Connectivity – The Backbone of Sustainable Automation
degrees IP65/66/67, ix Mag connectors featuring integrated magnets (Figure 2), or Ethernet- to-RJ45 cable assemblies with angled RJ45 connectors; they provide both 100-Gbit Ethernet and PoE/PoE+ functionality. ix Industrial use case The following example illustrates the enormous potential of high- performance, miniaturized Ethernet interfaces for Industry 4.0 applications: The XTS linear transport system from automation specialist Beckhoff is a drive solution that uses magnetically driven movers traveling along a track of fully integrated motor modules. According to Beckhoff, their independent control allowing for individual motion profiles is the starting point of new machine concepts that enable more flexible manufacturing processes with shorter downtimes, such as retooling.
In order for the movers to follow their movement pattern, a computer must constantly calculate the switching and current supply of the respective motor modules. For this purpose, a total of three computer boards can be combined, each of which previously had four RJ45 sockets as ports. To allow more movers to be operated in the latest generation of the XTS system without having to change the dimensions of the system, the RJ45 sockets were replaced by the ix Industrial interface from HARTING. Reliable shielding and high data throughput were the main requirements here. Unlike RJ45, each ix Industrial connector allows for two 100-Mbit/s Ethernet connections. Thus, eight instead of four ports could be mounted on the same board, and two Ethernet channels could be installed per port instead of one. As a result, 48 instead of twelve ports were implemented on
the three computer boards. Accordingly, with the latest XTS generation, 48 instead of twelve XTS lines can now be used per unit, corresponding to a 400-% increase in the performance of the transport system. Two wires – instead of four or eight One distinctive attribute of today's industrial automation technology is its migration from hierarchical to decentralized architectures. These are considered advanced and particularly productive and, moreover, promise increased network security. This is because intelligent nodes such as smart sensors or edge computers, which are capable of performing certain data processing tasks autonomously, reduce sensitive data traffic between the edge and the cloud. The advantages of decentralization are self-evident, but the number of connected devices
in the field is growing enormously, and so are the efforts for cabling and connectivity. Their economic use, both in terms of material and installation effort as well as energy consumption, is becoming a strong criterion for the sustainability of manufacturing facilities. Single-Pair Ethernet (SPE) is considered a decisive breakthrough in efficiency and cost-effectiveness. The communication technology is defined by the IEEE 802.3 standard; the IEC 63171-x series of standards applies to the respective connectors. Essentially, it enables field components to be connected via just one twisted pair, i.e., two wires instead of the previous four or even eight: low-cost, resource- efficient, and therefore extremely sustainable. Originally developed for automotive electronics, SPE meets the requirements of many automation providers: The single pair of wires enables them to integrate a large number of instruments, controllers, and other devices into Ethernet networks at gigabit data rates (Figure 3). Another advantage: thanks to PoDL compatibility (Power-over-Data- Line, IEEE P802.3bu), the same pair of wires is able to deliver not only data but also electrical power to the field devices. In addition to actuators and sensors, in the power range of the previous PoE supply, camera-based instruments can be connected and powered via PoDL, for example.
Figure 1: Considerably smaller and more robust than standard RJ45 connectors: HARTING's industrial Ethernet interface ix Industrial. (Image source: HARTING)
such as the ix Industrial interface from German supplier HARTING (Figure 1) are substantially smaller and much more robust, particularly resistant to shock and vibration. According to the manufacturer, space savings of up to 70% on the circuit board are possible compared to standard RJ45. The 360°-shielded connector is designed for 10-Gbit/s Ethernet communication and is compatible with PoE (Power-over-Ethernet) as well as PoE+ for power transmission.
and coding comply with the IEC 61076-3-124 standard. Other manufacturers, such as the US company Amphenol Communications Solutions, also offer products with comparable properties that are intermateable with ix Industrial: for example, push-pull connectors for harsh environments in protection
Figure 2: Amphenol ix Mag: Ethernet communication up to 10 Gbit/s, 360° shielding and PoE++ up to 90 W
(Image source: Amphenol Communications Solutions)
ix Industrial is an interface developed by HARTING in conjunction with Japanese
connector specialist Hirose. Its dimensions, electrical properties,
Figure 3. Single-Pair Ethernet allows for resource- and cost-efficiently integrating the field level into broadband Ethernet communication. (Image source: SPE Industrial Partner Network)
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