Fewer emissions with a higher overall equipment effectiveness

More countries are committing to net-zero emissions, aiming to limit global temperature rise to 1.5 °C. With the PLCnext Technology ecosystem and MLnext software solution, Phoenix Contact is helping tp reduce emissions.

The EU aims for net-zero greenhouse gas emissions by 2025, as part of the European Green Deal and the 2015 Paris Agreement. This transition to a climate-neutral society is both a challenge and an opportunity, involving all societal and economic sectors, from energy and industry to buildings, agriculture, and forestry.

Conversion of existing thermal processes along the entire production chain

For sustainable climate strategies to succeed, all areas of industrial facilities must be considered. Failure to do so will undermine efforts to reduce greenhouse gases and comply with environmental directives.

Energy-intensive industries must convert thermal processes to low-carbon methods urgently due to climate-driven geopolitical changes. This requires sustainable, minimally invasive technologies and secure digitalization platforms. Heating systems should use renewable energy, ensuring energy availability, product quality, and cost-effectiveness. Conventional heating concepts need rethinking for low-carbon heat generation.

Need for change through the use of hydrogen

The power-to-gas (PtG) principle, which converts electrical energy into chemical energy (gas) by means of water electrolysis, is crucial for modern gas and hydrogen networks. This creates new requirements for industrial furnaces.

Hydrogen and its mixtures lead to a reduction in the air requirements, a change in the calorific value, higher combustion speeds, higher flame temperatures, and an increase in nitrogen oxides (NO and NO2). This impacts the “machine,” including the melting tank, furnace, boiler, supply technology, burner, and especially the controller and automation system.

Requirements on the thermal processing technology

Integrating thermal processes into existing systems must be efficient and minimally invasive. Past digitalization often overlooked crucial mechanical equipment for fuel-air ratios and other key functions.

Future thermal processing technology requirements: • Operation on open, holistic ecosystems/platforms • Scalable integration of combustion and exhaust gas sensors • Functional safety and cybersecurity per IEC 62443 and NIS 2.0 • Introduction of ML and IIoT for monitoring and optimization • Increased agility with low/no-code apps for adapting fuel lines using platforms like Grafana

Machine learning for fuel and process optimization

By detecting unusual behavior patterns early, PLCnext Technology with MLnext software helps prevent malfunctions in combustion processes, enhancing overall equipment effectiveness (OEE), optimizing fuel-air ratios, and enabling intelligent cross-factory monitoring.

Phoenix Contact’s Digital Factory now initiative supports the All Electric Society principle, offering scalable, data-secure automation solutions via the PLCnext Technology ecosystem. In addition, these solutions facilitate easy integration into thermal processing machines worldwide, aiding manufacturers, system integrators, and operators in creating tailored products and systems.

Certification of functional and data security

The PLCnext Control product family, certified by TÜV Süd for OT Security (IEC 62443-4-2) and existing safety certification, sets new standards. The IEC 62443 standard emphasizes linking security and safety in automation solutions. With a focus on OT security and remote access, the PLCnext Control family complies with the upcoming Machinery Regulation.

Signal connection through intelligent isolators

Users must adapt fuel-air ratios to new fuels using parallel sensor systems for efficiency without impairing operation. Existing infrastructures should be converted to IEC 62443-compliant segmented networks to prevent data collisions or illegal access.

Both goals can be achieved in parallel. Field signals connect to PLCnext Control or edge devices using Mini Analog Pro signal isolators and the “PLCnext IIoT Framework” app. Phoenix Contact’s configurable thermal processing control cabinets process, normalize, and send signals in real time, saving space, hardware, and engineering time. The MLnext app can virtualize information from various sources on-premise or in the cloud (e.g., Proficloud.io).

Read more about PLCnext Technology.

Foundation for optimizing the entire value chain

Edge computing is closely tied to cloud computing, with the latter gaining importance in Industry 4.0 projects. Though relatively new, edge computing’s potential is exemplified by the EPC 1502 edge device.

A user needs an Internet connection to link systems to a cloud for data evaluation and storage. However, for applications requiring quick data processing, public cloud solutions are unsuitable due to Internet latency. Users are increasingly using Edge computing for these smart applications. Phoenix Contact’s edge devices, based on the PLCnext Technology ecosystem, combine robust industrial PCs with an open automation platform. This approach enables intelligent IoT edge concepts and optimizes the entire value chain by processing and analyzing large data volumes locally.

Easy to integrate box for collecting local data

Edge devices have broad applications, where data needs to be analyzed or is already being analyzed in the cloud. When developing edge applications, users often ask how to centrally accumulate data. Creating autonomous vehicles, traffic light systems, or intelligent thermostats that benefit from edge computing can be complex. The edge device must be flexible and able to collect large amounts of data from various sensors and manufacturers. Additionally, field devices use different industry protocols, and much of the data is analog, making accumulation challenging.

The tailor-made Edge Collection Box from Phoenix Contact is ideal for collecting local data. It gathers digital, analog, and temperature signals via connected sensors and integrates easily into existing production environments. Furthermore, Data collection takes place in parallel, preserving the CE marking of machines. The main component, the EPC 1502 PLCnext Control with an IIoT framework, facilitates easy collection of energy and process data using industry-standard communication protocols.

Secure Data Box as a secure interface to higher-level IT systems

Once data is collected and analyzed locally via the edge device, it often serves as an intermediate layer to the cloud. Transferring summarized data, evaluated alarms, and analyses securely to the cloud can be challenging. Moreover, Phoenix Contact’s Secure Data Box, used with the Data Collection Box, provides a secure interface between the production network and higher-level IT networks, external service providers, and cloud systems. The integrated FL mGuard security router’s firewall blocks unauthorized access, allowing only necessary data traffic. Via the mGuard Secure Cloud app, one can access the EPC 1502 edge device for remote maintenance information.

Reliable operation of automated guided vehicle systems

Additionally, using an edge device in an automated guided vehicle system (AGVS) bridges the gap between classic control functions and AGVS navigation. It offers a plug-and-play interface for the Robot Operating System (ROS) and supports high-level language programming, the ROS interface, and Docker software, allowing users to implement their own approaches. The PLCnext Technology online store provides apps for sending firmware and application updates to all controllers.

Furthermore, the edge device provides a secure entry point for remote maintenance and displays collected data via dashboards. AI algorithms analyze data to detect anomalies, enabling predictive maintenance and minimizing downtime. With atypical interfaces, data can be forwarded via WLAN, saving on cables. The large internal storage allows for long-term local data storage. Edge devices are essential for the reliable operation, efficiency, and flexibility of automated guided vehicle systems.

Wide range of possible uses in large and small applications

There are various applications for Edge computing. Ready-to-install edge boxes simplify implementing large systems that collect data using different protocols. Moreover, existing systems can be easily converted to edge computing with integration-capable solutions installed outside machines, retaining their CE marking. In smaller systems, edge devices must support many protocols and apps to provide added value with simple installation.

Read more about edge computing and PLCnext Technology

From hand tools to automatic tools

Before making an electrical connection, conductors need to be stripped a process that varies depending on the type and characteristics of the conductor. Stripping conductors is challenging due to the variety of types and their unique characteristics, with high demands on reliability and efficiency. Stripping involves removing the insulation to a certain length, as determined by the geometry of the terminal or connector. In addition, it can include removing the outer sheath of multi-core cables. Ensuring a safe electrical connection means avoiding damage to the litz wires, single-core wires, or braided shields. The process must conform to DIN IEC 60352-2 standards, which specify the requirements for a perfect stripping result. Depending on which tool is used, clamping the conductor can lead to pressure points and thus to discoloration of the insulation.

To avoid damage to litz wires, the stripping process involves two steps: “cutting into” and “pulling off” the insulation. First, the insulation is cut to a clearance of about 0.1 mm to 0.3 mm from the wires. Then, the uncut area of the insulation is pulled off to complete the removal.

Non-adjustable hand tools

Stripping can be performed using hand or automatic tools. Hand tools are categorized into non-adjustable, adjustable, and automatically adjustable types. Non-adjustable tools, like the Wirefox-MP VDE multifunctional tool, are the simplest and can handle a wide range of conductor sizes (0.2 to 10 mm²), allowing quick processing of different conductors. However, these tools require practice for perfect results and are not suitable when high level of process reliability is needed due to their lack of adjustability.

Adjustable hand tools

Adjustable tools enhance process reliability and require minimal practice. Tools with a rotating blade, like the Wirefox-D 40, are suitable for sheath removal and stripping in cross-sections over 10 mm², ensuring a uniform incision depth. For smaller cross-sections, non-rotating cutting edges are used, increasing the pull-off proportion.

While tools like the Wirefox-D 40 have broad applications, specific tools like the Wirefox D-CX series are designed for multi-stage stripping of coaxial cables. These tools are selected based on the connector type to achieve the required stripping lengths. However, they are not ideal for frequent material changes due to the time needed to set them up.

Automatically adjustable hand tools

Automatically adjustable hand tools offer the combined benefits of non-adjustable and adjustable tools, providing fast material changes and high process reliability. They use different blade geometries for various applications: flat blades for PVC cables up to 10 mm², half-round blades for cross-sections up to 16 mm² to minimize force required, and V-blades for hard insulation materials like PTFE and soft rubber. Stripping lengths can be set with an adjustable stop, and blades can be easily replaced without tools, ensuring long service life.

Automatically adjustable hand tools are also available for special applications, such as stripping SAC cables, AS-Interface flat cables, and flat-ribbon cables. These tools are recommended wherever applicable due to their versatility and efficiency.

Manually adjustable automatic tools

In series production, where quantities and quality demands are high, hand tools are reaching their limits. No matter how ergonomic the hand tools are, fatigue is inevitable. This is where automatic tools, like the entry-level electric WF 1000 stripping device, become essential. Once parameters such as cross-section, stripping length, and pull-off length are set, this device can quickly process many conductors without causing fatigue. However, each material change still requires some time to adjust the stripping parameters. This machine is especially suitable for processing identical materials efficiently.

Automatically adjustable automatic tools

The new E.Fox S 10 automatic stripping device is optimal for production processes that require frequent material or parameter changes. Its electrical adjustment of stripping parameters allows for swift material changes. The device is user-friendly, featuring an intuitive touch display interface. Users can save and recall favorite stripping parameters using a barcode scanner, significantly boosting efficiency.

The E.Fox S 10 automatic stripping device reduces the potential for human error compared to manual settings. It can function as a stand-alone device or be integrated with the Clipx Wire assist worker assistance software via an Ethernet interface. This allows for consistent use of production data and reliable processing of large, multi-version orders. When combined with other automatic tools and printing systems controlled by the same software, an efficient and customized worker assistance system for wire preparation can be created.

Read more about Automatic stripping devices.

With open automation into the electrified future

Audi uses PLCnext Technology from Phoenix Contact at its Ingolstadt facility in Germany for the body shop of the all-electric Audi Q6 e-tron series. This open ecosystem supports numerous IIoT functions and includes integrated cybersecurity compliant with the IEC 62443-4-2 standard.

Phoenix Contact supports sustainability through key technologies for electrification, networking, and automation. PLCnext Technology, an open ecosystem with numerous interfaces from sensor to cloud, facilitates continuous information flow in carbon-neutral production. It supports standard PLC programming (IEC 61131-3) and high-level languages (C/C++, C#, Matlab Simulink) running in real time on PLCnext Control controllers. This integration benefits both IT and OT specialists, aiding the automation of Audi’s production facilities.

Improving the greenhouse gas balance through optimized production processes

Audi aims for carbon-neutral production at all sites by 2025, a goal already achieved at Ingolstadt in early 2024. In the body shop, improving emission values through quality, availability, and adaptability is crucial. Production-related GHG emissions increase with no-load periods or rejected bodies, raising costs and impacting the GHG balance.

To prevent increased GHG emissions and costs, Audi implements shutdowns during no-load times and uses communication-capable energy meters. These include Phoenix Contact’s EEM-MA 370, to monitor consumption. Transparency in energy flows and early detection of malfunctions are crucial. Ultimately, identifying minor quality deviations early can significantly improve process flow. This in turn results in shorter cycle times and optimized energy balance for each car.

Taking faith out of the leap

A team from ccc software gmbh and the Institute for Applied Training Science in Leipzig has developed a complex analysis system for coaches, athletes, and sports scientists. The system includes a camera or video system and speed measurement. Furthermore, ensuring that recorded data is immediately available for analysis. Ski jumping, a sport with major international events. It is known for its spectacular jumps, with participants reaching speeds of up to 108 kilometers per hour. Moreover, The Audi Arena Oberstdorf in Oberstdorf, Germany, has one of the largest ski jump ramps in the world, with a ramp size of 235 meters and a record of 242.5 meters. The jumping tower is 72 meters high, and the run-up length for jumpers is 118 meters with a run-up inclination of 38.7 degrees. 

A variety of challenges 

The length of a jump is measured from the edge of the jump-off platform to the point of landing. The athlete’s body and ski posture significantly influence the aerodynamics. To optimize jumping performance, ccc software gmbh and the Institute for Applied Training Sciences have developed a sophisticated solution for training optimization and competition management. The camera must be mounted parallel to the jumper and at flight-path height. However, the jumper is only parallel with the camera for a fraction of a second. The IAT, founded in 1992, supports around 1,000 athletes and their coaches from 19 summer and six winter sports. Aiming to identify and tap into Germany’s top athletes’ performance potential. 

Compact Ex i isolators for quick and error-free connection in various applications

Green hydrogen (H₂) is emerging as a crucial alternative to fossil fuels like oil, gas, and coal. Chemical plants, refineries, copper smelters, steelworks, and the mobility sector, aim to use it to achieve climate neutrality. Ex i isolators are employed to safeguard systems from explosions.

In 2023, the German government decided to significantly enhance the role of hydrogen in its updated national strategy by 2030. They aim to have 95 to 130 TWh of hydrogen available by then, with demand projected to reach 500 to 600 TWh by 2045. For comparison, Germany consumed around 866 TWh of natural gas in 2022. To meet these targets, the entire hydrogen value chain must be rapidly expanded. From production by electrolyzers from renewable energy to storage, processing, and distribution.

Challenges in the use of hydrogen

Hydrogen’s high energy content and carbon-neutral combustion, producing only water (H₂O), are significant advantages. However, handling H₂ requires caution due to its properties. It is fourteen times lighter than air, leading to rapid evaporation in open-air systems. It also has high diffusivity, allowing it to penetrate other media. Hydrogen is also highly explosive, with a minimum ignition energy of 0.02 mJ, one of the lowest among flammable gases. It belongs to the most dangerous ignition group IIC, along with acetylene and carbon disulfide. It also has a wide explosive range from 4% to 77% by volume in air.

Floating connectors with considerable tolerance compensation and high-speed data transmission

When it comes to board-to-board connectors, there are numerous versions: small and large pitches, low and tall designs, robust and simple connectors. The Finepitch FS 0,635 series connectors with floating properties are a new addition to the Phoenix Contact portfolio. What makes floating board-to-board connectors so special? Where are they used? And are high-speed data transmission and floating a contradiction in terms?

Features of a floating connector

Board-to-board connectors consist of the contacts that establish an electrical connection and a housing that protects and fixes the contacts. While floating connectors have two housing parts connected by contact metals. The inner housing contains the pin connector pattern, while the outer housing protects soldering surfaces and contacts. The floating contacts are long and curved, allowing the inner housing part to move within the limits set by the outer housing. This allows the pin connector pattern to be moved within a large tolerance range while the soldering area remains fixed. The FS 0,635 series allows a tolerance of 0.6 mm in the plug-in direction, known as wiping. The FS 0,635 floating female connector strip can be combined with three male connector strips to create different stack heights.

Direct, on-site mobile marking for electrical installations

The increasing importance of clear marking in networked components, particularly in plant, control cabinet, and distributor construction, has made the development of mobile printing systems necessary in the field of electrical installation.

On-site marking demands are increasing, necessitating clear and consistent marking of terminals, wires, cables, equipment, and systems, as well as compliance with a growing list of standards.

Digitalization of marking processes

Phoenix Contact introduces the THERMOMARK GO thermal transfer printer. A mobile system solution that offers high flexibility, short working paths, and no accidental double processing of missing markings. The printer, software, and marking materials – THERMOMARK GO – are all integrated with the MARKING system app, allowing easy smartphone interaction with the printer.

Climate change and population growth are posing a global challenge. How to stop global warming and increase energy consumption while protecting the climate? The All Electric Society vision aims for a sustainable, affordable energy system where renewable sources, such as sun, wind, and water, are used. Researchers at Oregon State University predict that photovoltaics could cover all energy requirements globally, using less than 1% of the earth’s surface. However, achieving this energy revolution requires extensive renewable energy expansion of renewable energy and the technological approach of sector coupling.

Sector coupling

Sector coupling involves the comprehensive electrification, networking, and automation of all relevant areas of our lives and economies. Including industry, energy, mobility, infrastructure, and buildings. In the All Electric Society, these sectors are networked to create a self-controlling system that optimizes energy efficiency and energy savings by balancing loads, producers, and storage systems. This ensures stability and availability of power supply without excess capacity. Making energy storage systems a core element of sector coupling.

The role of energy storage systems in an All Electric Society

To ensure a stable power supply based on renewable sources like sun, wind, and water, reliable storage systems are necessary. There are various technologies for temporarily storing electrical energy, with the main difference being their physical principles. Mechanical storage converts electrical energy into mechanical energy. While purely electrical storage uses capacitors or inductors. Electrochemical storage uses electrochemical potentials and electrolytes to store electrical energy in batteries. Thermal storage generates heat and drives electrical generators.

High-speed data transmission for industrial applications

IDC predicts that by 2027, the volume of data created and replicated will reach 284 zettabytes, a 21-zero figure, threatening the Internet of Things without a nationwide broadband expansion, highlighting the need for significant data storage and replication.

The first transatlantic fiber-optic cable was operational in 1988, enabling high-speed data transmission between continents. The mid-1990s saw broadband expansion, adding more long-distance routes and moving fiberglass transmission paths closer to end devices like data centers, industrial plants, and personal computers, known as the “last mile.”

Data transmission across continents, countries, and municipalities requires high security and reliability. Speed, immunity to interference, and failsafe performance are basic requirements for industrial and semi-industrial data transmission.

The advantage of fiber optics

Fiber-optic cables (FO) transmit data in light over long distances by converting electrical signals into photon packets and sending them to the receiver via plastic or fiberglass. The light signals are then converted back into electrical signals for evaluation and processing.

This blog article explores the advantages of data transmission through fiber-optic cables over copper transmission, focusing on their characteristics.

Speed and distances

Fiber-optic cables use photons to transmit electrical signals, which are faster than electrons in copper conductors. Photons can travel up to 70% of the speed of light, with minimal signal loss. This allows for longer transmission distances of up to 50 km and data rates of up to 40 Gbps. The actual range depends on the chosen fiber-optic cable, making them suitable for long distances and large data volumes.

Reliability and security

Fiber-optic cables are reliable for data transmission due to their non-conductive cores made of glass or plastic, eliminating the need for complex shielding. They are metal-free, insensitive to EMC and ESD interference, allowing parallel use with other cables. Impedance problems and crosstalk are not issues. Fiber-optic cables with coatings protect against environmental influences in a much better way.

Fiber-optic cables offer enhanced cybersecurity due to their lack of external signals, requiring direct access via bend connectors or contact points, making them significantly more secure against eavesdropping than copper cables, despite not providing 100% protection against unauthorized access.

Costs

Fiber-optic technology has disadvantages such as complex assembly, precision, expensive equipment, complex measurement technology, and the need for well-trained specialists. Manufacturing and monitoring production are costly and require extensive expertise in this specialist field.