Connection technology

Connection technology

If you're troubleshooting repeated sensor dropouts electrical connections are usually the fastest place to reduce faults and installation rework. Common failure modes include improper sealing from under/over-tightening, vibration loosening, and voltage drop that leaves devices under-supplied at the far end of the run. On this page you will find a range of practical building blocks used on machines and distributed I/O: M8/M12 cables (pre-wired or by the metre), wireable plugs/sockets, jumper cables, and splitter boxes for clean distribution. 

What is Connection Technology?

Connection technology refers to the mechanical and electrical interfaces used to connect field devices to power, signal and communication networks. This includes:

• Pre-wired connection cables (moulded cables / flying leads)
• Cables supplied by the meter
• Wireable plugs and sockets
• Jumper cables (device-to-device or device-to-I/O)
• Splitter boxes and Y/T-splitters for signal and power distribution 

In industrial automation, connection technology must tolerate vibration, repeated movement, moisture, chemicals and temperature vibration while maintaining electrical continuity.

How to Select the Right Connection Technology

• Connector size and coding (M8 vs M12, A-coded vs fieldbus-coded)
• Required IP rating in real operating conditions
• Cable length and conductor cross-section (voltage drop)
• Shielding requirements against electrical noise
• Mechanical stress (vibration, drag chains, movement)
• Environmental exposure (chemicals, wash-down, outdoor)

Common Applications & Pain Points 

Sensors and actuators on machines

• Pain Point: Intermittent faults caused by vibration or incorrect tightening
• What Matters: Secure coupling, controlled sealing, vibration resistance
• Good Practice: Connector designs that prevent over-or under-tightening and protect sealing elements.

Wash-down and hygienic areas

• Pain Point: Water ingress during cleaning
• What Matters: IP67/IP68/IP69K sealing, chemical resistance 
• Good Practice: Purpose-designed connectors and cable jackets for frequent wash-downs

Distributed I/O and compact machines

• Pain Point: Excessive wiring and panel space 
• What Matters: Simple signal and power distribution
• Good Practice: Splitter boxes and jumper cables to reduce terminal wiring 

Key Component Types

M8 and M12 connection cables

• The most common connector formats in industrial automation
• Available with different codings (e.g. A,B,C,D,L,T) to prevent mis-connection
• Used for sensors, actuators, IO-Link devices and fieldbus applications

Pre-wired cables (moulded cables / flying leads)

• Factory-terminated for consistent quality and sealing
• Reduce installation time and wiring errors 
• Available in application-specific jackets (oil, chemicals, food, mobile, welding)
• Variants available with larger conductor cross-section for reduced voltage drop

Cables by the metre

• Used where customer lengths or terminators are required

Plugs and sockets (wireable connectors)

• Allow on-site assembly and repair 
• Separate strain relief and cable sealing improves durability
• Proper clamping prevents cable damage during movement and vibration

Jumper cables (double-ended leads)

• Pre-terminated cables for direct device-to-device or device-to-I/O connections
• Save time spent on wiring into terminals 
• Useful in modular machines and distributed I/O systems

Splitter boxes and splitters

• Splitter boxes: Centralised distribution of signals and power
• Y-splitters / T-splitters: Compact branching of sensor signals
• Reduce wiring complexity and installation while maintaining IP protection
• "Fast Connect" versions available to save more time when plugging in M12 plugs.