Surge protection for up to 1.5 Gbps

As telecommunications connections speed up and the active technology (e.g., router) is now moving into meter cabinets, protecting these devices from surge voltage is crucial for stable operation even during thunderstorms. The surge protection should be easy to install and not impair transmission.

No fear during a storm

Modern telecommunications devices are essential at home and in the office. Ensuring their unrestricted operation is now an absolute necessity. Using appropriate surge protection prevents unexpected failures due to voltage peaks. Besides power supply protection, VDE 0100-443 standard and TAR VDE-AR-N 4100 recommend protecting the communications interface. With many telecommunications systems available, which protective device is suitable?

DSL interfaces and their transmission speeds

DSL interfaces provide Internet speeds from 16 Mbps (ADSL2) to 300 Mbps (super-vectoring VDSL/SVVDSL). Vectoring VDSL reduces crosstalk interference in copper telephone cables. Transmission frequencies range from 2.2 MHz (ADSL) to 35 MHz (SVVDSL), important for selecting protective devices with matching cut-off frequencies. Manufacturers should specify both cut-off frequency and maximum DSL speed. G.fast offers speeds up to 2 Gbps over very short copper lines (<100 m).

Suitable protective devices

To prevent signal from being influenced, attenuation at high frequencies must be negligible. High-speed data transmission, especially with super-vectoring, requires symmetry of the copper wires against ground. The DT-TELE-WM-RJ45-PT-I product ensures minimal impact on transmission quality, even at 300 Mbps (VDSL) and 2 Gbps with G.fast. Deutsche Telekom tests confirmed its excellent transmission behavior and compatibility with VDSL, VVDSL, SVVDSL, and G.fast.

Quick and easy installation

The DT-TELE-WM-RJ45-PT-I can be easily snapped onto a DIN rail or mounted on a flat surface or perforated board using pull-out tabs. Its electrical connection is flexible and user-friendly due to the combinaton of Push-in technology for installation cables and RJ45 jacks for assembled telephone cables.

Protection against incorrect installations and power-cross

If a cable with too high a voltage is connected to the connection terminal blocks, the integrated current sensors limit the current and voltage to safe levels. Once the error is rectified, the sensors return to normal. Even in extreme cases, like a power-cross or a 230 V AC line connection, the DT-TELE-WM-RJ45-PT-I protects the end device (e.g., router) and remains in a safe state.

In case of thermal overload, an internal disconnect device disconnects the affected protective element from the data line. A red status indicator signals that the DT-TELE-WM-RJ45-PT-I needs replacement as its protective function is compromised. This surge protection limits high pulse voltages and harmful energy from miswiring, preventing damage to the TC device.

Required performance

The IEC 61643-22 standard provides information on the required performance of protective devices, specifying surge voltage categories (D1, C2, C1) based on installation location. Standardized testing verifies these properties. Well-documented devices provide data for various standard pulses, reflecting installation location. For example, devices at the building entrance (first lightning protection zone) should meet category D1 requirements, while subsequent levels should meet C2 and C1. The described protective device meets all these categories and can be used in any lightning protection zone.

Read more about The new DT-TELE-WM-RJ45-PT-I surge protective device.

Green electricity from wind and solar power can be abundant or scarce. Power-to-X technologies store this energy as electrochemically produced hydrogen, which is converted back into electricity in fuel cells. A modular solution with AC/DC converters supports various topologies for supplying electrolysis cells with direct current, simplifying maintenance and enhancing the availability and service life of electrolysis stacks.

The vision of an All Electric Society relies on affordable, renewable electricity. Wind and solar power are crucial but volatile, necessitating storage solutions. Future power grids will use pumped storage plants and battery storage systems to balance generation and consumption, though these aren’t suitable for long-term storage of large quantities of surplus electricity.

Power-to-X technologies can be used to store surplus electricity long-term by splitting water into hydrogen and oxygen via electrolysis. These can be converted into chemicals or fuels, or the hydrogen produced can be stored and later converted back into electricity in gas-fired power plants or fuel cells. Direct current through an electrolysis cell produces hydrogen at the cathode and oxygen at the anode, separated by a membrane to prevent reaction. The gases are vented off separately.

Modular concepts for electrolysis cells and power supply

Today’s electrolyzers are modular, with cells arranged in stacks, achieving powers from 10 kW to several MW. Larger plants, up to gigawatt scale, interconnect dozens or hundreds of electrolyzers. This modularity allows easy scalability and simplifies mass production. Designing a modular power supply for electrolyzers is ideal.

Scalable alternative to monolithic large-scale converters

All electrolyzers need direct current, so AC from the power grid must be converted by AC/DC converters. The cell voltage (1.6 to 2 V) must be maintained for the electrolytic process. Often, large monolithic converters are used, but a modular supply concept like the CHARX power system from Phoenix Contact offers an alternative. CHARX AC/DC converters convert AC to DC with the required voltage, ensuring high-quality electrical energy by reducing grid-side harmonics and the DC ripple is a maximum of just 1.5%. They also prevent short-term voltage dips and peaks.

Megawatt electrolyzer manufacturers impressed by modular supply concept

Phoenix Contact has implemented this concept in several electrolysis projects, equipping containerized units with modular rectifier units based on AC/DC converters. This modularized approach allows for standardized control cabinets that are adaptable to the power needs of each electrolysis module. Manufacturers were impressed by the technical details, such as integrated condition monitoring, long service life, easy maintenance, and high efficiency of the converters.

High-level efficiency and easy-to-integrate condition monitoring

Charx AC/DC converters, typically using IGBT technology with a 30 kW output, are highly efficient (up to 96%) and superior to monolithic converters. They offer a controllable DC output voltage range of 30 to 1,000 V, adaptable to various electrolysis stacks. Both voltage and current can be ramped up slowly. These converters provide internal electrical isolation between AC and DC grids, crucial for many electrolyzers. Charx converters with 20 kW output using SiC power semiconductors can achieve 97% efficiency, further reducing waste heat.

PLCnext Control devices from Phoenix Contact are ideal for control applications, offering library elements for simplified programming, flexible voltage and current control, and easy data integration for condition monitoring. Charx converters feature an openly accessible bus system. The modular power supply approach benefits electrolyzer manufacturers, allowing scalable green hydrogen production from pilot to megawatt plants.

Higher availability of converters and electrolyzer

Charx rectifiers optimize partial load operation by allowing parallel converters to be partially switched off, ensuring the remaining ones operate at optimal efficiency. This extends the service life by evenly reducing operating hours. Alternating the operation of converters also aids maintenance planning and prevents uneven loading

The concept benefits maintenance and servicing. Small-format modules can be easily kept as spares, and integrated condition monitoring alerts operators when replacements are needed. Modules can be replaced with standard tools while others continue to supply the electrolyzer, increasing system availability. Only during full-load operation is a slight reduction in supply noticeable when a module is replaced.

If a large monolithic converter fails, the entire electrolysis plant it supplies will stop. Replacement converters must be custom-made, causing the plant to be down for weeks and resulting in high yield losses.

Large megawatt converters supply multiple electrolysis stacks with the same voltage, but variations in stacks can cause issues. If one stack has a problem, it can affect the entire system. In contrast, using Charx modules allows individual stacks to be isolated and checked without shutting down the whole system, ensuring the remaining stacks continue to operate.

Using 19-inch modules may require more space and higher initial investment than large-scale converters. However, their advantages—higher availability, lower maintenance costs, and efficiency gains, especially in partial load operation—quickly offset these drawbacks.

Read more about AC/DC converters.

Single Pair Ethernet: Lean communication through to the field level of automation

Single Pair Ethernet (SPE) enables smarter, more sustainable connections, making it ideal for long-distance communication. Sensor manufacturer Jumo trusts SPE for its measurement technology, using connection solutions from Phoenix Contact, developed through close project collaboration.

“Single Pair Ethernet (SPE) enhances the use of intelligent sensors by transmitting more data, enabling profitable insights,” says Manfred Walter, product manager at Jumo. He highlights the seamless distribution of sensor information across system levels and the consistency it brings. SPE also saves cables by routing data and power via Power over Data Line (PoDL), allowing end-to-end communication from ERP to field level without media disruptions.

OEE as a basis for investment

Jumo and Phoenix Contact emphasize Ethernet’s consistency as crucial for sustainable production. It simplifies troubleshooting, facilitate condition-based maintenance, and improves Overall Equipment Effectiveness (OEE) by enhancing system availability. Additionally, it facilitates easier connections to cloud-based services.

Using SPE to combat media discontinuity in industrial communication could influence sensor-level connection technology choices. However, Manfred Walter notes that customer expectations in machine building and systems manufacturing are primarily price-driven, with limited budgets for measurement chains. The additional cost of SPE connections and the benefits of an end-to-end Ethernet architecture are difficult to present, especially in standardized tenders. Positive impacts on OEE are crucial for investment decisions and are best be argued directly.

Convergent networks are in demand

Martin Müller, a fieldbus expert at Phoenix Contact, views SPE as an important step towards convergent networks. TSN is designed for time-critical tasks like functional safety and motion control, while 5G is used for cellular communication needs. Similarly, WLAN 6 and 7 are used for license-free, wireless transmission.

“Single Pair Ethernet is ideal for communication at the field level,” says Martin Müller. The convergent Ethernet network is the common standard for industrial communication. If stakeholders in automation, electrical engineering, machine building, and systems manufacturing agree on this path, industry-specific fieldbus wars will end.

1,000 meters with 10 Mbit

The chances are favorable, supported by the transmission performance of standard consumer communication. SPE achieves a transmission rate of 10 Mbps over 1,000 meters, while I/O-Link delivers 230.4 kbps over 20 meters. Despite I/O-Link simplifying sensor connections, Manfred Walter believes its data rate won’t suffice for future tasks in coupled sectors.

Phoenix Contact and Jumo foresee a trend towards convergent Ethernet networks, particularly among younger specialists. “Digital natives are less tolerant of multiple systems in industrial automation,” says Martin Müller. The focus should be on maximizing sensor capabilities for efficient, resource-saving operations. “We see enormous potential for the future,” emphasizes Manfred Walter.

Hygienically clean IP67 connector solution

Install, connect, and you’re done: With SPE connectivity, installing a Jumo sensor is easy. The Ethernet layer eliminates the need for gateways or complex interface programming. Phoenix Contact’s M12 connector supports Single Pair Ethernet transmission up to 1,000 meters without limiting attenuation. “The M8 format wouldn’t fit a two-wire AWG 18 data cable for 1,000 meters,” explains Manfred Walter. The connection design ensures robustness and hygiene. Jumo’s “flowTRANS MAG H20” and “DELOS S02” sensors are popular in the pharmaceutical and food industries. High operational safety over long distances is achieved with connections that withstand demanding production processes or CiP cleaning. Phoenix Contact’s solution meets hygienic design standards and provides IP67 protection.

Read more about Sensor technology.

Safe and reliable operation with lower energy costs

A reliable power supply from renewable sources requires storing surpluses for times of low sunlight or wind. At the All Electric Society Park in Blomberg, Phoenix Contact demonstrates sector coupling for the electrification of society.

Climate change and geopolitical crises are accelerating the integration of wind and solar power into electrical power systems. However, these sources are intermittent. Battery energy storage systems (BESS) can store generated energy and supply it when needed. In Blomberg, a 1.2 MWh BESS ensures reliable operation and energy cost savings. Phoenix Contact uses its own electronic components to control the BESS, emphasizing quality, reliability, and safety. In addition, the company continues to expand its BESS portfolio, prioritizing these high standards.

Hybrid, battery-pole, and SPE connectors for a reliable connection

When creating battery storage systems, battery cells, and power electronics are usually prioritized. However, BESS systems are complex and require numerous technical components and electrical connections for power, signals, and data. Phoenix Contact offers a range of connection technology, including modular hybrid connectors that combine different connection types. These connectors can be customized to meet mechanical and electrical stability and safety requirements.

Often, people wire the systems discretely as an alternative to the hybrid approach. Battery-specific high-current connectors handle over 300 A and up to 1,500 V DC. Phoenix Contact’s battery-pole connectors, with UL 4128 approval, are widely available. For data communication, new solutions based on IEC 63171 Single Pair Ethernet standards are being established, offering robust, high-performance connectors with small sizes and high transmission capacities.

Certified hardware and software solution for feed-in control

The control cabinets, often divided into functional units, can be equipped using the Complete line range. This includes a comprehensive product portfolio for all control cabinet functions, such as uninterruptible power supplies, terminal blocks, and safety relays. The intuitive handling of these coordinated components saves time during planning, installation, startup, and maintenance, reducing operating costs.

In addition, the control systems of a BESS must communicate safely or be combined into one system. Managed switches like the FL Switch 2000 series provide necessary network functions. PLCnext Control controllers from the PLCnext Technology ecosystem integrate safety technology, eliminating the need for dedicated safety controllers. This allows for implementing standard and safety-related applications up to SIL 3 and PL e in the PLCnext Engineer environment. Using IEC 61131-3, high-level languages, and Matlab Simulink ensures faster and safer development of BESS control software.

The feed-in control system connects battery energy storage systems to the public power grid. Phoenix Contact offers a certified hardware and software system based on PLCnext Technology for users without their own solution. This system ensures low engineering effort, compliance with technical requirements, reliable operation, and easy grid connection. Intelligent automation solutions reduce operating costs, and preprogrammed software allows quick startup. Open interfaces enable customer-specific extensions.

360-degree security for protection against cyberattacks

Starting October 2024, the NIS 2 directive will tighten IT security rules for critical infrastructure operators (KRITIS). Neglecting IT security is considered negligent under this directive. Since prevention is more cost-effective than dealing with cyberattacks, Phoenix Contact offers TÜV-certified security products, services, and seminars. You can tailor these safety solutions to specific applications and requirements.

A challenge for battery energy storage systems is the international development and supply chains, with modules often developed and manufactured in distant locations. The complete solution is assembled at the user’s site, which can be anywhere globally. Manufacturers need internationally positioned partners with global expertise and production capacity. Components must meet all relevant international and local standards and have the necessary approvals.

Actively shaping the transformation to the All Electric Society

Phoenix Contact provides innovative products, solutions, and digitalization expertise for electrifying, networking, and automating economic and infrastructure sectors. Since its founding in 1923, optimizing energy flows has been a core expertise. The All Electric Society envisions abundant, affordable renewable energy. Achieving this requires comprehensive electrification, networking, and automation of all life and work areas. Phoenix Contact enables this transformation with numerous products, solutions, and services.

Read more about reliable components for battery storage systems.

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.