Halver, 8 June 2021 – In automotive production, connectivity has to meet different requirements in different production areas. The German connectivity specialist ESCHA offers special solutions taking into account the requirements in body construction on the one hand and in vehicle assembly on the other. Among other things, a cable quality with enlarged outer-jacket for excellent welding sparks resistance was developed for the body construction. For the area of vehicle assembly, extremely flexible cable qualities are offered due to the high density of robots. In both areas, the Automation Initiative of the German Automotive Industry (AIDA) defines so called safety applications in which only connectors with a yellow grip body and a yellow cable may be used. These special solutions are also part of the ESCHA automotive portfolio.
At ESCHA, automobile manufacturers obtain individual components that are optimally tailored to the different areas and their requirements. The connectivity specialist dealt in advance and in detail with the respective requirements and developed a suitable product range that goes far beyond single-ended- and double-ended cord sets. While Y-splitters from ESCHA enable automobile manufacturers to distribute signals quickly and easily, matching original accessories – like mounting clips – increase the clarity and safety in the system. M8- and M12-connectors are simply pressed into these clips. Then, the cables are securely attached and can be assigned more easily.
Connectivity for the body construction
Vehicle bodies are manufactured in the body construction, which is why welding robots are used and welding beads might occur. These welding beads must not permanently damage the cables so that machine failures do not occur later. That is why ESCHA offers a special cable quality with enlarged outer-jacket designated as «S740» for this application area. Despite its enlarged outer-jacket, this cable offers good drag-chain- and torsion capabilities and can withstand up to five million bending cycles without any problems.
Connectivity for vehicle assembly
There is a comparably high density of robots in vehicle assembly. Due to the constant movements, the mechanical stresses are very demanding for the connectors and cables. The connectors must have a reliable vibration protection to avoid disconnecting under permanent load and to ensure a constant data- and signal transmission. The cables must have to withstand several million drag-chain- and torsion cycles. For this area ESCHA has developed an extremely flexible PUR-cable called «S370» that can take up to five million drag-chain cycles and up to two million torsion cycles.
In order to distinguish between safety applications and other applications, the Automation Initiative of the German Automotive Industry (AIDA) has defined a standard. According to this standard, connectors and cables in safety applications must have a yellow grip body respectively a yellow cable jacket. Yellow serves as a signal color for visual differentiation and is intended to give installers and maintenance personnel a quick overview of the structure and function of the wiring. With «S740YE» and «S730YE», ESCHA offers yellow variants with identical properties and approvals of cable and connector to those of the black version.
Halver, 27 April 2021 – In times of IoT, Industry 4.0 and Big Data a fast and especially reliable data transmission becomes more important. As applications become more and more complex, the size of the data packages to be transmitted increases in parallel. The German connectivity specialist ESCHA offers a comprehensive product range that was developed specifically for the transmission of high data rates of up to 10GBit/sec in demanding industrial applications. By offering RJ45-, M8- and M12-connectors, ESCHA has the right solutions for a seamless data transmission from the office level via the control cabinet to the most compact sensor on field level. All connectors have been designed and tested according to current HF-aspects in the company’s own high-frequency test lab. They meet the requirements of the most common Industrial Ethernet protocols and, due to their data transmission reserves, enable a future-proof solution for tomorrow’s networks today.
Connectivity for all applications on field level
Data connectors are used in various applications on field level. These applications can be divided into three groups, having their individual requirements towards connectivity. The first group combines static applications, in which the connectivity is permanently installed. For example on conveyor- and transportation belts or in high-bay warehouses. Therefore, ESCHA has introduced a portfolio with a cost-optimized PVC-cable.
The second group has high demands towards flexibility and robustness of connectors and cables at the same time. This includes drag-chain-applications, such as those typically found in mechanical engineering. For this area ESCHA offers various PUR-cables that can withstand up to three million bending cycles without risk.
The biggest challenges exist in robotic applications. In addition to the drag-chain-properties, the torsion properties of the connectivity are also important in these applications. With connectivity from the «PROFINET robotic» range from ESCHA, data rates of up to 100Mbit/sec can be brought to the tip of a robot arm. The special cable called «S5100» withstands a combined load from horizontal movement (5 million cycles) and torsion (5 million cycles), as required by the industrial standard «Type R». In this way, for example, grippers with intelligent sensors or cameras can be reliably controlled via a Fast Ethernet transmission.
Wiring is the foundation for Industry 4.0
Networks are the backbone of automation and continuously increasing data volumes and transmission speeds can already be observed today. While current industrial communication-networks are still fault-tolerant to a certain extent, production processes – as they are envisaged in Industry 4.0 – can only be implemented using high-quality cabling in the future. Data connectors from ESCHA have been designed according to current HF-aspects and consist of data transmission rates. They enable a future-proof solution already today and form the foundation for the networks of tomorrow.
Halver, 23 March 2021 – A new standard called «Type R» defines requirements for Profinet cables used in robotic applications. The German connectivity specialist ESCHA has been offering a comprehensive product portfolio under the name of «PROFINET robotic» for over a year, which combines very good drag chain properties (5 million bending cycles) with very good torsion properties (5 million torsion cycles) and thus precisely meets the requirements of the new industry standard. The flexible cable designated as S5100 is based on a two-pair data cable that guarantees Fast Ethernet transmission according to Cat5e.
100Mbit/sec on the robot arm
With «PROFINET robotic» connectivity from ESCHA, data transmission rates of up to 100Mbit/sec can be brought to the tip of a robot arm. The S5100 cable withstands a combined load from horizontal movement and torsion, so that grippers with for example intelligent sensors or cameras can be reliably controlled. Due to its UL-approval, the PUR-cable is suitable for the North American market. The «PROFINET robotic» product range from ESCHA consists of various connectors in M8-, M12- and RJ45 design. These ensure that seamless data communication can be implemented between the sensors on the robot arm, the robot system and their connection to the control level.
Halver, 9 February – Despite the challenges of the past year, the ESCHA Group has achieved a stable result. At just over 70 million Euros, consolidated group sales in 2020 were fairly exactly at the previous year's level. As the connectivity specialist is positioned in various target sectors, the declines in weaker automotive-related industries could be compensated by rising demand from other markets. Compared to the previous year, the number of employees worldwide fell by 70 to a total of 780 employees.
"Every financial year is exciting and has its own challenges. Like other companies and private individuals, we had expected many new challenges for 2020, but not a pandemic. Through our subsidiary in Shanghai, we could already feel in January last year what this unusual situation can mean for a manufacturing industrial company. That is why I am grateful to our management team and our employees for their calm and deliberateness dealing with these conditions to this day," says Dipl.-Wirt.-Ing. Marco Heck, Managing Director of the ESCHA Group, and adds: "It was only by continuing to pull together that we were able to carry on our business, serve our customers and finalized with a group revenue of 70 million Euros, close to the previous year's level."
"Due to the ongoing Corona pandemic, all forecasts for the future can only remain bold and uncertain. However, we are currently experiencing a positive mood in our market environment associated with another positive plan for 2021, in which we want to grow again. In addition, I continue to see ESCHA very well positioned in the long run. The industrial transformation with the related megatrends as well as the accelerated digitalization will play into our hands and our products," says Marco Heck.
With Fritz Kupferschmied from Israel and Mardal Systems from Ukraine, the ESCHA Group was able to welcome two new partners to its international sales network in the first half of 2020. This means that the German connectivity specialist is present in a total of 33 countries – either with the support of partners or through its own sales. Thanks to production facilities in Germany, China and the Czech Republic as well as license production in the USA and Mexico, ESCHA guarantees high availability and consistent quality of its products worldwide.
Halver, 10 November 2020 – The German connectivity specialist ESCHA is well-known for a fast and flexible implementation of current customer requirements to its standard portfolio. For example with two new cable qualities which were launched within a very short time due to increasing customer demand and are now available. A new PVC-cable is aligned to Industrial Ethernet applications which have minimum demands towards drag-chain- and torsion capabilities. A new EtherCAT-cable with yellow outer jacket is particularly predestined for application areas in automotive assembly where this jacket color is mandatory. At the market launch, ESCHA has prepared a broad range of products for both cable qualities, each consisting of M8-, M12-, and RJ45-connectors in different variants.
PVC-cable for Industrial Ethernet
For many years, ESCHA has been offering a wide choice of connectors and cable qualities for Industrial Ethernet applications. These cable qualities are suitable for medium and high mechanical stresses as well as robotic applications with high demands towards flexibility. Due to rising customer demands for a cost-effective solution for applications with low mechanical stresses, the connectivity specialist is now rounding off its portfolio and offering a corresponding PC-cable called S5200. This new cable is PNO-compliant and perfectly suitable for applications in which drag-chain- and torsion properties are not important. ESCHA is already presenting a comprehensive product portfolio with M8-, M12-, and RJ45 connectors at the market launch. All components with the new cable quality guarantee a reliable data transmission according to Cat5e and meet the tightness requirements of protection classes IP67 and IP68.
EtherCAT with yellow cable quality
In the meantime, a cable quality with yellow outer jacket has become mandatory in many EtherCAT-applications – the demand is especially rising in the area of automotive assembly. The connectivity specialist ESCHA extends its EtherCAT-program with a corresponding cable called S1329. This cable guarantees an industry suitable data transmission according to Cat5e which meets the real-time requirements according to IEC 61158. Due to its flexible structure, it is drag-chain suitable and can withstand more than 5 million bending cycles. Different versions with M8- (four-pole), M12- (four-pole, D-coded), and RJ45 connectors are now available. Thanks to their UL-certification the products can also be used on the North American market.
Halver, 7 October 2020 –Field-wireable connectors are used wherever a high degree of flexibility is required. For instance in case of initially unknown cable lengths or panel feedthroughs. However, these often have two weak points compared to overmolded connectors: On the one hand, their installation requires a great deal of sensitivity and is therefore more complex. On the other hand, they are much larger than overmolded versions and therefore require more installation space. The German connectivity specialist ESCHA has now developed two new and extremely compact field-wireable M12-connectors that compensate for these weak points. The new products feature crimp-contacts that can be assembled quickly and easily with a crimping tool. Thanks to their slim and compact housing, they take up less space and are therefore particularly suitable for space-critical applications.
The new field-wireable M12-connectors from ESCHA are available in two versions: A-coded variants are designed to meet the requirements of sensor/actuator wiring, while D-coded variants guarantee permanent data transmission according to Cat5e. Both variants are adapted for cable diameters from 4.5mm to 8mm and wire-cross-sections between 0.25mm² and 1mm². This means that they cover a very wide range of cables and can be used in a variety of applications. Without any problems, they can be used in an ambient temperature range from -40°C to +90°C. In screwed status, they meet the tightness requirements of protection class IP67. A reliable 360°-shielding ensures secure data- and signal transmission.
The corresponding crimping tool and the required locator are also available from ESCHA. Both accessory products are exactly adapted to the requirements of the field-wireable connectors and guarantee a smooth assembly.
Halver, 9 July 2020 – The connectivity specialist ESCHA does not only offer unique single-ended- and double-ended cord sets, it also offers manufactured cable harnesses adapted to individual customer requirements. Complex wiring structures can easily be realized with these harnesses. Overmolded round connectors from ESCHA can be combined into inch-perfect cable harnesses basically facilitating and speeding up fitters’ work. It is possible to label cables through a variety of markings and printings simplifying allocation of cables and contributing to reducing installation time as well.
Meanwhile, single connectors are no more used in many applications but readily made cable harnesses. To this effect, the rail industry is a classic example where an individual cable harness is made for each wagon as cable harnesses have many advantages over single cables: They need small space; they can be installed more easily and quickly and can occasionally be more simply maintained.
Individualization upon customer request
Upon customer request, ESCHA equips overmolded round connectors in cable harnesses with markings, printings facilitating installation even by unskilled staff. In order to make sure cable harnesses can be directly installed, they undergo a hundred percent electrical test at ESCHA. On demand, they are packaged and shipped as customer individual sets.
Halver, 10 June 2020 – On 1 June 2020, the German connectivity specialist ESCHA welcomed a new sales partner to its international network. An agreement was signed with Mardal Systems LLC for the Ukrainian market. Both partners see an increasing demand for high-quality and above all customer-specific connectivity in the Ukraine in the coming years. Particularly in key sectors such as the wood- and metal processing industry, the demand for sophisticated automation solutions will increase in the future.
“Mardal Systems was established in 2019 and is therefore a relatively young company. We are pleased that ESCHA is one of the first partners, together with other well-known brands in the field of industrial connectivity”, says Dipl.-Ing. Ulf Eilhardt, Regional Sales Manager at ESCHA, and adds: “In addition to its start-up spirit, Mardal Systems convinced us with more than twenty years of industry- and sales experience of company founder Valeriy Mardal.
“Lots of products are manufactured in the Ukraine, which are exported to Europe and consequently have to comply with international standards. Due to the increasing export business, the demand for high-quality components is growing. This specifically holds for factory automation, where standard products and customized solutions are required. This is where ESCHA’s strengths lie and thereof we want to profit mutually”, says Valeriy Mardal, founder and Managing Director of Mardal Systems LLC.
With the new sales partnership, ESCHA extends its international network and is present in more than 30 countries. With production facilities in Germany, China, and the Czech Republic as well as licensed production in the USA and Mexico, the company guarantees high availability and consistent quality of its products worldwide.
Halver, 27 May 2020 – The food industry sets high demands in terms of hygiene and process security. These demands can be transferred on-to-one to connectors and cables. To withstand aggressive cleaning- and detergent agents, it is common to refer to special plastics or V4A stainless-steel as material. As of now, the German connectivity specialist ESCHA offers new variants of its connectivity range for the food- and beverage industry. The new connectors abandon the comparably expensive stainless-steel locking nuts and are optionally equipped with cost-effective plastic locking nuts in so called Hygienic Design instead.
Hygienic Design prevents the formation of dirt pockets and residues. Therefore, connectors with optional plastic locking nuts can be used in the product contact zone without more ado. The new plastic locking nuts developed by ESCHA are extremely robust and can be tightened by hand as well as with a torque-wrench. Afterwards, they fulfil the protection standards according to IP67, IP68, and IP69. Due to their unique plastics compound they are resistant to Ecolab detergents. Furthermore, they can promptly be used in a temperature range from -40°C to +105°C.
The new plastic locking nuts are available for M12-connectors in three-, four-, or five-pole version. Three cable qualities can be combined with male- and female connectors in straight or angled housing style.
Halver, 21 April 2020 – The trend towards more and more compact installations requires similar compact interfaces. When it comes to power transmission, the industry-proven M12-interface has taken the center stage of development. Since 2015, the connectivity specialist ESCHA offers and continuously extends its M12 connector portfolio for power transmission. For the first time, ESCHA presented M12 power connectors at SPS 2019, meeting the demands of the Profibus User Organization (PNO). These have been available since the beginning of the second quarter 2020.
The PNO-compliant connectors dispose of a standard-corresponding five-pole L-coding. Their grey cable and grey contact carrier help to differentiate from other M12 power connectors. For the market launch ESCHA offers the new PNO connectivity as single-ended- and double-ended cord sets as well as receptacles and splitters. All components facilitate a safe and reliable power transmission of up to 63V DC at a current rating of up to 16A. The splitters are available in H-, h-, and T-housing styles. These splitters realize a decentralized power wiring following the bus wiring.
Halver, 24 March 2020 – At SPS 2019 the German connectivity specialist ESCHA showed its new M12-connectors with plastic locking nut for the first time. As of now, these are available in four different colours, especially adapted for demanding applications in utility vehicle area or agriculture. The plastic locking nuts developed by ESCHA are extremely robust and provide a cost-effective alternative to stainless steel. Through their unique design, they can be tightened by hand as well as with a torque wrench. They meet standard IEC 61076-2-101 and fulfil the high protection degrees according to IP67 and IP68.
Plastic locking nuts dispose of a decisive advantage over stainless steel locking nuts: They are a cost-effective, but no means a cheap alternative. Due to high-quality plastics, they are media- and temperature resistant and are perfectly suitable for applications in the field of mobile automation. In this environment, containments with pressurised water, mud or oil are typical. Additionally, it is predominated by extremely high temperatures in the summer and extremely low temperatures in the winter. Plastic locking nuts and grip bodies from ESCHA can easily be cleaned and withstand temperatures from -30°C to +90°C. Furthermore, UV stabilizers prevent them getting porous or rough.
Colour coding enhances clarity
The new connectors are optional available with black, grey, red or blue plastic locking nuts. This helps the user to easily mark, match and differentiate the connectors in the end. Clarity in the application enhances noticeably and mismatching while mounting can be avoided.
Halver, 10 March 2020 – The connectivity specialist ESCHA has had a new sales partner in Israel since the beginning of the year. Since then, Fritz Kupferschmied (FRK) has been exclusively selling and assembling the connector- and housing solutions of the German company on the Israeli market. Both partners perfectly complement each other and together intend to focus on the sales of customer-specific developments. Short after the beginning of the cooperation, first projects could already be implemented.
“Fritz Kupferschmied has been in the demanding Israeli market for more than 30 years. I am pleased we have won such an experienced partner for ESCHA, who is excellently networked in the Israeli industry as well“, says Dipl.-Ing. Ulf Eilhardt, Regional Sales Manager at ESCHA and adds: “The Israeli economy has grown steadily in recent years and is forecasted to grow further in the years to come. Together with Fritz Kupferschmied, we plan to benefit from this development. Particularly in the area of customer-specific solutions.“
“Israel is a start-up nation. That is why we have specialized in the sales of high-grade cables and connectivity. One of our focus areas is the implementation of customer-specific requirements resorting to solutions of renowned suppliers from Europe and North America. We dispose of own production capacities and repeatedly put together the adequate package for our customers. ESCHA products and services perfectly complement our product portfolio“, says Moni Gabrieli, Joint CEO at Fritz Kupferschmied. Operation Manager Meir Cohen adds: “We have gained good experience through our short cooperation. ESCHA has exactly offered the products our customers have been looking for. First projects are already in the sampling phase.“
With the new sales partnership, ESCHA extends its international network and is now present in more than 30 countries. With production facilities in Germany, China, and the Czech Republic as well as licensed production in the USA and Mexico, the company guarantees high availability and consistent quality of its products worldwide.
Halver, 10 February 2020 – The connectivity specialist ESCHA has launched a comprehensive product portfolio for the automotive industry. The new single-ended- and double-ended cordsets in housing styles M8 and M12 are optimally adapted for the diverse requirements within the body construction as well as the vehicle assembly. Moreover, a distinction is made between standard- and safety applications in both application areas.
Portfolio for the body construction
With the new cable designated S740, ESCHA now offers a cable quality perfectly suited for weld-field applications in body construction. Due to an enlarged outer-jacket, the PUR-cable is particularly resistant to welding beads. Good drag chain- and torsion properties as well as a UL-certification complement the cable’s profile.
For safety applications, the cable designated S740YE is also available with a yellow outer jacket and yellow overmolded grip body. The properties and approvals of cable and connector remain unchanged.
Portfolio for the vehicle assembly
For the vehicle assembly and other crafts, ESCHA has already opted for the proven and versatile S370-cable for a long time, which can be combined with different M8- or M12-connectors. This PUR-cable quality disposes of good drag chain- and torsion properties as well as an UL-approval.
With the new cable quality designated S370YE, a yellow variant is now available that can be used in safety applications. For the S370YE, connectors with yellow overmolded grip bodies are available as well. The properties and approvals of cable and connector are identical to those of the black version.
Matching ESCHA original-accessories – such as Y-splitters or mounting kits for M8- and M12-connectors – complete the product portfolio for the automotive industry. With Y-splitters, branches can easily be realized, and double-ended cordsets can be saved. Mounting kits ensure a safe hold in the open routing of single-ended- and double-ended cordsets. In addition, they increase clarity and order in the system.
Halver, 23 January 2020 – Following six years of strong growth – several of which were in the double-digit percentage range – the ESCHA Group had to report a drop in turnover for the first time in the fiscal year 2019. At around 70 million Euros, the consolidated total turnover was below the previous year’s level. The tense economic situation in the Machine-building and Automation Industries caused a drop in sales for the German connectivity specialist. In contrast, other markets, such as Renewables and Transportation, developed positively for ESCHA. The number of employees declined slightly. In 2019, 850 employees worked for the family-controlled company worldwide. That is fifty fewer than in 2018.
“The fiscal year 2019 was not an automatic success. After a long period of growth and two extremely strong years in 2017 and 2018, we were not quite able to achieve our revenue target for 2019. We missed the original target by around three percent. The negative impacts of trade tariffs, the general insecurity concerning the Brexit and the structural transformation in the Automotive Industry have affected the general market situation and have left their marks on our company”, says Dipl.-Wirt.-Ing. Marco Heck, Managing Director of the ESCHA Group.
Outlook into the future
At the same time, Heck is cautiously optimistic about the future: “The digitalization and automation of the industry offer ESCHA plenty of opportunities in the future. In industrial communication, there is a cross-industry trend towards more participants and higher data volumes. This is exactly where we are positioning our products.“ Further growth areas for ESCHA lie in the fields of Intralogistics, Renewables, and Transportation. In these sectors, a rising demand for high-quality connectors and cables can be identified combining the safety of high protection classes with the benefits of manufactured connectivity.
In June 2019, the ESCHA Group commissioned an approximately 5,000 square-meter extension to its production- and logistics hub at its headquarters in Halver. Thus, sub-areas of the production division could be restructured, and production-related divisions could be united under one roof. In order to meet the rising demand in China, the production facilities there were extended as well.
Halver, 2 October 2019 – The German connectivity specialist ESCHA is showing two new product premieres at this year’s SPS. In Hall 10.0, Stand 321 of Nuremberg show ground, M12x1-connectors with plastic locking nuts will be on display for the first time. The plastic locking nuts provide a cost-effective alternative to stainless steel locking nuts. Furthermore, ESCHA is presenting five-pole variants of its L-coded M12x1-power-connectors. These are PNO-conform due to a grey contact carrier and a grey cable and facilitate a power transmission of up to 63V DC at a current rating of up to 16A. Naturally, ESCHA is again showing solutions out of its comprehensive standard portfolio as well as interesting customer-specific developments.
M12x1-connectors with plastic locking nut
Plastic locking nuts dispose of a decisive advantage over stainless steel locking nuts: They are cost-effective, but by no means a cheap alternative. The plastic locking nuts developed by ESCHA are extremely robust and can be tightened by hand as well as with a torque wrench. They are media- and temperature resistant and especially adapted for applications in utility vehicle area or agriculture. In addition, ESCHA plastic locking nuts come in four colours (black, grey, red and blue). Thus, connectors can easily be marked facilitating a quick allocation or distinction.
In the food- and beverage industry, connectors of special plastics are used ensuring connector resistance to aggressive media and detergents. ESCHA has developed a grey plastic locking nut in a so called ‘Hygienic Design‘ exactly for this application area. This prevents the formation of dirt pockets and is resistant to Ecolab-detergents. In this way, F&B-sector customers can also make use of the cost benefits of a plastic locking nut.
Extension M12x1-power-product portfolio
In the automation industry, the trend is moving more and more towards a reliable power transmission via compact interfaces. Particularly, the popular M12x1-interface is in focus of the current developments. ESCHA has decided to further extend its comprehensive M12x1-power-product portfolio and add PNO-conform variants with grey contact carriers and grey cables. At the SPS, the five-pole connectivity components with L-coding will be on display as single-ended- and double-ended cord sets as well as receptacles in various versions.
As a supplement to the M12x1-power-connectors and -receptacles, ESCHA also offers matching five-pole M12x1-power-splitters in H-, h- and T-housing styles. These splitters provide an easy decentralized power wiring following the bus wiring. In addition to the five-pole L-coded variants, ESCHA has already had on offer M12x1-power-connectivity with four-pole L-coded as well as S-, T- and K-coded for a long time. All ESCHA M12x1-power-components are dust- and waterproof according to protection classes IP65, IP67 and IP68 in screwed condition. They have been designed in such away meeting the UL2237 requirements. They provide a large extension of power transmission through a connection cross section up to 2.5mm². A big advantage – particularly with direct voltage distribution – is the small voltage drop in contrast to smaller cross sections.
Standard, Special, Tailor-made
In addition to the two new developments, ESCHA is again showing solutions out of its comprehensive standard portfolio as well as interesting modification projects and customer-specific developments. Visitors can get information on these topics on Stand 321 in Hall 10.0 from 26 to 28 November.