Ensuring signal integrity and uptime for reliable
automation control systems
Smart factories demand high-speed, reliable connectivity to integrate power, signal and data across complex systems. High-reliability components like RJ45 and ERNI connectors, relays, filters, resistors and switches are critical for maintaining signal integrity, minimizing downtime and ensuring optimal performance of PLCs, control panels and automation systems in harsh industrial environments.
AI’s growing role on the factory floor
Over 95% of manufacturers are investing in AI to accelerate smart manufacturing.
Source: Rockwell Automation, State of Smart Manufacturing Report
AI in the global industrial automation market was valued at $20.2B in 2024 and is set to grow to $111.8B by 2034 (18.8% CAGR).
Source: Insight Ace Analytic, Global AI in Industrial Automation Market Report
Meeting the demands of AI
Adds more sensors, faster data loops & tighter synchronization.
Systems require higher bandwidth & greater power delivery in smaller footprints.
Connectors must transmit data & power without signal loss or heat buildup.
Automation runs on data — until the connection breaks
40–50% of electronic failures are traced to interconnect degradation
- Elevated contact resistance → localized heating → accelerated oxidation
- Vibration, misalignment, and plating fatigue compound over time
- Result: rising impedance, unstable logic signals, and system drift under load
Source: NAVSEA, Connectors Failure Mechanisms and Anomalies
Every connection counts. Not all connectors are created equal.
When minutes mean millions
Unplanned downtime costs global manufacturers ≈ $1.4 trillion per year (11% of annual revenue).
Source: SIEMEMS, Report on the True Cost of Downtime
In automotive lines, one hour downtime = $2.3 million or $600 per second.
Maintenance and downtime dominate lifecycle cost
Maintenance = 15–70% of manufacturing operating cost
Source: Advanced Maintenance in Manufacturing
1-10-100 Rule: Every $1 spent in prevention avoids $10 in correction and $100 in failure costs.
Source: Prevention Detection Correction
Reliable, industrial-grade connectors and electromechanical solutions components reduce returns, maintenance and line stoppages long-term.
Designed for high reliability
TE Connectivity’s industrial-grade interconnects and electromechanical solutions are designed for mechanical stability, signal integrity, power continuity and environmental reliability across automation systems.
Relays: Safe power switching
Filters & Resistors: Noise and surge control
Switches: Reliable human-machine input
RJ45 & ERNI connectors: High-speed data backbone
Relays: Safe power switching
Switches: Reliable human-machine input
Filters & Resistors: Noise and surge control
RJ45 & ERNI connectors: High-speed data backbone
