specified properly. By Joe Kimbrell, AutomationDirect Mechanical movement generated on automated machinery and equipment almost always needs to be monitored by sensors to provide a robust motion control solution. This is especially…

Truffle Kerfuffle The factory’s robotic truffle picker is making gift boxes with a single row of seven unique types of truffles. The assortment includes three white chocolate truffles, while the other four are milk or dark chocolate. The placement of the seven truffles in the row is completely random.  What are the odds that a…

Applying commercial off-the-shelf automation products can provide the most capable and supportable solution for end users trapped with underperforming automation systems, as with this application. By: Aaron Stahl and Edward Stahl, Spring Valley Electric Worldwide, there are countless examples of businesses forced to work inefficiently because they are using equipment which is automated by systems…

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…

This FIRST award, sponsored by AutomationDirect, celebrates the art of digital animation and its close relationship to STEAM (Science, Technology, Engineering, Art, and Mathematics).  NEW FOR 2025: Separate competitions for FIRST Robotics Competition and FIRST Tech Challenge teams. The 2025 Digital Animation Awards are offered to help encourage students to cultivate skills in design and creation of animation…

November 6, 2024 – AutomationDirect has added Bondhus hex and Torx tools, which are precision machined in the USA with a proprietary high-torque steel for reliable, long-lasting service life. Hex-end L-key sets have chamfered tool tips to eliminate burrs and provide a proper seat. Ball-end L-key sets insert at a 25° angle, allowing for superior…

With more than 100 years of experience developing, manufacturing and selling electrical insulation solutions, Plymouth Rubber knows quality is key to continuous success for its business and its customers. With this in mind, the company has a dual focus on delivering products that offer both high-efficiency and durability to reduce costs, while improving the longevity…

October 30, 2024 – AutomationDirect has added new Schmersal 250 series heavy-duty limit switches featuring rugged cast iron housings for the harshest environments. The selection includes models with side rotary levers with metal or plastic rollers, metal belt alignment rollers, and high-temperature models with metal rollers. The belt alignment switches prevent costly equipment damage by…

October 30, 2024 – AutomationDirect has added the powerful LS Electric XMC motion controller to provide full EtherCAT master motion control. With a blindingly fast processor (scan times as low as 5ns) and built-in support for 8 or 16 axes of EtherCAT-based motion control (depending on the model), the XMC controller can handle virtually any…

Early fault detection and simple plug-and-play field replacements In addition to the large amount of process data available cyclically, faults can be identified easily through diagnostic information messages. This includes device faults, such as memory or processor failures, or process faults like empty pipe detection. Comprehensive diagnostics reporting increases overall system reliability and boosts customer…