Building Blocks for Industry 4.0 Applications

The remarkably diverse industrial segment embraces a wide variety of automation solutions, each tailored to specific operational needs and all of which can benefit from advanced Industry 4.0 technology.

While the fourth industrial revolution did not emerge overnight amidst clamorous celebrations, it has been proceeding at the board level, one reliable switch and sensor at a time. A prime illustration of progress is the recent disclosure that Amazon aims to employ robots to eliminate the need to hire 600,000 human operators by 2033 as it expects to double the current volume of shipped products.[1]

As factories, vehicles, and infrastructure become smarter, the electronics content within each system continues to rise sharply. Demand for components and applications will soar as manufacturers and other industrial companies seek to employ next-generation control systems, advanced safety solutions, and optimized communications to boost data transfer. A brief dip into a comprehensive array of Industry 4.0-ready components from TE Connectivity provides a quick overview of some available building blocks for new designs.

Integrating advanced technologies

The global market for Industry 4.0 electronics exceeded $146 billion in 2022. By 2030, the convergence of cutting-edge technologies such as AI, machine learning, Internet of Things (IoT), and cloud services, among others, will spur that to more than $627 billion.[2]

Savvy product designers stand to reap many of the profits in this upsurge by integrating advanced power, switching, connectivity, and AI processing technologies into every corner of the industrial landscape. Communication capabilities will not only monitor and control Industry 4.0 components in real time, but also leverage data analytics to diagnose and predict potential issues and failures before they occur.

At the heart of this technological revolution are switching relays, EMI filters, safety systems, and new and more compact I/O connectors. Also instrumental is single-pair Ethernet (SPE) that combines data and power into just two wires, replacing today's four wires while reducing weight and cost with more resilient, longer-lasting wiring solutions.

The increasing complexity and automation of industrial processes drive a growing demand for reliable, compact, and powerful switching solutions. TE Connectivity addresses this opportunity with a diverse range of compact relays, including:

• The high-power 22 V_DC T9GV1L14-22 (Figure 1), PCB-mount, 30 A relay.

Figure 1: The T9GV1L14-22 relay provides high-power switching in a compact footprint. (Image source: TE Connectivity)

• The low-power T77S1D10-12 that provides 10 A switching in a smaller footprint, letting designers balance power and space without sacrificing reliability.
• The T9GS5L24‑24 (Figure 2), a more robust 24 V_DC PCB-mount relay suitable for control racks and appliance panels.

Figure 2: The T9GS5L24‑24 delivers 20 A switching capability for high current loads. (Image source: TE Connectivity)

Safety-critical applications

TE Connectivity also offers a range of force-guided relays like the 1-8588020-1 (Figure 3) for safety-critical applications. These components utilize a mechanical interlock to ensure all contacts operate in unison, reducing the risk of electrical faults and providing diagnostic coverage. With a slim profile format of 28 mm × 6 mm × 15.5 mm and coil power consumption of 210 mW, it can support dense arrangements in hot environments.

Figure 3: Force-guided relays like the SRS2 family are a critical component for reducing risks of electrical faults, while offering diagnostic coverage. (Image source: TE Connectivity)

Safety is a crucial factor in Industry 4.0 applications to ensure high productivity while protecting workers, as humans increasingly collaborate with robots and interact with automated systems. Safety relays such as the SRS4-2NO (Figure 4), monitor inputs from safety devices such as safety curtains so that emergency stops, interlocks, and safety circuits are operating properly.

Figure 4: The SRS4-2NO safety relay ensures circuits are operating properly in order to prevent damage and injuries. (Image source: TE Connectivity)

Safety relays are integral to safety light curtains such as the SLC4-H30-031 (Figure 5) that provide an invisible fence of infrared beams between an emitter and receiver. Safety light curtains are designed to protect human operators, machinery, and the environment.

Figure 5: Safety light curtains like the SLC4-H30-031 provide reliable sensing and monitoring to protect workers and machinery. (Image source: TE Connectivity)

With increasingly dense automation environments, compact connectivity solutions are at a premium. TE Connectivity's mini-I/O connectors, like the 2069577-1 (Figure 6), are just 25% the size of traditional RJ45 connectors, enabling very compact DIN rail system modules. Mini-I/O connectors can provide serial, bus, or Ethernet connectivity, support Power over Ethernet (PoE), and data rates from 10 Mbps to 10 Gbps. Compact latching mechanisms ensure stable connections, and a double point of contact prevents unnecessary communication losses.

Figure 6: Space-saving Industry 4.0 designs can take advantage of mini-I/O connectors like the 2069577-1. (Image source: TE Connectivity)

Designers can also simplify cabling with single-pair Ethernet that simplifies and combines data and power into just two wires, replacing the four wires required by traditional Ethernet. This reduces complexity, weight, and cost, and enables cost-effective gigabit speeds without the need for costly bus couplers or gateways. TE Connectivity's 2364150-1 IP20 SPE connector, for example, enables Power over Data Line (PoDL) for device powering and data speeds up to 1 Gbps. SPE cabling withstands more bending cycles than traditional options, a key benefit for robotics.

Conclusion

TE Connectivity offers comprehensive suites of products geared toward Industry 4.0 applications. This blog just scratches the surface of relays and connectivity options, which can be complemented with a broad array of smart sensors and advanced electromagnetic compatibility (EMC) filtering products to meet Industry 4.0 requirements.

[1] "Amazon Plans to Replace More Than Half a Million Jobs With Robots," Oct. 21, 2025. New York Times.

[2] "Industry 4.0 Market (2023 - 2030)", September 2023. Grand View Research.