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August 13, 2025 – AutomationDirect now offers ProSense LPD5-A series large process meters that deliver a rugged, easy-to-use field display with exceptional visibility for demanding industrial environments. Units feature a bright 100mm (4-inch), 5-digit LED display that is easily readable from up to 50 meters away, even in direct sunlight. The meters support a wide…

August 13, 2025 – AutomationDirect has added A-coded M8 and M12 sensor and signal cables to facilitate accurate data transmission between sensors and control systems. New D-coded M12 Cat5e and X-coded M12 Cat6a Ethernet connection data cables support the high-speed Ethernet communication essential for network reliability and performance. Additional Murrelektronik A-coded 3-pin M8 and 5-pin…

August 13, 2025 – AutomationDirect has added Konnect-It KN-P series screwless terminal blocks that accept solid, stranded, or ferrule-ended wire types and offer fast, tool-free wiring using spring clamp or push-in technology. These terminal blocks come with the highest UL94 V0 flammability rating and are available in single-, double-, and triple-level models, with options including…

A system integrator supports their food processing client, implementing industrial automation technologies for a mix of OEM equipment and systems throughout the facility. By Jordan Hulsey, Caldwell Electrical Contractors, Inc. With busy lives and schedules often bursting at the seams, ready-to-eat (RTE) food has become a convenience that many indulge in—and some may even rely…

Closed-loop PID control is indispensable for a myriad of automation applications, and designers need to know the options for implementing PID using either dedicated devices or automation controllers. Automated regulatory control of characteristics like flow, level, pressure, temperature, and many other types of analog values is essential for countless types of machinery, processing equipment, and…

August 6, 2025 – AutomationDirect.com has added Atkore Liquid-Tuff conduit which provides versatile cable protection and routing in hazardous environments, is UL-listed in all trade sizes, and is marked for outdoor use, direct burial, and concrete embedment. Atkore’s Type LFNC-B non-metallic liquid-tight flexible conduit is a raceway with a smooth polyvinyl chloride (PVC) inner surface…

August 6, 2025 – AutomationDirect.com has added ASO Safety Solutions safety mats which provide a horizontal detection area (typically on the floor) to sense and protect personnel when entering dangerous areas. This safety mat addition includes yellow mats in 24 x 24 inches, 24 x 60 inches, and 36 x 36 inches with tapered or…

August 6, 2025 – AutomationDirect.com has added Minerallac’s comprehensive range of electrical fasteners and support systems ensures secure mounting, reliable positioning, and efficient installation of electrical conduit, piping, or equipment in commercial and industrial applications. Minerallac beam and flange clamps feature screw-on and hammer-on designs for secure attachment to structural beams. Conduit straps and clips,…

Since 1977, Ever Motion Solutions has been a trusted leader in industrial automation, designing and manufacturing high-performance motion control solutions including stepper, brushless motors and drives. The company uses its nearly 50 years of expertise to simplify motion control for customers worldwide and deliver reliable, durable products with an emphasis on innovation. Founded by engineer…

Square the Steps Can you cut the shape below into four identical shapes that will fit together to form a square? Cells within Cells Can you move exactly two of the load cells to new squares, so that all the rows and columns will have an even number of load cells?  Word is: there are…

July 30, 2025 – AutomationDirect has added Ardent digital multimeters, testers, and testing accessories which are ideal tools for diagnosing and maintaining electrical systems. Digital and clamp-on multimeters measure voltage, current, resistance, and continuity with high accuracy, helping identify faults and verify system performance. Ardent’s auto or manual ranging digital multimeters feature an Automatic terminal…

July 30, 2025 – AutomationDirect has added di-soric 2D S-mount lens cameras, which utilize a standard interchangeable M12 lens. These cameras provide powerful imaging capabilities and can also function as vision sensors, making them ideal for applications that require flexibility and adaptability. They support functions such as localization, detection, counting, measurement, and code reading, and…

July 30, 2025 – AutomationDirect has added WAGO JUMPFLEX® 857 series signal conditioners and temperature transmitters which deliver reliable signal conversion in a compact 6 mm-wide housing, ideal for high-density DIN rail installations. With configurable input and output ranges, these modules adapt easily to a wide range of industrial applications. WAGO conditioners and transmitters easily convert…

Beyond Safety Slogans: Cultivating a Workforce Culture to Protect People and Productivity Industrial safety standards have undergone a significant transformation in recent years, primarily driven by the integration of automation and robotics into manufacturing environments. Traditional lockout and tagout procedures have evolved into sophisticated safety systems that incorporate real-time monitoring, predictive analytics, and zone-based safety…

July 23, 2025 – AutomationDirect adds Metal Work ISO 6432 non-repairable pneumatic air cylinders, providing an ideal solution for metric applications where an inexpensive actuator is desired. These cylinders are a great choice for machinery with limited installation space, and the self-lubricating bronze bushings provide many years of maintenance-free operation. They are interchangeable with other…

This OEM systems integrator has standardized on a common touchscreen user interface, improving their ability to create automated equipment for their clients. While automated equipment ideally runs itself, there remains a need for humans to interact with machinery for setup, monitoring, troubleshooting, and more. This role was once fulfilled by buttons, switches, lights, and the…

July 16, 2025 – A new CPU has been released for the Productivity3000 PLC line. The P3-622 CPU has all the functionality and many features of the P3-550E CPU including up to 50MB ladder memory, embedded LCD status display, and USB data logging. In addition, this new CPU has dual software-configurable serial ports (RJ12 and…

July 16, 2025 – AutomationDirect has added a pre-cut DINnector steel DIN rail, available in lengths ranging from 50mm to 600mm, which helps eliminate the risk to personnel and saves time spent on cutting and drilling products with sharp edges and blades. Pre-cut DIN rail is also deburred for safety and to prevent damage to…

July 16, 2025 – AutomationDirect has added the Murrplastik MP3000 series cable/hose drag chains, which are constructed from rugged polyamide (PA) and are available in various sizes, supporting cables up to 15mm in diameter. Drag chains route cables/hoses to moving components while keeping them organized and protected. They help extend cable and hose life, provide…

July 9, 2025- AutomationDirect has added MK Morse bi-metal hole saws, which are a cost-effective, high-performance solution for various cutting tasks. These saws feature a patented tooth set design that enables faster hole cutting. For tougher materials, carbide-tipped hole cutters deliver clean, efficient cuts in stainless steel, aluminum, pipe, conduit, and composites, ensuring long-lasting use….

Anyone who has ever observed a modern factory in action, whether in person or perhaps via an episode of the “How It’s Made” documentary television series, is aware of just how impressive machine automation can be. This is especially the case when witnessing robotic arms and other machine motion control, as mechanical apparatus and payloads…

This home-built robot was created with industrial-grade automation technologies, providing a unique platform for learning career-enhancing skills. Inspired by science fiction movies featuring robots like R2-D2 and WALL-E, Justin Flynn, a controls engineer, embarked on a journey to build a personal animatronic robot named Hubert Evolution 2 (HEV2), reminiscent of Johnny 5 from the 1986…

A manufacturing company teamed up with a systems integration firm to significantly accelerate an infrastructure project by integrating a robotic welder with precision motion control, intelligent safety systems, and other advanced automation components. Tasked with producing over three miles of steel fencing in just 90 weeks, a leading steel fabrication company knew it needed to…

June 25, 2025 – AutomationDirect has added Endress+Hauser iTHERM and iTEMP series temperature transmitters that offer precise and reliable temperature measurements with easy integration, a rugged design, flexible configurations, and IO-Link or HART communication options. Endress+Hauser’s TM311 iTHERM CompactLine integrates an RTD and transmitter in a stainless steel housing, featuring an adjustable temperature range within…

June 26th, 2025- AutomationDirect has added LUTZE® SILFLEX FBP VFD cable that provides the ultimate solution for the cabling challenges faced by today’s food and beverage machine builders and processing companies. Phthalate-, talc-, and silicone-free cables reduce contamination risk and provide resistance to oils and fats that are common to food processing. SILFLEX FBP flexible…

June 18, 2025 -AutomationDirect has added WAGO lean managed industrial Ethernet switches that provide a cost-effective managed network solution. These switches integrate principles of lean manufacturing into their design and functionality, offering advantages such as waste reduction, improved efficiency, and more. Their web-based interface and easy-to-use diagnostic tools reduce configuration, monitoring, and troubleshooting time, and…

New Product Giveaway – CHANNELLOCK! Enter your info for a chance to win some of our newest products. This giveaway includes (2) 9.5-in. pliers, (2) 6.5- in. pliers and (2) 6-in. wire strippers. You will also be entered to win 1 of 5 drill bit sets. Contest is open for approximately 3 weeks after the…

June 18, 2025 – AutomationDirect has added Define Instruments Twin Link series point-to-point wireless I/O devices, which provide a cost-effective solution for applications where wiring is difficult or impractical, such as long distances, physical obstacles, or moving equipment. They create a dedicated, bidirectional radio link between a pre-paired set to reliably transmit analog or digital…

Autonics has been making automation easier for almost 50 years. In fact, the slogan “Make Life Easy,” captures what the company is all about: simplifying industrial automation while making the world more convenient. Based in South Korea with a network of 13 global subsidiaries and 100+ offices (including U.S. headquarters in Illinois), Autonics makes a…

Pilot devices are essential operator interface components for most automated equipment and processes. As the industrial age dawned, machinery and equipment were controlled manually by operators pulling levers, turning hand cranks, and making similar actions and adjustments as they saw fit. Industry 1.0 was powered by water and steam, 2.0 relied on electricity and added…

June 11, 2025 – AutomationDirect has added Ashcroft B-Series mechanical pressure switches to deliver precise, reliable pressure sensing in a compact and rugged design. Equipped with cost-effective, high-capacity 15A relay outputs, they eliminate the need for external contactors or interposing relays. Select models feature a narrow deadband for highly accurate trip points. With adjustable setpoints, wide…

Readers demonstrate enthusiasm for the CM5-RHMI, a cost-effective and flexible headless HMI with remote connectivity, advanced functionality, and a compact footprint. AutomationDirect’s C-more CM5-RHMI has been announced as the 2025 Silver winner of Control Engineering’s Product of the Year program in the human-machine interface (HMI) category. Check out the award announcement here! Control Engineering subscribers…

I remember physical education from elementary school back in the 1980s. Phys ed was always a treat as I got to get out of our regular classes and do something besides sit in a classroom. It was almost as if I had a bonus recess that day. Now, that was until third grade when my…

May 28, 2025 – AutomationDirect has added CHANNELLOCK tools, which are designed with strength and durability in mind. CHANNELLOCK tools are made in the USA with high-carbon USA steel.  The CHANNELLOCK straight jaw pliers feature undercut tongue-and-groove channels to prevent slipping, and Griplock jaw tongue-and-groove pliers have an offset head for greater leverage with patented SAFE-T-STOP® technology to…

May 28, 2025 – AutomationDirect has added Laumas precision-engineered load cells, transmitters, and accessories that deliver reliable performance in industrial weighing and force measurement applications. The FCAL series high-precision bending beam load cells are ideal for low- to mid-capacity systems. CTL series load cells are designed for both tension and compression, with excellent linearity. The…

May 28, 2025 – AutomationDirect has added new Gates hydraulic hose assemblies from Royal Brass & Hose. These hose assemblies eliminate the need to cut and terminate hydraulic hoses on-site and are offered in the ProFlex or MXT series. The ProFlex series features a compact construction with a smaller outer diameter, allowing them to flex…

May 21, 2025 – AutomationDirect has added ifm fail-safe inductive sensors featuring (2) OSSD outputs that can be connected to a safety relay for safety applications requiring the detection of metal objects. These sensors are designed to trigger a safe state (like stopping a machine) if the sensor fails, reducing the risk of injury to…

May 21, 2025 – AutomationDirect has added additional drag chain options to route cables/hoses to moving components and help extend cable/hose life. The igus 2500 series cable/hose drag chains feature a snap-open mechanism along the chain’s outer radius to allow convenient access to the chain’s channel after installation. The hinged crossbar can be swiveled by more…

May 21, 2025 – AutomationDirect has added Patlite industrial signal beacons, which provide a clear and unambiguous visual indication, ensuring quick and easy detection by floor personnel. These beacons are available in three series with various monocolor options and a Fresnel lens that distributes ambient, uniform light from all globe surfaces, including the top. All…

May 21, 2025 – AutomationDirect has added IronHorse VP1 series DC gearmotors that are designed to power high-torque mechanical loads at lower speeds with a compact motor. They are powered by 90 VDC and are designed for use with unfiltered SCR or PWM waveforms generated by a DC drive. They can also be used in across-the-line applications….

Solving Frequency Signal Conditioner Challenges 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 associated with a spinning sprocket, between digital motion control systems requiring…

May 14, 2025 – AutomationDirect has added WAGO 787-3861 series single-channel electronic circuit breakers that offer a lower cost option and a compact 6mm form factor to provide safe and reliable supplementary protection for 24 VDC control circuits. These electronic circuit breakers offer remote monitoring and control, clear LED indicators, and fast response to overloads…

May 14, 2025 – AutomationDirect has added Pfannenberg DTT 6000 series top-mounted air conditioners which are 100% condensate safe, provide up to 14,000 BTU/H, and are ideal for space-saving installation on the top of a NEMA 12 control enclosure. Pfannenberg’s DTS series 3000 air conditioners are made in the USA, offer cooling capacities up to…

May 14, 2025 – AutomationDirect has added Comepi SB series pre-assembled polycarbonate control stations, which offer emergency stop and start/stop combo options. The emergency stop control stations include one red mushroom head twist-to-release pushbutton with various contact configurations. Models with guards that are padlockable and models with M12 quick-disconnects are available. The start/stop combo control…

May 14, 2025 – AutomationDirect has added AchieVe FKL series 18mm tubular photoelectric sensors, which feature a rugged nickel-plated brass construction and a high IP67 protection rating. They employ Class 1 or Class 2 red lasers to provide sensing distances up to 50 meters. These sensors, in diffuse with background suppression, diffuse, polarized retroreflective, and…

May 14, 2025 – AutomationDirect has added Balluff EtherNet/IP IO-Link master modules that provide EtherNet/IP communication for IO-Link systems, with a REST API and/or MQTT support depending on model. They are available in a rugged IP67 die-cast zinc nickel-plated housing for harsher environments or in a weld-proof potted plastic format. Select models include built-in screen…

Because industrial automation systems often remain in service for decades, it is important to select a hardware/software supplier and integration specialist familiar with performing incremental updates as needed. By: Randy Ames, Ames Electrical Consulting, Inc. Repair or replace: a conundrum familiar to owners of appliances, consumer electronics, cars, homes, and also industrial processing facilities. For…

May 7, 2025 – AutomationDirect has added Lumher vision lighting fixtures, including bar, ring, flat, and spot lights. Bar lights are available in two series: the standard power PD series and the high-power FD series, which emit twice the light from the same package. They are available in semi-diffuse and ultra-diffuse lighting angles, as well…

May 7, 2025 – AutomationDirect has added AttaBox Heartland/Heartland SL series hinged screw cover enclosures that provide an alternative to conventional latch enclosures. The hinged screw cover configuration gives the enclosure the highest level of protection against water intrusion (NEMA 6P), and the polycarbonate resin in the Heartland series has attained the best available “F1”…

May 7, 2025 – AutomationDirect has added pre-cut aluminum DIN rail, available in sizes from 72mm to 858mm, which helps eliminate the risk to personnel and saves time spent on cutting and drilling products with sharp edges and blades. Pre-cut DIN rails are also deburred for safety and to prevent cables and wires from being…

When you hop on a thrilling amusement park roller coaster, Ferris wheel, or pendulum ride, you probably don’t think about what makes it stop when it’s time to do so. More likely, you are relieved to finally get on the ride after standing in a long line! And chances are good that you don’t wonder…

Many industrial automation end users are not staffed to deploy cutting-edge cybersecurity provisions, but they all will benefit from performing attainable and practical basic steps. By Tim Wheeler, AutomationDirect Albert Einstein said, “Genius is making complex ideas simple, not making simple ideas complex.” Modern cybersecurity is an example of an extremely complex subject, where a…

AutomationDirect has created an extensive portfolio of professional-grade control panel products, tools, and test equipment, all readily available at reasonable cost so that shops can equip their technicians to deliver high-quality results. By Zach Ganster, AutomationDirect The “good/better/best” concept is familiar to most people. When it comes to obtaining anything we use in our daily…

This student team gained valuable STEM experience by developing an underwater remote operated vehicle, and they accelerated their efforts by using commercially available industrial-grade components. By: Geoff Gardener, North Paulding High School Exploration of both the deep sea and of outer space share a lot in common. Both are extremely unforgiving environments where it is…

By Travis Morris, Safety Administrator, AutomationDirect As we recognize National Safety Month this June 2025, it’s the perfect time to reflect on how industrial safety has evolved alongside technological advancement. At AutomationDirect, we’ve seen firsthand how the safety landscape in manufacturing and logistics continues to advance rapidly, creating both new challenges and unprecedented opportunities for…

By: Larry Reynolds, AutomationDirect Safety systems play a crucial role in industrial equipment, protecting personnel, guarding against machine damage, and minimizing unscheduled downtime. To make a machine totally safe, we could build a wall around it, cut the power, send staff home, and lock the doors after them. That approach isn’t particularly practical, however. Instead,…

Highlights In the world of manufacturing, efficiency and productivity often take center stage. However, there’s one element that must always be prioritized above all else: employee safety. Recognizing that June is National Safety Month, AutomationDirect is dedicating much of this issue of NOTEBOOK to addressing the issues that impact safety in the manufacturing workplace —…

Polka Dot Remainder Find the area of the blue shaded portion in each figure below: Area Sensors Speaking of Area – did you know that AutomationDirect offers multiple types of Area Sensors? Also known as Measuring Light Grids, these sensors can detect the presence of an object within the grid, AND measure that object’s height….

April 30, 2025 – AutomationDirect has added Helukabel’s HELUKAT industrial Ethernet and Profinet cables featuring a halogen-free, flame-retardant, and durable construction built to support a variety of industrial requirements. New Type B, Type B Hybrid (with power conductors), Type R, and Type C Profinet cables are designed to provide reliable data transmission in dynamic or…

April 30, 2025 – AutomationDirect has added Lika draw wire linear measurement devices, also known as string encoders or string potentiometers, which use a steel cable wrapped on a spring-loaded reel to measure distance. The reel is connected to a rotary encoder or potentiometer that can provide very accurate feedback on how far the steel…

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 has been setting the standard for encoders and position measuring systems since 1982. Headquartered in Carré, Italy, the family-owned company has grown into a forward-thinking global leader with more than 150 employees and production facilities and sales offices in Italy, Germany, Thailand and the United States. Today, the company is one of 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…