Switching devices Ten Advantages of Industrial Wireless Switching Devices

There are applications where wireless communication clearly offers advantages—for example, in signal transmission to rotating machine components. Ten such typical wireless use cases in industrial production are presented here.

Every machine and system contains numerous power and signal cables. However, there are situations where wired communication reaches its limits. In such cases, it can be beneficial to use industrial switches that communicate wirelessly with a corresponding receiver unit, which then feeds the signals into the wired network. These use cases can be classified, and there are practical system solutions available with robust wireless transmission and industry-grade switches.

1. Rotating Parts

Both in robotics and machine tools, signals and power are transmitted to rotating machine components (grippers, rotary tables). This can be achieved using a slip ring or a rotary union, which, however, are subject to wear, occupy space, and increase the weight on the robot arm. For transmitting position signals or querying positions, battery-powered wireless sensors or wireless position switches can take on this task.

2. Linear Movements

The "classic" in automation technology. Power and data can be delivered via cables guided in a cable carrier and designed for use in moving applications. This works reliably, but every movement comes with (potential) wear. If you want to avoid it, you transmit the signals wirelessly.

3. Fast Three-Dimensional Movements

Cables on six-axis robots, which are routed to the "end of arm," i.e., the gripper, perform three-dimensional movements that place significant strain on the cables and can potentially lead to "corkscrews" and failures. Here too, wireless switching devices and sensors offer a wear-free alternative.

Sensors in the Wireless Network

This Makes the Material Flow Transparent

4. Long Distances Indoors and Outdoors

When cables need to be laid over long distances, for example, to connect a position switch for valve position monitoring to the power supply and query the signal, the installation is often several times more expensive than the switch itself. This can even be the case if a sensor or switch is "only" mounted on the hall ceiling. Wireless switching devices—possibly with an external, aligned antenna – reduce these costs.

5. Manual Control Units

Handheld control devices for machines, used for example during setup operations, are more ergonomic to use when signals are transmitted wirelessly. Additionally, the operator has more flexibility without having to worry about the cable.

6. Operation by Foot

Another advantage: Footswitches have no cable wear when operated wirelessly. Cable damage from industrial trucks cannot occur, and there are no cables that could act as "tripping hazards."

7. Footswitches in hot environments

In operations that handle hot materials, there is an added advantage: molten cast iron or welding sparks cannot destroy cable sheaths and disable the footswitch.

8. Heavy-Duty Applications

Under harsh environmental conditions, the use of heavy-duty switching devices with a wireless module offers advantages. Damaged cables cannot cause the switches to fail, and a robust antenna specifically designed for such applications is used.

9. Extensive Bulk Material Conveyor Systems

The (often kilometer-long) bulk material conveyor systems in extraction and handling facilities are monitored by pull-wire emergency stop switches and belt misalignment switches. Wireless technology simplifies installation here—even in hazardous areas. The external antenna is aligned with the receiver unit.

10. Modular machines

In machining production, mobile units that "dock" to a machine and provide raw parts for an unmanned (night) shift are becoming increasingly common. If they communicate with the machine wirelessly, the operator does not need to connect any cables.

A Diverse Field of Application

The ten examples show: the advantages of wireless switching devices are diverse and vary depending on the application area. Accordingly, the range of wireless switching devices and sensors offered by Steute's Controltec division for the industry is extensive. This includes multiple series of inductive sensors, position switches, foot switches, laser sensors, and belt misalignment switches.

All Steute wireless switching devices share the interference-resistant sWave wireless system developed by Steute for signal transmission, which can be adapted to individual use cases through various functionalities and is internationally deployable. The energy-efficient operation enables long battery or power cell lifetimes, and the bidirectional communication ensures high communication density.

Modular System

The program is modularly designed according to the system concept. Switch, wireless module, antenna, and receiver unit can be combined. If required, multiple switches can also be integrated into the wireless system via a shared transmission unit. The assignment of switch or sensor to the receiver unit and the configuration of the wireless system can be completed in just a few steps.