New-Tech Europe | June 2017

commissioning and during operation. Designing and implementing this type of technology still demands a relatively high cost both inside and outside of the switch cabinet. Data transparency routes to even the simplest device Generally, only the more complex equipment has its own electronics, which can be used to record data and sometimes even pre-process it. Variable frequency drives and servo drives, for instance, provide a versatile range of motor data, can communicate via virtually every fieldbus system and often already have externally usable memory and computing capacity. In the process they bring with them all the requirements for high data transparency of a machine and are already potentially in a position to respond as ‘smart components’ within an Industry 4.0 environment. It is a different situation with a large number of components that have previously been connected via classic control wiring to digital or analogue inputs/ outputs of the control system in use. In this case, as well, it would be desirable to receive more data, but this is often not possible due to high costs, or is only possible with a great amount of effort. For example, if an operator wishes to process differentiated information on the reason why a manual motor starter or circuit breaker has tripped (overload or short circuit), auxiliary switches and digital inputs for the control system must be installed and wired for each type of data. More information only available through additional equipment To increase availability and reduce operating costs, machines must be equipped to offer comprehensive process monitoring and analysis options. Additional equipment is required for this, which can record or generate the desired data and

sensors, switchgears, pushbuttons or other field equipment. This level of transparency for a machine, which goes right to the sensor, also meets Industry 4.0 criteria. Machines of the future will consist of ‘smart’ products that transmit relevant data, take local decisions, can establish communication with other machine assemblies and are ultimately connected to the Internet of Things. By exchanging information as seamlessly as possible between global production sites on the one hand and commercial entities and supply chains on the other, machine operators will be able to design all their commercial procedures more efficiently and operate the machine with maximum economy. This will provide a clear advantage in the global competitive environment. However, the need for a high-grade networked machine structure with a large number of smart, communication- enabled components must not result in longer project timeframes. On the contrary: in a globalized world, time and cost pressure increases even during the project design phase. New machines must be designed, installed and commissioned within shorter and shorter timeframes. Current situation: expensive wiring and insufficient depth of data In today’s machines, automation is often only implemented in one, but sometimes multiple programmable logic controllers (PLCs). These devices are then connected to motor starters, variable frequency drives, soft starters, pushbuttons and modern control systems installed in the field or in switch cabinets. All of these components are usually installed via industrial fieldbus systems or complex, expensive point-to-point control wiring, both of which are prone to error both during installation and

forward it. This means a significantly upgraded infrastructure with additional components that must be connected to the control system. As a result, planning becomes more complicated, the overall design of the machine becomes more complex and the potential for error increases. Such upgrades also result in a greater need for input/output modules for the control system being used – for which there is not necessarily enough space reserved in the switch cabinet. If no smart, communication-enabled variant is available for ‘simple’ devices, the machine operator may have to make a decision between either modernizing the entire automation system or not being able to carry out comprehensive analysis of all machine parts, despite the high costs associated with this. An intelligent wiring and communication system Technology that offers a solution to the above challenges must meet multiple criteria: Local intelligence for recording and pre-processing information Ability to communicate in order to convey this information Minimal dimensions in order to be used even in compact devices such as pushbuttons or auxiliary switches Universal applicability thanks to integration into existing industrial fieldbus systems Reasonable price in order to justify its use even in the simplest switchgear Smart devices do not require complex point-to-point wiring, nor do they need to be connected to the control system via expensive fieldbus circuitry. The intelligent wiring system allows for direct integration of connected devices to the central control system or into the machine’s existing communication environment. Frequently used pushbuttons as well as contactors and manual motor starter or circuit breakers are involved

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