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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…

October 23, 2024 – AutomationDirect has added M12 field wireable connectors with additional cable size options from Murrelektronik. New 5-pin A-coded connectors are available for 4-8mm/26-18 AWG cable sizes, in axial or 90° male or female connector styles. New D-coded connectors offer 4-pin configurations for 4-8mm/26-18 AWG cable sizes, in axial or 90° male connector…

October 23, 2024 – AutomationDirect has added the CITO StackFlow series of modular process valves.  This system of high-flow, robust components can stack together to form a valve bank assembly. Each module includes common inlets at each end and an outlet discharge at the bottom. Manual and solenoid valves are available, as well as distribution…

Industrial automation products can also be applied to unique applications, like the advanced control needed for a sophisticated escape room. Escape rooms are immersive adventure games where players solve puzzles to break out from a themed environment within a set time. While seemingly unrelated to industrial automation, a systems integrator (SI) leveraged expertise gained from…

October 9, 2024 – AutomationDirect has added more top-of-the-line Wera tool options to their continuously growing Tool and Test Equipment lineup. New tool sets include maintenance sets, a Joker self-setting/self-adjusting wrench set, a Tool-Check PLUS socket/driver bit set, and Kraftform Kompakt multi-bit screwdriver sets. Screwdriver additions include Kraftform Micro precision screwdriver sets, Kraftform Kompakt multi-bit…

October 9, 2024 – AutomationDirect has added Endress+Hauser intrinsically safe analog input isolators to provide cost-effective galvanic isolation for process instruments located in hazardous locations. This ensures that only a safe amount of energy resides in a potentially explosive atmosphere. Endress+Hauser RN22 0/4 to 20 mA input isolators are offered in 1-channel, 2-channel, or signal…

October 9, 2024 – AutomationDirect has added Crohm brand VFD brake resistors, which feature NEMA 1 enclosures and installed thermal switches. These resistors are offered in many popular resistance values from 3.7 ohms to 400 ohms and power ratings from 240 W to 18 kW to ensure a good match per your manufacturer’s recommendation. The…

Here are some of the typical continuous/analog level measurement methods, with a summary of their strengths and weaknesses: Ultrasonic level sensors: These are generally installed at the top of a vessel looking down into the product. They generate a periodic ultrasonic sound impulse and measure the echo’s return time to determine the distance to the…

Here are some of the typical discrete level detection methods, with a summary of their strengths and weaknesses: Float level switches : These simple devices provide an on or off signal as a liquid moves up or down. Some travel along a guide rod, while others just bob up or down on a cable, and either…

Detecting the level of a product or liquid in a vessel is required for many machinery and process applications, so designers need a working understanding of the available technologies and best practices. Manufacturing and processing equipment automation systems often need to detect the presence/absence, or even the exact level, of a material in a bin,…

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 at fixed speed, and other times they are driven using a variable frequency drive…

In the manufacturing industry, companies are clamoring for products that can automate processes to increase efficiency. The safety and comfort of machines and their operators is also paramount, causing a rising demand for more protective workplace solutions. That’s why innovative solutions, such as programmable support arms, operator control systems and enclosures, are becoming more essential…

Big Rig Custom Shop Accelerates Automation into the Passing Lane “Less is more” and “function over form” are phrases often associated with the design of objects—anything from office supplies up to buildings or larger—to promote a concept of simplicity, clarity, and essential purpose. However, there are plenty of cases where most people would agree that…

September 25, 2024 – AutomationDirect has added LUTZE ELECTRONIC shielded or unshielded flexible control and signal cable. This industrial-grade multi-conductor cable is ideal for use in machines and machine tools, plant cabling, HVAC technology, assembly/production lines, process instrumentation, and industrial controls. These cables are 300V rated and are third-party evaluated by ECOLAB for resistance to…

September 25, 2024 – AutomationDirect has added a variety of new Metrol limit switches to their growing lineup of precision limit switches. These ultra-precise mechanical limit switches have a repeatability down to 0.5 microns (µm) and are some of the smallest switches/sensors available. Their tiny size allows them to be mounted in extremely tight locations….

September 25, 2024 – AutomationDirect has added the RHINO PSE-S series power supplies which are fully encapsulated in ultra-compact, low-profile housings and ideal for space-limited applications. These cost-effective power supplies offer a wide input voltage range, up to 89% efficiency, and are available in 5, 12, 15, and 24 VDC output voltage options with up…

September 18, 2024 – AutomationDirect has added ProSense FSC series mechatronic digital flow sensors that monitor liquid media and provide flow sensing up to 50 GPM and temperature measurement up to 212°F. They feature a stainless steel construction, are available with 3/4”, 1”, or 1-1/2” FNPT process connections, and provide two analog, frequency, or switch…

September 11, 2024 – AutomationDirect has added Master Appliance heat guns, which are quality heating tools used extensively across various industries for tasks such as shrinking tubing, activating adhesives, bending plastics, thawing frozen pipes, circuit board manufacturing, and so much more. These heat guns deliver high temperatures quickly and efficiently and include various models to fit most applications….

September 11, 2024 – AutomationDirect has added more options to the ReeR MOSAIC safety controller family. The MOSAIC-M1S-USBC has all the features of the enhanced MOSAIC-M1S master controller module, including embedded digital inputs, OSSD outputs, and expansion capabilities, but also offers a USB-C programming port. The new ReeR MOSAIC MZERO controllers are simple standalone safety…

September 11, 2024 – AutomationDirect has added more 1- and 2-channel E-stop relays, light curtain control relays, motor standstill monitoring relays, and combination speed/standstill monitoring relays from Dold. These additions offer more wire termination options, including push-in cage clamps, and the new combination speed/standstill monitoring relays provide a more versatile motor monitoring solution. All Dold…

September 11, 2024 – AutomationDirect has added new ProSense thermistor temperature sensors in a wide range of probe and installation styles. The 10K3 series sensors offer hex nipple probes, attached plug probes, lead wire transition probes, flange mount probes, bolt-on ring probes, cuttable probes, new bead and junction box probe styles, and more. They provide…

Because AC motors are essential workhorses for industry, designers need to understand their applications to make detailed selections, such as single-phase or three-phase styles. Electric motors are a fundamental force for creating powered motion in any type of equipment. Initially developed in the 1800’s and refined significantly over the years, electric motors are now available…

September 4, 2024 – AutomationDirect has added the new Flowline LR80 EchoBeam® FMCW (Frequency Modulated Continuous Wave) radar level transmitter featuring Flowline’s 80 GHz radar technology that is unaffected by most media, processes, or environmental factors. Using the change in frequency between the transmitted and reflected signals, the EchoBeam level sensor can measure liquids up…

September 4, 2024 – AutomationDirect has added new Penn Union power distribution blocks featuring a modular design that allows easy assembly into multi-pole block configurations. Penn Union blocks offer a rugged aluminum construction, dual ratings for aluminum and copper conductors, and are suitable for DIN rail or panel mounting. With amperage ratings up to 760A…

September 4, 2024 – AutomationDirect has added new Endress+Hauser Cerabar PMP23 series hygienic pressure transmitters. These transmitters feature a compact stainless steel housing, a fully welded 1-1/2” sanitary tri-clamp process connection, and are approved for Food and Beverage applications. Select models offer IO-Link compatibility for easy setup, integration, and on-the-fly configuration changes. Cerabar hygienic transmitters…

A digital graphical human-machine interface is usually the best way for users to interact with any type of monitoring or control system, and industrial versions are specially designed to withstand challenging environments. For practically every type of machinery or equipment ever put into service, there has been a need for some type of operator interface…

Featured Products LS Electric XGB PLCs are advanced controllers geared for motion applications with high-level features, such as IEC programming, that can be beneficial in any automated system PLCs starting at $279 LS Electric L7C AC servo systems combine a high-performance servo motor with a servo amplifier (drive) to achieve accurate position, velocity, or torque…

August 28, 2024 – AutomationDirect has added Gladiator GR series DIN rail or panel mounted quad-port power receptacles. These receptacles provide convenient power outlets and are commonly used in electrical enclosures to temporarily power laptop computers and test equipment. The GR-REC4 consists of two NEMA 5-15R duplex receptacles, while the GR-REC4-GFCI includes one standard NEMA…

August 28, 2024 – AutomationDirect has added new versions of the AchieVe WDW and WDN series wire ducts which provide easy wire management at great prices. These rugged, wide and narrow finger wall, rigid wire ducts are made of self-extinguishing UL 94 V-0 rated flame-retardant PVC material. AchieVe wire ducts feature convenient upper and lower…

August 28, 2024 – AutomationDirect has added a wide assortment of world-renowned Wiha tools to their ever-expanding Tool and Test Equipment lineup, including various types of standard, insulated, electric, and precision screwdrivers, multi-bit drivers, nutdrivers, standard and insulated t-handle hex keys, wing and flag handle torx keys, tool pouches, tool bags, tool backpacks, many tool…

August 28, 2024 – AutomationDirect has added IDEM universal gate boxes designed for machine guard doors that act as an integrated locking guard with a double tamper-resistant interlock mechanism. These boxes provide high-level RFID-coded interlocking and machine control in one unit. Capable of holding guards closed with up to 3,000N holding force, these boxes can…

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…

Options for Open Industrial Programming Industrial automation designers now have a variety of ways to incorporate an open programming approach for their projects. Although industrial-grade digital technologies have been available for over five decades, much of that time the hardware and software has been specialized and even proprietary. This is at odds with a large…

August 21, 2024 – AutomationDirect has added the STRIDE SE3 series PoE++ Ethernet switch that provides both power and Ethernet communication to connected devices, allowing even more savings in your network design. This switch will auto-detect the presence of a PoE enabled device and provide up to 240W of DC power along with Fast or…

August 21, 2024 – AutomationDirect has added the BLOCK PM series mini power supplies which feature a compact form factor, excellent transient voltage protection, and an affordable price. They are robust and adaptable for a range of applications, offering performance and reliability without the higher cost of full-featured power supplies. The new BLOCK PM-0624-100-0 redundancy…

August 21, 2024 – AutomationDirect had added a wide array of vinyl electrical tapes and insulated mastic and splicing tapes from Plymouth Rubber®. Vinyl electrical tape is a high-quality, all-weather tape that easily applies to surfaces and withstands a wide range of temperatures. These tapes include versions that can be used as protective outer jackets…

August 21, 2024 – AutomationDirect has added new WERMA eSIGN series LED signal towers that have the same advanced features as the original series but provide a white polycarbonate housing that offers a crisp, clean look.  These signal towers are available in 9- and 15-tier models, with select models offering IO-Link v1.1 compatibility. They offer…

August 14, 2024 – AutomationDirect has added new SureMotion lighter-duty carriages and guides for linear motion applications. Carriage and guide systems are machine elements that move objects in a straight line with minimal friction or resistance. They are offered in two varieties: external carriages with wheels that ride outside the guide tracks and internal carriages with…

August 14, 2024 – AutomationDirect has added the Murrplastik MP18 series cable/hose drag chains which are built from rugged polyamide (PA) and are available in various sizes with support for cables up to 15mm diameter. Drag chains are used to route cables/hoses to moving components while keeping them organized and protected. They help extend cable…

Modern PLCs and HMIs have empowered a big rig customization shop to create increasingly sophisticated automated lighting effects for their customers. Byline: Dustin Dickerson, Dickerson Custom Trucks “Less is more” and “function over form” are phrases often associated with the design of objects—anything from office supplies up to buildings or larger—to promote a concept of…

What is a Power Supply? Industrial power supplies are an integral part of manufacturing and automation. They convert AC power to reliable DC power for a wide range of equipment, such as PLCs, HMIs, relays, sensors, actuators, and drives.  By ensuring a consistent, clean DC power source, these power supplies significantly enhance the performance, reliability,…

The decision to purchase a high-performance power supply is often a balancing act between upfront costs and long-term benefits. While standard power supplies may be sufficient for basic operations, high-performance models offer a range of advanced features designed to enhance efficiency, reliability, and overall system performance. While the initial expense may be higher, it is…

August 7, 2024 – AutomationDirect has added a variety of new NITRA push-to-connect fittings. These fittings feature durable nickel-plated brass bodies, threads, and release sleeves. They have a maximum pressure rating of 300 psi and can withstand temperatures up to 175℉. Numerous fitting styles have been added, including male straight fittings, male elbows, branch tees,…