Empowered by cutting-edge automation technology
An excellent example of sensor product families that holistically support the IIoT approach to production is the Snap Signal portfolio from US supplier Banner Engineering. In general, the users’ challenge is to first identify relevant data and, in the next step, to extract it from existing equipment. If the need is identified to integrate additional sensor technology for measuring further variables, such as vibration and temperature at a drive, this should not require any changes to the existing control architecture. It is also important to standardize communication and convert all sensor and control data to a common protocol. For this purpose, the Snap Signal product line (Figure 2) offers smart sensors, signal converters, controllers, signal adapters, and wireless communication modules, as well as wired connectivity technology that enables automation engineers to plug-and- play to resolve these tasks.
The processing and analysis of such sensor data – performed either centralized in a cloud or directly in the field – then allows conclusions to be drawn regarding error and optimization potential in the processes or the need for maintenance. In this way, energy losses can be reduced and the use of resources minimized. On the other hand, predictive maintenance makes it possible to plan service work in advance and thus reduce downtime, which in turn helps avoid additional expenditure on energy and materials.
a system, which significantly reduces power consumption, particularly in variable-load applications. Regenerative drives can further reduce consumption by capturing and reusing braking energy. They are becoming increasingly important in the course of modularization and flexibilization of production plants, which is considered one of the core components of Industry 4.0. In the concept of the modular factory, automated guided vehicles (AGVs) and mobile assistance robots take on supporting functions, for example in handling and assembly. Low weight and recuperation are essential features here because they not only ensure economical energy use and a small eco- footprint, but also a long range for AGVs and cobots. French manufacturer Schneider Electric is addressing this market segment of highly efficient drive technology with its compact VFD Altivar ATV320. It is suitable for controlling three-phase synchronous and asynchronous motors in the power segment from 0.18 to 15 kW at variable speeds. According to the supplier, it combines integrated safety with numerous ready-to-use functions designed to support application efficiency. These include low-speed torque and speed accuracy, high dynamic response featuring flux vector control without a sensor, and an extended frequency range for high-speed motors. The
ATV320 (Figure 3) is particularly notable for its improved resistance to polluted atmospheres typical to many industrial processes, and meets IP20 as well as IP6x protection degree specifications. The VFD is designed to be fully integrated into different system architectures. It is equipped with RJ45 connectors for integrated Modbus and CANopen connectivity. Other communication options include Ethernet IP and Modbus TCP, Profinet, EtherCAT, DeviceNet, and PowerLink.
Figure 3: Altivar ATV 320 VFD for controlling three-phase synchronous and asynchronous motors at variable speed. (Image source: Schneider Electric)
Smarter control
Energy-saving drive technology
In the quest for a more sustainable use of energy and industrial resources, optimizing control technology is an inevitable part of the equation. When it comes to collecting, processing, and analyzing production data in automated plants, state-of-the-art edge controllers play a key role today. Compact, scalable and connected via Industrial Ethernet, these devices can be used to implement both cloud-based and local solutions. Dedicated functions for diagnostics and energy management help automation engineers analyze manufacturing processes, identify bottlenecks, and initiate optimization measures based on industrial controllers such as the Simatic S7-1200. Advanced control algorithms as well as integrated communication and safety functions make a decisive contribution to precise process execution.
With regard to the energy demand of production plants, for example, drive technology plays a major role. Efficient drive systems equipped with advanced variable frequency drives (VFDs), for example, are able to precisely match motor speeds to the true demand of
Figure 2: Supporting the IIoT approach to production: smart sensors, converters, and controllers from the Snap Signal family. (Image source: Banner Engineering)
Figure 4: Efficient process execution based on manufacturing data analysis using the Siemens Basic Controller, both cloud and local solutions can be implemented. (Image source: Siemens)
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