Industry 4.0 based primarily on the Communication of all components involved from the temperature sensor to the process plant. Of the fieldbus connects them all to the IT world. Protocols determine who can and should communicate what, when. There are around 50 different fieldbuses that network technology make it very diverse. We report here on new products, maintenance and applications of these communication systems.

Contents

• Multifunctional fieldbus modules with IO-Link
• Safety Fieldbox for additional fieldbus systems
• Wireless fieldbus for frequent tool changes
• Fieldbus system for particularly high machine safety
• Safety Fieldbox with reduced wiring effort
• Ethernet gateways with IIoT functions
• Field box for predictive maintenance in packaging technology
• Compact fieldbus 4 I/O module for intralogistics
• Fieldbus and industrial network also require maintenance
• Archive for fieldbus innovations
  
  

Multifunctional fieldbus modules with IO-Link

08.12.2023 | Murrelektronik expands its IO-Link portfolio to include two fieldbus modules in IP76. The "MVK Pro" and "Impact67 Pro" fieldbus modules offer all common protocols or fieldbus-independent use in a robust housing, 4A port output current and on-board diagnostics.

The completely new developments have eight multifunctional master ports and can also realize high currents thanks to L-coded M12 connectors. They operate the Ethernet protocols Profinet, Ethercat and Ethernet/IP. Fieldbus-independent use is also possible via OPC UA, MQTT and JSON REST API with the already integrated Standardized Master Interface (SMI).

In addition to pure process data (I/Os), the new modules generate additional data Diagnostic data such as voltage, current and temperature for the respective ports and the entire module. Operators can use it to detect anomalies and optimize their processes using data analysis. Thanks to the IIOT protocols, this is possible in a standardized and control-free manner.

Thanks to the integrated A/B ports The function can be freely parameterized on each pin - regardless of whether it is IO-Link, DI, DO, DIO or a combination of everything. Thanks to automatic switching of the supply voltage, the correct voltage supply is always used. The module serves devices with high energy requirements directly and without cross-feeding. Compact M12 power cables can carry currents of up to 16A per pin. Looping the power supply through several modules simplifies installation and reduces cable routes. The plastic or metal housing with protection class IP67 makes the modules particularly robust.

Safety Fieldbox for additional fieldbus systems

24.08.2023/XNUMX/XNUMX | Schmersal presents two new versions of its Safety Fieldbox. In addition to Profinet/Profisafe, they are now also for the bus systems Ethernet / IP with C.I.P. Safety and Ethercat available with FSoE. The designer can now plan the safety functions of his machine independently of the fieldbus, because the three versions cover the most widely used control systems internationally.

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Wireless fieldbus for frequent tool changes

21.10.2022/XNUMX/XNUMX | With frequent changes of tools such as Robotic grippers or welding tongs robotic arms A wireless connection to the units used significantly simplifies the workload. The EX600-W wireless fieldbus system from SMC was designed for such applications. Using such a fieldbus, tools can be changed and ready for use again in a short time thanks to the fast connection establishment of 250 ms.

Interference-free transmission is guaranteed thanks to the use of the 2,4 GHz ISM frequency band. The transmitted data is encrypted. That comes into use frequency hopping with 5 ms with 79 available channels. Certain channels are hidden. These three measures ensure a secure and trouble-free connection. 

The connection of the EX600-W modules to the higher-level steering takes place in the conventional way to the PLC via a stationary base unit. The most widely used network protocols are used Ethernet/IP and Profinet supports. The wireless fieldbus systems have up to 1280 inputs and outputs. Depending on the base module used, up to 127 remote modules can be integrated. The range of the wireless connection remains stable over a distance of 10 m, making the EX600-W series ideal for large automation systems.

The low Weight of only 300 g ensures low additional mass on moving axes. The resulting moment of inertia changes only slightly. Axes can be accelerated faster, resulting in shorter cycle times. The net payload on the supporting axle can be higher. Subsequent changes to the hardware make the fieldbus module updateable. This allows for additional scaling effects.

SMC exhibits at SPS 2022.

Fieldbus system for particularly high machine safety

20.10.2022/XNUMX/XNUMX | With the fieldbus of the series EX260 FPS1 (Picture above), SMC offers a communication solution that can be used to meet particularly high standards in terms of machine safety. Thanks to the integrated safety output for Profisafe protocols, there is no need for a separate safety output unit.

In addition, the wiring between the fieldbus module and the safety output device. This saves the user space and hardware costs and he fulfills with the fieldbus module the safety standards ISO 13849-1 PL e (highest performance level) and IEC 61508/IEC 62061 SIL 3 (second highest safety integrity level). A particularly high level of machine safety is achieved in this way.

Safety Fieldbox with reduced wiring effort

20.09.2022/XNUMX/XNUMX | Presented for the first time Schmersal a revised device version of its Safety Fieldbox at the SPS 2022. About the Safe field box can be very different Safety relays such as safety interlocks, safety sensors or safetylight grid Connect decentrally in the field and link freely. 

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Ethernet gateways with IIoT functions

28.04.2022 | Turck improved with the firmware Update FW 1.6.0 for its Ethernet gateways GEN-3G and GEN-N of the IO system Excom whose IIoT capabilities. This simplifies maintenance and commissioning of the gateway. The HCiR now also allows device replacement as well as expansion and maintenance in potentially explosive areas and high-availability applications during ongoing operation. 

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Field box for predictive maintenance in packaging technology

16.03.2020/XNUMX/XNUMX | The packaging industry, with its sometimes complex processing and production systems, places high demands on the Safety Technology, because it has to be flexible, efficient and available and contribute to the connectivity of the systems. Schmersal presents a secure field box with Profinet, Profisafe fieldbus interface with new safety solutions for the packaging industry. 

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Compact fieldbus 4 I/O module for intralogistics

10.03.2022/XNUMX/XNUMX | Especially for use in fieldbus technology applications with low I/O requirements as in logistics offers Turck now that Ethernet IO module TBEN-S1-4DXP. In the TBEN-S design, the compact block module offers four flexibly usable inputs or outputs. The components have eight channels as standard. 

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Fieldbus and industrial network also require maintenance

05.03.2020 | The functioning of fieldbus and Industrial network far too often, users equate this with the sufficiently high quality of data communication. Although this is absolutely necessary for stable machine and plant operation, there is an awareness of the need for monitoring for predictive condition monitoring in industrial applications Automation only slowly through. With a recent survey of webinar attendees and its annual Vortex Report shows Indu-Sol the catch up.

Once every two years or every 30.000 km are, for example, the recommendations of motorists for the intervals of a regular inspection. Although these dates are based on many years of experience, they are only guidelines. In addition, depending on the operation, other minor work may be necessary between the intervals, such as topping up the cooling water or checking the tire pressure. The driver has a good feeling when his inspection specifications are complied with.   

In the case of cars, the more sophisticated one is also contributing to this Onboard diagnosis at. It provides timely information about component anomalies, makes a diagnosis and, at best, issues a recommendation for action. This principle is also common today for mechanical components in machines and systems. The function of fieldbus and industrial network is, however, far too often assumed to be without maintenance. But is this negligible and if not, how much maintenance is required?

Practical report on the maintenance of fieldbus and network

The measurement engineers at Thuringian Indu-Sol GmbH are called 400 to 700 times a year by customers from a wide range of industrial sectors. The reason: there are increasing numbers mysterious, non-reproducible events sporadically in their production facilities, which occasionally disrupt the processes.

If at all, replacing the components only helps in the short term. A metrological analysis of the data communication However, many symptoms can be identified, such as outdated device firmware or worn contacts. An electromagnetically incompatible machine and system installation also has a negative effect on the quality of communication in machine and system operation.

Smart maintenance: what influence does Industry 4.0 have?

In its annual Vortex report Indu-Sol publishes the current findings from the measuring operations of the previous year. In 2019, the measurement engineers turned out a total of 437 times. Of these, only about every second use was scheduled and therefore of a preventive nature as part of a regular inspection of fieldbuses and networks.

The other half consisted of troubleshooting due to a noticeable deterioration in quality in the automation processes that the operators could neither explain nor rectify themselves. Under 185 there were even troubleshooting 123 SOS missions. Here, the service technician had to come to the site immediately due to a serious disruption in order to avert the otherwise persistent production standstill.

When troubleshooting in Profibus networks more than every second operation was declared as an SOS call, in Profinet only every fifth. With Profinet, based on the experience with Profibus, preventive maintenance with regular to permanent measurements has prevailed.

Can the longevity of the fieldbuses be planned?

A good third of the participants in one Indu-Sol webinars however, stated that they did not perform targeted network maintenance. According to this survey, there is a separate budget item only in 7% of cases. Permanent condition monitoring of field buses and industrial networks is still not a standard. After all, at least the participants in the above-mentioned webinar mainly plan with a machine and system availability of at least 95%, often for at least 20 years.

To achieve this goal, a permanent one is needed Condition monitoring from the start in all fieldbuses or networks. With new Profinet systems, this idea is becoming increasingly popular. An acceptance measurement is carried out as soon as the field devices are commissioned. This can be used to demonstrate the quality of the installation. It also ensures that the system is at the start with a 100% functional reserve.

In addition, the current topology is documented, so that later changes in the network structure of the bus systems can be identified. This wins not least in relation to the increasing networking and the associated higher Security requirements in importance. Permanent condition monitoring from the first telegram ensures needs-based maintenance.

Monitor automatically, report if necessary

With the system developed by Indu-Sol Permanent network monitoring (PNÜ), fieldbuses and networks can be permanently monitored without feedback. In this way, you can immediately make a statement about the current status of the fieldbus systems if required. To do this, so-called inspectors, i.e. passive data collectors, determine the necessary quality values ​​from the networks and use preventive alarms as soon as critical changes become apparent.

In Ethernet based networks, the Ethernet switches can also do this to some extent, provided they can be managed. The central Promanage NT monitoring software reads the diagnostic data from the isspectors and the port statistics from the switches and bundles them on a central server. This results in an easily comprehended general overview even in widely branched structures. If necessary, the analysis can be traced back to the individual device that sent the message with just a few clicks.

In Promanage NT operators can combine this information with topological representations and hall layouts to form a central database. This updates itself, reports preventive critical events and provides precise diagnostic information with the help of artificial intelligence. Thanks to the maintenance that is now tailored to your needs, the initial investment in the solution pays for itself quickly. This prevents premature device replacement because the condition monitoring indicates when there is a need for action.

Archive for fieldbus system technology innovations

• I / O System Field in IP67 for the automation of modular machines
• Safe field box for variety of security solutions
• CANopen I/O modules with FD functionality
• Five installation solutions for optimum machine safety
• network, how are you? - Interview
• Safe field box with Profinet / Profisafe fieldbus interface
• Don't wait until the bus breaks down - interview

I / O System Field in IP67 for the automation of modular machines

06.11.2019 | The new I/O System Field with IP67 protection from Wago integrates fast, Ethernet-based fieldbuses such as Profinet, technologies such as OPC UA or web server and in the future also MQTT as a communication protocol, for example for connection to the cloud. In addition, the system is prepared for TSN, the key technology for consistent, flexible, powerful and secure networking.

The I/O system field supports all the important ones Ethernet, fieldbus and industrial IoT-Standards. Various IP67 housing variants are available for optimal adaptation to the respective application and machine: fully encapsulated metal housing for harsh environments and additional lightweight, non-encapsulated plastic housing with low mass for moving applications. Narrow housing variants and side mounting options create more space and offer additional protection options.

In combination with IO-Link, the system plays to its strengths as more flexible IO distributor when collecting and distributing data. The communication standard enables a seamless data flow from the sensor level to the control level.

Ethernet APL | Current status, applications and implementation

The sensors and actuators are connected via worldwide available M8 and M12 cables. In the IO-System Field, the power supply is solved with a high-current-capable M12 connector with L-coding. It is smaller and cheaper than commercially available solutions in 7/8 inch and M23 and is able to provide up to 16 A. As a result, more power can be connected to less space.

Safe field box for variety of security solutions

05.08.2019 | flexibility and ease fail-safe installation are central requirements of manufacturers and users of machines and automation systems when it comes to integrating switching devices into the control infrastructure. To the Safety Fieldbox from Schmersal safety switching devices of different technologies can be connected.

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CANopen I/O modules with FD functionality

13.03.2019 | microcontrol is present in MSR-based markets and shapes the market in I/O technology, interface definition, controls and MSR in heavy-duty environments.

With the provider's solutions, analog measurement signals can be converted to the fieldbus interface in the middle of the process. The company is now presenting the “µCAN.8.dio-Snap”. I/O module with "FD ready" functionality. 

The DIN rail module can be operated in a classic CAN/CAN open network or alternatively in a CAN open FD network. Thanks to the FD ready functionality, the operator can easily switch the module himself at any time.  

The existing infrastructure will continue to be used unchanged, no additional investments are required. Self installed Cables and Plug do not need to be changed/replaced.

The available power through CANopen FD reaches previously unimaginable dimensions that will be absolutely necessary in the future. Especially the technological advances in the Measurement Technology already demand these performance parameters today.

Five installation solutions for optimum machine safety

30.01.2019/XNUMX/XNUMX | Thanks to their newly developed Safety Fieldbox is the Schmersal Group is now able to offer five different installation solutions for protecting different systems. This variety of variants has so far been a unique selling point in the market. 

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network, how are you?

29.11.2018 | Indus Sol is a specialist in the field of network infrastructure. As a competence partner for industrial communication, the company helps with the design of structural foundations and the guarantee of safe operation. In an interview at SPS 2018 we Karl-Heinz Richter, Managing Director, Indu-Sol GmbH, Schmölln asked the following questions and gained interesting insights:

• How is the current state of network technology in our increasingly smart production facilities?
• The automation networks are therefore constantly changing: which ones Changes are you currently watching?
• What can you company along the way give?
• What should you look out for in the planning of networks firefighter protective gloves?

Safe field box with Profinet / Profisafe Fieldbus Interface

16.10.2018/XNUMX/XNUMX | the Schmersal Group presents their new Safety Fieldbox SFB-PN-IRT-8M12-IOP, which will be launched in 2019. The safe field box for Profinet / Profisafe systems is suitable for the simple plug-and-play installation of up to eight safety switching devices. A wide variety of safety switching devices can be installed thanks to the universal device interface with an 8-pin M12 connector.

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Don't wait until the bus breaks down - interview

Karl-Heinz Richter, Managing director of Indu-Sol GmbH, Schmölln misses the monitoring software in automation, because the industry can learn from the IT world, he said in a presentation at the trade press days in Karlsruhe. We asked a little more detail with the following questions:

• If the fieldbus doesn't work, should one call Indu-Sol: Why?
• They proclaim that the Learn automation from the IT world target. What should one convey to the other?
• What products do you provide for that network monitoring to disposal?