Transforming Industries

The goal of these manufacturing revolutions is "batch size one," where every product is uniquely customizable by the consumer. Products can be manufactured using only the precise amount of raw materials, energy, and other inputs required, and there are no defects. Constant monitoring of the machinery will also allow preventative maintenance to stop unplanned breakdowns, maximizing productivity.

We are currently in the early stages of Industry 5.0’s implementation, but the fundamentals needed for full integration are already established. Robotics are currently at the heart of the production line. They are quicker, more productive, and more precise than human operatives. In an Industry 5.0 implementation, many production robots will have to become collaborative robots (cobots) to work closely with human staff in complete safety without the usual protections of safety curtains and cages. This means using advanced sensing to detect problems and fast processing to enable swift safety action.

It is not just on the production line that organizations will need to adapt robots to better work alongside humans. Robots are also used in industry to transport production pieces from one area to another. In the past, rudimentary autonomous mobile robots (AMRs), which follow markings on the wall or lines on the floor, have been employed to carry items between two points. But if these AMRs encounter a problem, they halt until the issue is resolved. Industry 5.0 requires more sophisticated autonomous guided vehicles (AGVs) for higher levels of safety and reduced stoppages. These robots scan their surroundings to build a constantly updating picture of their operating environment and then calculate the most efficient and safest route to their destination. If they detect a problem, they plan a different route and continue, whether that problem is a human, fellow robot, or a blockage. They can also be used on any route in the production area, not just between fixed points.

Robots make extensive use of electrical motors for mobility, tactility, and strength. While motors are responsible primarily for robots' movements, they also play a role in safety. Additionally, motors drive conveyors, fans, blowers, and many other applications inside of the workplace and are estimated to use over 40 percent of the electricity generated globally to accomplish these tasks.¹ The industry has increasingly adopted silicon carbide (SiC) and gallium nitride (GaN) to achieve higher energy efficiency and improved performance. These materials reduce conduction and switching losses, enabling smaller, more power-efficient systems. Their ability to operate at higher frequencies and integrate with sophisticated control architectures enhances responsiveness, ensuring precise motor control, real-time fault detection, and optimal safety in industrial environments.

While robots grab most of the headlines, many other components need to perform optimally to make Industry 5.0 systems function correctly. For example, sensor accuracy is essential when data is critical to performance, whether in complex vision systems for inspection or simple temperature sensors. Sensor measurements must then be amplified and conditioned for processing with the utmost precision. Connectors must also provide the highest signal integrity to ensure the signal that reaches the processing unit represents the one taken at the source as precisely as possible.

In power delivery, the GaN and SiC components that provide higher efficiency depend on supporting components, both to get the required performance and to counter the electromagnetic compatibility (EMC) problems that occur when switching current quickly. Capacitors, EMC components, and filters that are implemented incorrectly could reduce system lifetimes or even cause catastrophic failure. Components such as the DC link capacitor are vital to ensure power is delivered as safely and efficiently as possible.

These components must perform their designated jobs while being compact, power-efficient, and rugged enough to operate in harsh industrial environments. The demand for supporting components will increase as the industry approaches batch size one. TDK is at the forefront of providing solutions for the new industrial revolution, designing and building its own machinery to maintain tight control over every aspect of the production process, from manufacturing the materials to the end product. This ensures that TDK's signal chain, power chain, sensor, passive, and magnetic components consistently push the boundaries of innovation. 

¹https://iea.blob.core.windows.net/assets/d69b2a76-feb9-4a74-a921-2490a8fefcdf/EE_for_ElectricSystems.pdf

Key Components Enabling Compact Design

To achieve the compact and efficient designs needed for AGVs and AMRs, components must work together. Power systems, surface mount technology, and sensors all play a role in optimizing space and energy usage.

Power Systems

The evolution of power systems plays a crucial role in the comp act design of AGVs and AMRs. While lithium-ion batteries currently dominate this market, solid-state batteries are emerging as a promising next-generation technology. These batteries offer higher energy density, potentially allowing for smaller battery sizes without sacrificing runtime. They also provide improved safety—due to the elimination of flammable liquid electrolytes—and offer faster charging capabilities, significantly reducing downtime for AGVs and AMRs.

A revolutionary approach to AGV and AMR power management is the implementation of dynamic wireless charging systems. This technology allows vehicles to charge while on the move, which could eliminate the need for dedicated charging stations and reduce battery size requirements.¹ Additional benefits of this approach include continuous operation without charging downtime, smaller onboard batteries that reduce vehicle weight and cost, and simplified fleet management with less need for a charging schedule.

Advanced battery management systems (BMS) also transform how AGVs and AMRs utilize their power sources. Through a BMS, predictive maintenance can forecast battery failures before they occur, minimizing unexpected downtime. Dynamic power allocation optimizes power distribution based on real-time operational needs, extending battery life. Cloud-based fleet management enables centralized battery health monitoring across an entire fleet, allowing for more efficient scheduling and maintenance.²

Surface Mount Components

Surface mount technology (SMT) has become widely adopted in producing electronic components for AGVs and AMRs. This technology enables efficient printed circuit board (PCB) designs that make these robots cost-effective and easy to manufacture. SMT offers compact components that enable higher packing density and the ability to mount components on both sides of the board, increasing circuit density. Moreover, SMT production can be easily automated, reducing manufacturing costs and producing lighter products.

An example of an essential SMT component for AGVs and AMRs is the TDK J404 inrush current limiter (ICL), a recent surface mount ICL development based on positive temperature coefficient (PTC) technology. Designed for DC voltages up to 500V and AC voltages up to 350V, this thermistor can switch off defects (e.g., short circuits) up to 100 times and handle up to 100,000 cycles when charging and discharging capacitors. Compliant with RoHS and JEDEC-J-STD-020D standards, it supports compact design by saving PCB space up to 70 percent, compared to non-surface-mount components, while providing reliable switch-on current protection for power supply systems.³

Sensors and Actuators

Compact sensors and actuators are essential components for AGVs and AMRs. Ongoing miniaturization has led to increasingly smaller devices that save space in the overall design, allowing for the integration of additional functions and components on the circuit board. Many modern compact sensors and actuators combine multiple functions in a single component. For instance, some sensors can simultaneously measure temperature, humidity, and pressure without requiring several components. This significantly reduces space requirements and design complexity.

Smaller, more efficient sensors and actuators usually consume less energy, resulting in better overall system performance. This means that batteries or power supplies can be made smaller, saving even more space and extending the service life of the system.

Design Strategies for AGVs and AMRs

Designing AGVs and AMRs requires various strategies. Here are some key design strategies that enable engineers to create more efficient, scalable, and lightweight robots.

Modular Design for Flexibility and Scalability

Modular design approaches offer significant benefits for AGV and AMR development. Some manufacturers are adopting modular battery designs that allow for quick swapping of depleted batteries with charged ones. This approach minimizes downtime for battery replacement, provides flexibility to adjust battery capacity based on specific mission requirements, and facilitates easier maintenance and upgrades of individual battery modules.

Space optimization is another advantage of modular design. Modular PCB designs better utilize the limited space within AGVs and AMRs, especially when combined with flex-rigid assemblies. This approach enables more compact and efficient robot designs. Additionally, a distributed architecture with smaller PCB modules placed in different locations throughout the AGV or AMR can lead to better weight balance and more efficient use of space.

Optimized Layout to Save Space

In addition to modular design, intelligent layout helps to maximize the space on the PCB. Careful placement of components and optimized routing of traces can minimize unused space, resulting in more compact designs. This is particularly important in SMT designs, where the high density of components requires meticulous planning to avoid problems with signal integrity or thermal hotspots.

Modern PCB design software optimizes SMT layouts for AGVs and AMRs.⁴ These tools often incorporate advanced algorithms that automatically suggest optimal component placements and routing paths, considering signal integrity, thermal management, and manufacturing constraints. Some software even incorporates machine learning techniques to continuously improve layout suggestions based on successful designs.

Advancements in automated optical inspection (AOI) systems with AI capabilities are enhancing the quality control of SMT assembly, ensuring reliability in increasingly complex and dense PCB designs.⁵ These systems can detect defects, such as misaligned components, solder bridges, or insufficient solder joints, with high accuracy and speed. This means that AGV and AMR manufacturers can maintain higher quality control standards, even as designs become more compact and complex.

The trend toward smaller components in SMT has also led to innovations in PCB manufacturing. Techniques such as high-density interconnect (HDI) allow for smaller vias and finer trace widths, enabling even greater component density. Some advanced AGV and AMR designs may incorporate HDI techniques to achieve the miniaturization required for their specific applications.

Material Choice and Weight Reduction

For AGVs and AMRs, lightweight materials are crucial to reduce overall weight while improving performance and efficiency. Developers use materials such as aluminum, carbon fiber, magnesium, and various composites, offering an optimal combination of strength, lightness, and cost-effectiveness. The choice of material depends heavily on whether the specific application prioritizes structural strength, weight savings, or cost efficiency. Combined with modern design and manufacturing techniques, these materials enable lighter, more energy-efficient, and higher-performing robots.

Innovative materials such as graphene, nanocomposites, and self-healing materials offer significant potential for the future of materials science and engineering in AGV and AMR design.

Additional Benefits of Compact Design

Compact design offers several additional benefits for AGVs and AMRs. A key advantage is improved maneuverability, as smaller, compact robots can move more easily in confined spaces or warehouses. This is particularly important in production lines with limited space for moving parts and where robots must navigate thresholds or door frames.

Cost efficiency is another significant benefit. Compact design and low weight save material costs in manufacturing, lowering acquisition costs for end customers and reducing the total cost of ownership, especially when purchasing large quantities. Greater energy efficiency also reduces operating costs, which can be decisive for the operating results in large production facilities or warehouses.

Furthermore, energy-efficient products contribute to greater sustainability. In times of climate change and rising energy costs, energy-efficient appliances are crucial. A long battery life increases the overall service life of the devices, contributing to greater sustainability and reducing the company’s overall CO₂ footprint.

Future Trends in Compact Design of AGVs and AMRs

The future of AGVs and AMRs lies in even smaller and more compact designs coupled with higher energy efficiency. This trend is driven by the increasing miniaturization of components and the development of increasingly energy-efficient technologies. The use of AI in the development, production, and operation of these vehicles will also play a significant role in their evolution.

The further development of compact designs for AGVs and AMRs will be closely linked to sustainability goals. The focus will be on resource efficiency, sustainable materials, energy savings, and extending product lifetimes through modular, repair-friendly designs. Advances in miniaturization, materials science, and networking are enabling compact robots to become more agile, powerful, and environmentally friendly, meeting industry demands for smaller, more efficient robots.

Conclusion

The future of AGV and AMR design is centered on optimization using lightweight materials, energy-efficient components, and advanced battery technology to reduce energy consumption and increase performance. Miniaturization and intelligent PCB layouts will enable more functionality in smaller spaces, improving both these robots' agility and resource efficiency. Modular design approaches will extend the life of AGVs and AMRs, reducing waste by enabling easy upgrades and repairs. Using sustainable materials and environmentally friendly production methods will promote resource-efficient manufacturing and reduce these technologies' ecological footprint.

Advancements in networking and data optimization will help to use energy and resources efficiently during operation, meeting industry demands for smaller, more agile, and environmentally friendly robots. As these technologies evolve, they will play an increasingly important role in shaping the future of industrial automation and logistics. 

¹https://www.roboticsandautomationmagazine.co.uk/news/agvs/wireless-agv-and-amr-charging-what-to-know.html
²https://www.wiferion.com/us/energy-management-software-fleet-agv/
³https://www.tdk-electronics.tdk.com/en/373388/company/press-center/press-releases/press-releases/tdk-presents-world-s-first-smd-inrush-current-limiter/3188678
⁴https://blogs.sw.siemens.com/valor-dfm-solutions/how-to-optimize-pcb-design-for-the-smt-assembly-process-flow/
⁵https://www.smtfactory.com/what-makes-smt-aoi-ai-inspection-technology-superior.html

Another tool for industrial automation is light detection and ranging (lidar), which offers greater precision than radar. By emitting and receiving light pulses, lidar systems can map the shape and position of objects in dynamic environments, which makes lidar a good fit for areas where multiple machines are working simultaneously. For example, lidar can help AGVs and AMRs move around tight corridors or crowded factory floors.

Other technologies, such as ultrasonic sensors and optical cameras, work with radar and lidar to provide short-range, high-resolution data and visual feedback for navigating confined or visually complex spaces. Each of these technologies plays a role in industrial navigation, from wide-area monitoring to fine-grained obstacle detection in tight quarters.

While these technologies can address certain aspects of industrial navigation, they may face limitations in environments requiring more compact and low-power solutions optimized for short-range detection. ToF sensors, particularly ultrasonic ToF sensors, are well-suited for these scenarios.

ToF Sensors: Compact Solutions for Confined Spaces

Unlike lidar or radar, which excel in broader spatial awareness, ultrasonic ToF sensors specialize in real-time, high-precision measurements in short distances. They emit either ultrasonic sound waves or infrared light and calculate the time delay of their reflection to determine distance. This precise distance measurement capability makes ToF sensors essential for dynamic environments where real-time adaptation is critical. Lidar, radar, and ToF sensors can be viewed as complementary to ensure seamless industrial automation.

ToF sensors enable automated vehicles or machines to adapt to a dynamic environment as it changes around them, a key factor in maintaining optimal performance and reducing gridlock or unscheduled downtime. Multiple, simultaneous object detection is essential for mobile robots and self-guided vehicles. Modern manufacturing facilities have many moving parts, and sensors need to provide them with the ability to negotiate more than one potential obstacle at a time.

Practical Applications

ToF sensors like TDK’s ultrasonic sensor modules determine object proximity by emitting ultrasonic waves from a piezoelectric disc. The piezo disc transmits and receives ultrasonic waves, and an integrated driver and signal processing ASIC calculate the time of flight. An external control unit then converts the time of flight into distance.

The USSM1.0+FS sensor is a robust option for industrial applications, offering protection against dust and water, which are common in manufacturing settings. In addition, its sensor package is decoupled from the sensing element, reducing the impact of external vibrations and ensuring reliable performance in rugged environments. These features, along with a detection range of up to 500cm and the ability to detect multiple objects simultaneously within its field of view, make the USSM1.0+FS sensor an ideal choice for mobile robots and self-guided vehicles in manufacturing settings.

Although real-time obstacle detection and processing are the most appealing features of ToF technology, data from these sensors can also be analyzed to uncover long-term production and manufacturing trends while improving overall efficiency. For example, proximity sensor data might indicate that a particular robotic arm is struggling to complete a particular movement or operation. Facilities managers can then replace the failing device or component or redesign the arm itself for more variable mobility.

Similarly, data collected from proximity sensors on individual mobile machines can help facility managers coordinate entire fleets of self-guided vehicles or drones to optimize overall production and performance. AI- and machine learning-powered algorithms can process data received from proximity sensors in real time and make wholesale adjustments to production processes if a minor fault in a single component or device is causing macro-production issues.

Future Prospects

As industries continue to embrace automation, ToF sensor technology will need to evolve to accommodate the growing demand for precision and reliability in close quarters and, especially in the case of aerial drones, more wide-open spaces. Technologies like lidar, coupled with machine learning capability, could enable an entire fleet of aerial drones to perform tasks without any human supervision, resulting in a truly automated workforce. On the ground, ToF sensors that can simultaneously detect multiple objects in motion are imperative to designing robots and mobile machines that can take on responsibilities that only people can fulfill to this point in time.

Modern manufacturing facilities are replete with articulating robotic arms and machines that simulate human movement. In the future, devices like those might be replaced by humanoid robots that can walk on two legs and mimic almost all human body movements. Humanoid robots, particularly in industrial settings, will require the same kind of spatial awareness that human beings use to protect themselves and other robots and equipment. Simulating that kind of awareness will require sensor arrays with a 360° line of sight—a complex and expensive proposition. Ultrasonic ToF sensors seem like a better fit for this kind of complete spatial awareness as they’re a more compact alternative to light-based sensors and consume less power.

Conclusion

As production facilities continue to adopt automated processes and systems, sensor technology will be at the forefront of that transformation. ToF sensors will be critical in ensuring machines can safely and efficiently navigate increasingly complex environments. By combining ToF, lidar, and AI-powered data analysis, manufacturers can create smarter, more adaptive systems that optimize performance and minimize downtime. 

In response to these challenges, the TDK ModCap capacitors—specifically the B25645A ModCap MF series for IGBT modules (Figure 1) and B25647A ModCap HF series for silicon carbide (SiC) MOSFET modules (Figure 2)—offer a new approach.

These capacitors are designed with low stray inductance and biocircular films, with the B25647A providing high-frequency capability, positioning them as critical components in revolutionizing power management for industrial automation.

Key Features of Modern Capacitors

One of the standout features of modern capacitors is their ability to operate efficiently at frequencies typically used in industrial power applications, ranging from tens to hundreds of kilohertz. This capability enables faster and more efficient power conversion in DC link circuits.¹ High-frequency operation improves real-time control in motor drives and inverters, reduces energy losses across the system, and enhances the responsiveness of automation processes.

Minimizing stray inductance is another critical advancement in modern capacitor design, especially for DC link circuits. Low stray inductance enhances system stability by preventing potentially damaging voltage spikes that can occur during rapid switching in power converters.² This feature is particularly important in applications using fast-switching semiconductor devices like SiC MOSFETs, which operate at high frequencies, and some advanced IGBTs designed for higher switching speeds. By reducing stray inductance, these capacitors simplify overall system design by eliminating the need for additional protective components like snubber capacitors, improving reliability and efficiency with fewer parts.

Using Biofilms for Better Sustainability

Biocircular polypropylene films (Figure 3) in capacitor construction represent a significant leap forward in sustainability for DC link applications. This innovative material, made from 100 percent sustainable sources and certified by the International Sustainability and Carbon Certification (ISCC) scheme, maintains the same high-performance standards as conventional polypropylene films. The biocircular polypropylene film exhibits identical electrical and physical properties to its traditional counterpart, ensuring no compromise in capacitor performance for critical DC link applications.

Adopting biocircular polypropylene films in capacitor manufacturing reduces the carbon footprint of industrial automation systems without compromising performance or reliability. By using renewable resources, manufacturers can decrease their reliance on fossil-fuel-based materials, helping companies meet increasingly stringent environmental regulations and customer demands for greener technologies.

This shift helps conserve nonrenewable resources and supports the broader industry goal of developing more environmentally friendly technologies. Incorporating biocircular polypropylene film capacitors in DC link circuits offers a tangible way for automation systems to contribute to sustainability goals while maintaining the high standards of performance required in modern industrial applications. As industries worldwide strive to reduce their environmental impact, these sustainable capacitors represent a significant advancement in balancing ecological responsibility with technological progress.

Impact on Industrial Automation Systems

Integrating these advanced capacitors into industrial automation systems yields several significant benefits, particularly in DC link circuits. Cost reduction is achieved through lower initial system costs due to reduced need for auxiliary components, decreased maintenance expenses, and minimized downtime thanks to extended capacitor lifespans. Long-term operational cost savings are also realized through improved energy efficiency in power conversion processes.

Space optimization is another key advantage. Modern capacitors’ higher power density and compact size allow efficient power delivery and storage in smaller form factors, making them ideal for space-constrained applications. This feature is particularly valuable in DC link circuits, where space is often at a premium. The resulting streamlined designs improve space utilization in industrial settings, allowing for more compact and efficient automation systems.

System design is significantly simplified with the use of advanced DC link capacitors. Fewer components and simpler layouts reduce design complexity, accelerating prototyping and integration processes. This leads to shorter development cycles, enabling faster time-to-market for new automation systems. The ability to quickly respond to market demands and technological advancements increases competitiveness in the fast-paced industrial automation sector.

Conclusion

The advent of modern DC link capacitors, featuring high-frequency capability, low stray inductance, and biocircular polypropylene films, is transforming the landscape of industrial automation. These advanced components enhance system efficiency, stability, and sustainability across a wide range of applications. As we look to the future, it’s clear that these innovative capacitors will continue to play a crucial role in optimizing power systems for maximum performance, driving down costs across the entire automation ecosystem, and enabling more innovative and sustainable designs in industrial automation. 

¹https://eepower.com/technical-articles/evaluating-the-effect-of-high-switching-frequency-on-the-performance-of-an-active-front-end-converter-results-in-985-efficiency/
²https://benthamopenarchives.com/contents/pdf/TOEEJ/TOEEJ-7-98.pdf

Introduction to Energy Efficiency

Energy efficiency is the practice of maximizing useful energy output per unit consumed. As a part of the drive to reduce overall energy consumption, energy-efficient designs help directly improve climate change by reducing carbon emissions. Organizations can improve energy efficiency by using efficient appliances, improving building insulation, and optimizing commercial and residential heating, ventilation, and air conditioning (HVAC) systems. By adopting energy-efficient practices, individuals and organizations can significantly reduce their energy consumption and stress on the power grid (e.g., brownouts), lower their energy bills, and contribute to a more sustainable future.

Industrial Energy Conservation Opportunities

The industrial sector accounts for a large amount of total US energy consumption—33 percent in 2022—due to its power-intensive manufacturing processes.¹ This level is the highest fraction of consumption and is nearly equivalent to combined commercial and residential usage. As a result, industrial manufacturing is an ideal target for reducing energy usage through opportunities for functional films.

Smart Windows for Industrial Settings and Energy Savings

Smart windows use conductive films to control the light and heat entering a building. By adjusting the window’s transparency, these systems can conserve energy by reducing the need for artificial lighting and air conditioning or heating, leading to lower energy consumption (Figure 1).

In industrial settings, where energy use can be exceptionally high due to large spaces and constant operation, smart windows equipped with conductive film help regulate the internal environment more efficiently. This feature reduces operational costs and supports companies’ efforts to meet sustainability targets.

OPV Cells

OPV cells generate electricity by converting sunlight into energy, and their efficiency is highly dependent on the materials used. High light transmittance and low resistance are ideal for these cells, as the combination allows for more efficient conversion of solar energy to electrical in OPV cells (Figure 2).

OPV technology is becoming increasingly important as industries seek decentralized energy solutions. With the ability to integrate OPV cells into various surfaces, including flexible and curved ones, TDK’s film enables innovative applications, such as solar-powered windows or flexible energy-harvesting surfaces.

Organic EL Lighting

Organic EL lighting is known for its energy efficiency. Combined with conductive film, it reduces energy consumption while maintaining light output. This combination provides substantial cost savings for facilities, leading to consistent utility cost savings when replacing traditional incandescent light bulbs with energy-efficient LEDs and CFLs.

ZEBs, Greenhouse Gas Emissions, and the Role of Functional Films

As global industries pursue net-zero sustainability, ZEBs have become more prominent. ZEBs are buildings that produce as much energy as they consume, mainly by employing renewable energy sources and energy-efficient technologies. Transparent, conductive film plays a vital role in this transition by supporting the integration of energy-saving and energy-generating systems into building design.

Functional films for smart windows can significantly conserve a building’s energy load by managing heat gain and loss. Similarly, OPV cells integrated into building surfaces can generate renewable energy, helping buildings achieve a net-zero energy footprint.

Advanced Features of TDK Ag-Stacked Film

Traditional films are based on an optical transparent conductive material called indium tin oxide (ITO), which is composed of indium oxide with 10 percent tin additive. This composition provides transmittance in the visible light region while delivering high electrical conductivity. However, two limitations created a need for innovation in transparent conductive films:

• To enhance performance, there is a conflict between design levers: Reducing film thickness increases transmittance, but it also increases sheet resistance, which erodes conductive performance.
• Indium, the base material in ITO film, is occasionally in uneven supply and is at risk for material shortages and pricing spikes.

TDK’s Ag-stacked film mitigates these factors in several ways. The first is that the material reduces resistance to one-tenth (or lower) that of ITO films while maintaining parity transmittance. Pure silver deteriorates when exposed to oxygen, water vapor, or heat, causing instability for Ag thicknesses at or below 20nm. The TDK material sandwiches a silver alloy layer between two high-transmittance protective layers (Figure 3) to ensure transmittance performance and guard against material degradation simultaneously. (Note: The illustration does not show the additional adjustment layer for improved optical performance.)

Another advanced feature of the TDK Ag-stacked film is an extension in spectral profile over traditional ITO films. The film delivers transmittance between 380nm and 780nm (the visible region) and adds high reflectance in the infrared band, creating a high heat shielding effect.

Conclusion

Functional films like TDK’s Ag-stacked transparent electrically conductive material are transforming industrial energy conservation. Its low resistance, high transmittance, and mechanical flexibility support applications ranging from smart windows and OPV cells to organic EL lighting and flexible displays. Furthermore, its role in promoting sustainable building practices, such as ZEBs, highlights its significance in the future of industrial energy efficiency.

As industries seek sustainable solutions for reducing energy consumption and minimizing environmental impact such as carbon footprint, functional films like TDK’s Ag-stacked film will play an increasingly important role. By adopting these advanced materials, industrial sectors can achieve energy conservation goals while contributing to a more sustainable future.  

¹https://www.eia.gov/energyexplained/use-of-energy/industry.php

This article discusses some trends in modern industrial machinery and how these trends pertain to the increased need for robust thermal sensing technology. It also shares insights on thermal sensors and their use in industrial machinery to monitor and maintain machinery safety, efficiency, and longevity.

Trends In Industrial Machinery

One of the key trends in the realm of industrial machinery is a move toward enhanced levels of automation. This means that industrial machinery is becoming more complex, with more functions and moving parts. Along with the trend toward more and greater operational data for analysis and efficiency improvement, modern industrial machinery is now integrating more sensors into the platform. With more complexity and higher levels of automation, modern industrial machinery today is often electronically controlled by microprocessors or computer systems. In an increasing number of cases, the "brains" of these machines are connected to the cloud or an intranet to allow for monitoring and control from remote workstations or by advanced centralized control schemes.

Examples of these trends are the increased use of autonomous robotic systems for everything from product assembly to order fulfillment. More recently, these robotic systems have been designed to be mobile to fulfill more roles and enhance efficiency compared to stationary robotic systems. These robotic systems have paved the way for autonomous mobile robots (AMRs) that include a host of sensors and are now most commonly driven by advanced, connected compute systems or advanced microprocessors with sophisticated interfaces.

With the myriads of industrial machines, sensors, and actuators being controlled electronically over wireless or wired communication channels, these systems cannot be feasibly monitored by a limited crew of operators. Algorithms are doing more equipment monitoring with parameters set to initiate human intervention.

In some cases, machine learning (ML) and artificial intelligence (AI) algorithms further minimize the need for human intervention. Human operators are still needed to perform maintenance, safety checks, and troubleshooting, but increasing complexity and automation demand more sophisticated software and algorithmic control. Though this approach can significantly enhance efficiency and minimize downtime, organizations must implement checks to ensure safe operation and avoid catastrophic machinery failures that may go unnoticed by high-level operational control systems.

Role of Thermal Sensors in Industrial Machinery

One common sign of machinery failure, especially in linear or rotary moving parts, is the temperature state during nominal operation and the temperature profile of the mechanism over time. For instance, the most common sign of bearing failure in railcars is an increased operating temperature, and proper monitoring of train bearings can prevent many derailments.

In many cases, control algorithms change the operational parameters of these systems to ensure certain output goals that may result in highly dynamic operations. For highly dynamic systems, developing a baseline temperature operation for key mechanisms in an industrial machine is often challenging, but not impossible. For example, suppose a system operator implements a robust data acquisition and analysis system with highly responsive thermal sensors. This system can deduce trends in mechanism operation and even predict failure conditions or enhance maintenance schedules. With greater insights into the thermal condition of an industrial machine's mechanisms, a control algorithm or operator could be more effective at reaching process goals, such as maximizing output or reducing downtime.

This type of system would require a host of highly reliable and accurate temperature sensors placed as close as possible to the machine mechanisms for optimal accuracy. These thermal sensors would need to be particularly robust, with high moisture resistance, a wide operating temperature range, and diverse mounting or attachment options. A good temperature range for thermal sensors on electrical, hydraulic, pneumatic, or mechanical systems is −40°C to +85°C, but higher maximums allow for use in hotter environments—critical in many industrial settings. Designers may select thermal sensors with operating ranges far beyond what is expected of the equipment to ensure the longevity and reliability of the sensors over time.

A good candidate for many industrial machines is negative temperature coefficient (NTC) thermistors, often designed for extremely rugged operation and long lifetimes in harsh conditions. These transducers are intrinsically mechanically robust and can also be designed with high dielectric strength compact packages. For example, TDK's SMD NTC thermistors offer a small 10mm × 3mm × 3mm package, are fully sealed with epoxy, exhibit resistance tolerances of 1 or 2 percent, and feature a wide operating temperature range of −40°C to +150°C. This, along with high dielectric strength and waterproof performance of up to 500 hours, makes these rugged surface mount temperature sensors ideal for various industrial machinery applications.

Conclusion

The increased complexity of modern industrial machinery necessitates more sensors and complex control and operations systems. Reliable and robust temperature sensors are needed on virtually all essential electronics and mechanisms that exhibit thermal variation during operation. These sensors provide the necessary insights and data to fuel these control and operations algorithms, achieving optimal efficiency and safety and minimizing downtime. NTC thermistors are a technology well suited to this use case and provide many technical advantages compared to other thermal sensor technologies. 

Haptic technology requires both haptic sensors and actuator elements. The haptic sensors can be used in control loops to enhance the performance of the haptic actuator and gather data on environmental conditions. This data can then be captured and emulated in virtual environments to enhance realism. Haptic actuators are devices that apply forces to users by changing the surface conditions, vibrations, nervous response, or momentum of the user’s various sense regions.

Piezoelectric Technology in Haptics

Piezoelectric technology applies force to certain dielectric structures, allowing charge development at the location where the force is induced and, hence, an electric field. Moreover, reverse piezoelectric response can be used to change the dimensions of dielectric materials by applying an electric field that deflects dielectric structural elements. Hence, a piezoelectric device can be designed to both sense and induce force, pressure, vibrations, and shock.

These functions are essential in modern haptic technology, and the latest piezoelectric transducers/actuators are extremely well-suited to haptics applications. For instance, TDK’s latest PowerHap and PiezoHapt piezoelectric actuators incorporate advanced multilayer piezoelectric elements paired with mechanical displacement amplification structures (Figure 1). This design enables precise, high-efficiency displacement with greater responsiveness across a broad range of frequencies. The PiezoHapt actuator, for example, uses a high-efficiency unimorph structure that delivers larger displacement at lower voltages, providing effective haptic feedback without requiring soldered wire joints. Such actuators are ideal for applications involving force and vibration sensing, as well as vibrotactile and force feedback, making them versatile components in haptic technology.

Compared to other technologies for vibrotactile actuation and force feedback, piezoelectric actuators can be designed with the capability for both sensing and actuation in a highly compact and power-efficient package. Moreover, TDK’s PiezoHapt actuator is optimized to operate across the full range of human vibration-sensing capability (~50Hz to 500Hz), surpassing the performance of traditional eccentric rotating mass (ERM) and linear resonant actuators (LRAs). PiezoHapt actuators’ high-speed response allows the devices to convey complex, nuanced vibration patterns in real time, providing a more dynamic and precise tactile experience. The rapid response and ability to produce distinct vibrations across varying frequencies are demonstrated, highlighting its capability to switch almost instantly between multiple patterns (Figure 2).

PiezoHapt actuators’ multilayer structure achieves controlled, amplified displacement at low voltages, enabling large, effective vibrations ideal for immersive haptic feedback (Figure 3).

The actuators’ stable response across a wide frequency range maintains consistent amplitude for applications requiring frequent adjustments in haptic intensity.

Using Piezoelectric Haptics in Industrial Robotics

Modern industrial robotics may require an operator for manual control, be semi-manual/semi-autonomous, or even be fully autonomous to various degrees. However, it is still impractical to fully automate some industrial functions, such as controlling heavy machinery and more nuanced tasks that require advanced and complex automation systems. In these cases, haptics is an invaluable technology that can heighten an operator's interaction experience, enhance safety, and improve performance.

With the increasing electrification of many industrial robotics systems, there are fewer hydraulic and mechanical systems powering industrial systems. Legacy hydraulic and mechanical systems often come with additional haptic feedback, such as vibrations, sounds, and shocks that indicate operation dynamics. Electrically powered and controlled systems have some of these aspects but may not be as readily interpreted by a user. This is where haptic technology can be invaluable in enhancing industrial robotics and equipment interaction with operators. For example, force feedback sensors in grabbing devices tell the operator how much force is being used to hold an object, ensuring the grip is just right. Piezoelectric haptics sensors can measure the grip's force and nuance as well as vibrations emitted by the interaction of the gripped object with the grip actuator contact elements. Moreover, piezoelectric actuators and haptic algorithms could clearly translate that gripper-object interaction to an operator station equipped with haptic feedback. Because piezoelectric haptic devices are compact and responsive, they can be more readily integrated into ergonomic operator controls than legacy haptic technologies.

Conclusion

The future of piezoelectric haptics technology in industrial robotics applications is enhancing operator experience and industrial probiotics, and it can even be used to generate training data for ML/AI algorithms for fully autonomous robotic control. Moreover, piezoelectric haptics, with superior response time and performance range, are ideal for fully autonomous robotics systems to provide more timely and detailed information to the robotic control systems and algorithms with object/actuator interactions. Piezoelectric actuators are even used in applications where very precise forces and vibrations may need to be applied to target objects by robotic systems. 

The drive for improved performance and efficiency is especially relevant to industrial applications, which use large amounts of energy and resources. As a result, there has been a significant focus on optimizing power supplies, refining motor control, and enhancing power quality and efficiency for smart industries. Further, despite initial appearances, many of the same considerations also affect automobile design, where space is at a premium. Yet, designers must somehow pack more functionality into a constrained volume; power and thermal issues have system-level implications, and reliability is also a priority.

Component and system designers are also concerned with sustainable development, with goals that include responsible consumption, less wasteful production, and industry innovation. Artificial intelligence (AI) will play a role, but ultimately, it will require more efficient electronic components—both active and passive—to meet these objectives.

To address these issues, designers are developing new power-related architectures or applying newer, more efficient passive components to older architectures. Among these are hybrid DC/DC converters, which step the output of a 48V automobile battery down to 12V (Figure 1). This design eliminates the need for a separate 12V battery while mimicking the attributes of that battery, such as fast response to load transients. Eliminating a separate 12V battery saves weight and space, both at a premium.

Another significant power-related innovation is the AC/DC bidirectional power converter. This converter allows AC grid power to charge batteries but also enables those same batteries to feed power back to the grid when available power and system needs warrant that directional flow. This approach has applications in industrial backup power installations and automotive vehicle-to-grid (V2G) operations.

Components Illustrate Reality

Recent passive components show how innovative design, advanced fabrication, and enhanced packaging enable the leading-edge systems that the market requires.

The TDK ERUC23 SMT flat-wire coupled-inductor family features low-loss ferrites, high saturation currents, and low DC resistance. These compact coupled inductors offer self-leaded construction with flat-wire winding for minimal size (Figure 2). The form factor and lead-free tinned terminals are compatible with automated pick-and-place manufacturing.

Typical applications for the ERUC23 include 48V-to-2V hybrid converters and dual-phase buck, boost, and buck-boost converters, enabling reduced ripple with improved efficiency. The inductors are RoHS compatible and AEC-Q200 (automotive) qualified and include detailed models for comprehensive circuit simulation (Figure 3).

The TDK B43659 ultra-compact snap-in capacitor series (Figure 4) provides high reliability and high ripple-current capability in a −40°C to +105°C temperature range. Units in the series, housed in an aluminum case, offer a rated voltage of 450V_DC and a capacitance range of 140µF to 1030µF with ±20 percent tolerance. These capacitors have very high CV components (capacitance × voltage = charge Q) and feature snap-in solder pins to hold the capacitor in place on PCBs to simplify production. They are well-suited for use in power supplies, frequency converters, uninterruptible power supplies (UPS), medical appliances, and solar inverters.

The physical size of these cylindrical units ranges from 25mm (ø) × 25mm (ℓ) to 30mm × 60mm, which is smaller than alternatives for these capacitance and voltage ratings, with additional size ranges available by request. As a further benefit, the RoHS-compliant capacitors include integral overload protection via a pressure relief device on their base.

The TDK T850 negative temperature coefficient (NTC) thermistors are designed to measure surface temperature, which is among the most widely measured physical-world parameters (Figure 5). These temperature-dependent NTC devices offer 10kΩ-rated resistance with 1 percent or 2 percent tolerance.

The lead- and halogen-free T850 thermistors combine high humidity resistance with fast response time and a high dielectric strength of 2500V_AC for 60 seconds. They are well-suited for monitoring the temperature of industrial processes and power module heat sinks, as they can be attached to a metal heatsink or bars and directly to a chassis.

T850 NTC thermistors provide rugged performance while maintaining a high electrical insulation rating between the body and the measured surface. The units are waterproof for up to 500 hours and suitable in harsh environments with temperatures ranging from −40°C to +150°C. The miniature package has an aluminum-oxide ceramic surface, providing high electrical insulation between the measurement surface and the thermistor. Dimensions are just 10mm × 3mm × 3mm, and additional features include phosphor bronze electrodes and mechanical robustness.

Conclusion

Passive components are essential to implementing high-performance, compact, and efficient power-related circuits and systems. Innovations in the components’ materials, design, fabrication, manufacturing, and testing are advancing their capabilities to provide critical support for modern power subsystems. As a result, designers can develop end products that leverage the full potential of both newer and legacy active devices without compromise.