Virtual commissioning with the RF::Suite and PLCnext Technology

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Cost and time savings with increased safety and better quality

The digital twin, often associated with the Asset Administration Shell (AAS) in the German “Plattform Industrie 4.0” initiative, is a crucial tool in the manufacturing sector for securing automation applications. It provides a digital image of a complete automation application, enabling users to simulate individual components’ behavior and provide a comprehensive view of the entire production process.

Virtual commissioning with the RF::Suite and PLCnext Technology

Decisive use case of the industrial digital twin

The digital twin is a digital representation of manufacturing system components, used to simulate and analyze production systems. It helps identify potential fault scenarios and simulates system behavior under different conditions. Virtual commissioning is a crucial use case for industrial digital twins, especially in complex production systems. It allows for cost-effective testing of virtual models before completion, enables safe testing without endangering people, machines, or the environment, and helps detect faults early, improving end-product quality and shortening startup time.

Decisive use case of the industrial digital twin

Efficient implementation based on the RF::Suite

EKS InTec GmbH’s RF::Suite is a software tool for virtual commissioning in machine building and systems manufacturing. Its modular and scalable approach allows for flexible use in various applications, making it an integral part of the automotive industry. The tool also offers benefits beyond virtual commissioning, such as instructing employees and ensuring realism independently of the production system’s control hardware.

PLCnext Technology open ecosystem for current and future automation tasks

Phoenix Contact’s PLCnext technology is an open ecosystem for automation, combining automation tasks and IIoT demands in a single device. It includes the PLCnext Engineer software platform, PLCnext Store digital marketplace, PLCnext Community, and systemic cloud integration. The firmware architecture is Linux-based, allowing users to use IEC 61131-3 code, high-level languages, and Matlab Simulink control algorithm models. The platform also allows users to add Linux-based components, data management, and communication protocols.

PLCnext Technology open ecosystem for current and future automation tasks

Virtual SiL simulation of the complete system to be automated

Virtual commissioning can involve various control systems, including hardware-in-the-loop (HiL) concepts and virtual automation systems. The RF::Suite generates simulations of the planned physical system, allowing for initial test scenarios and code improvements. PLCnext Engineer Simulation allows users to configure, execute, and test projects in a virtual environment, including IEC 61131-3 code, Matlab Simulink models, and high-level language components. Further development of PLCnext Engineer Simulation will enable the simulation of the entire automation system, creating a digital twin for automation. This approach allows for seamless interaction between the physical and virtual systems, ensuring optimal performance and optimization.

Virtual SiL simulation of the complete system to be automated

Learn more about PLCnext technology and Virtual commissioning

Varioface system cabling for the Simatic ET 200SP HA distributed I/O system

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Smart connectivity

Phoenix Contact offers Varioface system cabling, a plug-and-play solution for fast and error-free connection between control and field-level sensors and actuators. Embracing the plug-and-play principle, this product family aligns with the All Electric Society vision of the future, offering comprehensive planning tools and hardware products. In addition, the Varioface system cabling is industry-compatible, contributes to greater clarity and efficiency, and reduces costs. It saves up to 90% of the time required for conventional single-core wiring by using various components and D-Sub connector connections.

Smart connectivity

Use of more compact and less expensive 24 V DC I/O modules

Digital control and power signals are processed differently in various applications. 230 V I/O modules are more expensive and require more space than 24 V signal levels. To optimize cost and space, a 24 V DC I/O module combined with Phoenix Contact’s PLC-Interface relay family is ideal. This results in a compact eight-channel relay module, which can be integrated directly into the system cabling solution. Moreover, the PLC-Interface product family offers several advantages, including plug-in design, screw or push-in connection technology, numerous switching elements, special sensor/actuator series, narrow design, and modular design, allowing space and cost-optimization for a wide range of application requirements.

Use of more compact and less expensive 24 V DC I/O modules

Quick and easy wiring with Push-in or screw connection technology

Phoenix Contact offers termination boards for control cabinets. In addition, this allows users to wire single-core wires of sensors and actuators quickly and easily using Push-in direct connection technology or screw connection technology. The VIP series features terminal block markings that correspond to Simatic ET 200SP HA terminal blocks. This ensures quick mounting and vibration resistance. Additionally, the complete variable coupling level from Phoenix Contact is equipped with high-position D-Sub connectors, allowing connections between passive or active field modules and plug-in I/O devices. A range of lengths and halogen-free materials are available for optimal cable connection.

Quick and easy wiring with Push-in or screw connection technology

Tailor-made solution with the online configurator

Lastly, Phoenix Contact offers a comprehensive web shop for system cabling products. This includes an online configurator for component selection. Furthermore, users can easily select the desired Simatic ET 200SP HA I/O module, navigate through options, and transfer the solution to their shopping cart. what’s more, this efficient, modular, and plug-in solution saves time and money.

Tailor-made solution with the online configurator

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Smart management of street lighting from Giardinello

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Energy savings of up to 80 percent possible

Smart infrastructure solutions are not limited to large cities, as evidenced by the Sicilian municipality of Giardinello. While some think of smart cities as futuristic mega-cities, there are many smaller towns and villages where these solutions can be implemented. The principle behind smart city applications is to make life more convenient for citizens, contributing to improvement or mitigating deterioration. In times of crisis, such as the Corona pandemic and energy shortages, smart city solutions can offer opportunities for smaller cities to adapt and improve their infrastructure.

Smart street lighting

The challenge: integrating different types of luminaires

Giardinello, a small Sicilian town, is considering smart solutions for its public infrastructure to reduce energy consumption and save costs. The town has converted to LED technology and is now implementing a modern, digital solution for public street lighting management. The goal is to provide flexibility, energy savings, and a scalable technology that eliminates dependence on one manufacturer. The application must be designed and protected accordingly, considering the different types of luminaires and their impact on the village’s character.

Smart street lighting

The solution: communication via the LoRaWAN standard …

Modern lights use a Zhaga socket for interface and communication, unlike historical lamps with no modern Zhaga interface. The LoRaWAN standard, based on the OSI model, includes both the link and network layers, with double AES encryption for end-to-end cryptography. This new communication technology addresses the limitations of traditional Zhaga sockets and offers improved connectivity and security.

communication via the LoRaWAN standard

… as well as the Zhaga interface or a universal control device

LoRaWAN is a low power (LP)WAN technology used in Europe for data forwarding. It operates in the narrowband ultra-high frequency range (863-870 MHz) and offers up to 40 kilometers of range in rural areas and high penetration of building walls in urban areas. To implement a LoRaWAN network, luminaires use Luminaire Controller Units (LCU) or universal control units (LCU) with Dali-2 protocol. The system architecture follows a classic star topology, with three LoRaWAN gateways in Giardinello for high-quality illumination and connectivity.

Smart street lighting

The special feature: Lighting management as software-as-a-service

The Sicilian municipality is using the Grovez.io IoT platform for urban infrastructure applications. The platform features a LoRaWAN network server, decoder applications, and interfaces for communication. The municipality’s street lighting operator, Giardinello, now uses the Smart Lighting Service as a SaaS, allowing employees to control street lighting remotely. The combination of modern LED technology and LoRaWAN-based control technology allows for individual luminaire control and diagnosis.

Smart street lighting

The future: integration of vehicle traffic sensors and establishment of an environmental monitoring system

The Smart Lighting Service offers lighting management software that allows users to set various dimming levels, affecting energy consumption and luminaire lifespan. The solution simplifies the setting, and sensors in the field trigger automation. With demand-based lighting, energy consumption can be reduced by up to 80%. Giardinello is exploring further possibilities, including integrating traffic sensors and environmental monitoring systems using LoRaWAN-capable sensors. The community is already smarter than many large cities.

Learn more about Intelligent street lighting and Smart city: sustainable and livable.

Wireless communication in production facilities

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The key to efficient, sustainable, and reliable operation

Phoenix Contact aims to address climate change challenges by focusing on the All Electric Society, a world with abundant and affordable renewable energy. This involves optimizing communication infrastructure in manufacturing, reducing primary energy demands, and increasing machine efficiency. Companies must support this development across all areas, particularly in production, to avoid a competitive disadvantage. Technological approaches like Industry 4.0 and powerful network infrastructure are essential for rapid response to changing market and environmental conditions.

New automation approaches in the logistics sector

Industry 4.0 involves digitalizing and networking automation devices within and across a company, using technologies like WLAN, Bluetooth, and 5G. The Internet of Things (IoT) integrates even the smallest devices and new automation approaches like automated guided vehicles. This approach improves manufacturing system availability, performance, and quality while increasing flexibility.

Wi-Fi 6 with up to 70 percent lower latency

Industrial trends like IoT and AI demand high-performance systems for data availability, latency, and throughput. Wireless LAN (WLAN) solutions can extend or replace wired data transmission, simplifying handling of mobile machines and docked parts. The Wi-Fi 6 standard has increased theoretical data transmission speed by 30% and reduced latency by up to 70% through Multi-User MIMO. The Wi-Fi 6(E) extension offers license-free 6 GHz frequency band with additional 80 MHz and 160 MHz channels, allowing for additional WLAN networks without mutual interference.

Compact and robust wireless modules for AGVs and AMRs

Phoenix Contact has developed FL WLAN 1010 and FL WLAN 1100 wireless modules for automated guided vehicle (AGV) and autonomous mobile robot (AMR) systems. These modules address the challenges of reliable data connection, limited installation space, quality wireless communication, QoS availability, vehicle robustness, and diagnostics and maintenance functions. The integrated REST interface allows for easy installation in vehicles, saving time and eliminating incorrect configurations during vehicle commissioning.

Careful planning of the wireless channel design

WLAN building infrastructure is crucial for AGVs/AMRs, with proper placement of access points, metal installation, and suitable antenna positioning determining wireless coverage. Simulation tools can help determine coverage and reflections. Careful planning of wireless channel design and application can reveal potential issues early. Designing WLAN infrastructure can be complex and requires experience. Phoenix Contact specialists offer support in WLAN infrastructure design.

Learn more about Digital Factory.

Image data in industrial applications

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Ensuring reliability and performance during transmission

Optical sensors play a crucial role in industrial applications, ensuring reliable image processing and performance. As they become more powerful, they are used in various applications, including quality management and documentation systems. Machine vision systems must remain functional even under demanding conditions, such as mechanical stress. Data connectors must meet these requirements to prevent wear and downtime. Miniaturization in smaller systems poses challenges, including electromagnetic interference pulses, reduced system architecture, and thermal problems. Solutions include miniaturized interfaces, device-integrated connection technology, optimized component positioning, and simulations of heat generation, signal integrity, and impedance.

Ensuring reliability and performance during transmission

Standards for optimized image processing

Phoenix Contact, a leading industrial connection technology company, offers a range of data connectors, including D-SUB, RJ45, USB, HDMI, coaxial, and fiber-optic connection technology. They are also experts in new components like Single Pair Ethernet and RJ45 Industrial, ensuring optimized image processing for machine vision applications.

RJ45 Industrial

Phoenix Contact has developed the RJ45 Industrial product family for industrial applications, featuring an optimized 360° shielding concept. The product family includes raised housing shield springs and pins for printed circuit boards to counter electromagnetic interference. The connection between RJ45-IND connectors and female printed circuit board connectors has been optimized, resulting in a perfect match and increased contact depth. The temperature resistance of the female PCB connector has been improved using fiberglass technology, allowing temperatures from -40 to +105 C. The RJ45-IND patch cables are robust and feature an IDC fast connection for easy assembly.

RJ45 Industrial

Single Pair Ethernet

The IEEE 802.3 task force has created transmission standards for Single Pair Ethernet (SPE), enabling data rates of 10 Mbps to 1 Gbps at distances of 15 to 1,000 m. The MultiGigBASE-T1 standard supports data rates of up to 10 Gbps at distances of up to 15 m. SPE is an exciting field for industrial image processing due to its potential to transmit data and power. Phoenix Contact’s SPE portfolio offers compact and 50W consistent designs, including compact IP20 connectors and IP67-protected M8 connectors. SPE components are available for machine vision sensor developers, including new semiconductors, magnetics, and SPE-compatible cables.

data connectors

Board-to-board connectors

Phoenix Contact’s Finepitch product series offers a professional contact system for space-saving PCB connections, offering high-speed data transmission rates of up to 52 Gbps. The system features ScaleX double contacts (FP 0,8) for vibration-resistant connections in confined spaces. Phoenix Contact provides support during the design-in process, allowing device developers to obtain preconfigured 2D/3D data for their CAD software. They also offer individual thermal and housing simulations, free simulations for data and signal integrity, and a free sample service.

Board-to-board connectors
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Components for charging infrastructure in a 19″ format

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Simple and fast setup of a modular DC fast charging station

Phoenix Contact has introduced preconfigured and scalable modules for 19″ rack mounting. Enabling fast commissioning at low system costs. These modules contribute to the All Electric Society (AES) vision, which envisions renewable energy as the primary type of energy worldwide. The modules simplify the design process, allowing industry newcomers to participate in the charging infrastructure market. The distribution, power, and control modules allow for quick

Simple and fast setup of a modular DC fast charging station

The DC fast charging station for everyone

The modular 19″ Charx system from Phoenix Contact offers a cost-effective solution for developing and constructing DC fast charging stations by the international IEC 61851 standard. This system allows for quick assembly, maintenance, and repair, with the ability to replace individual modules. It reduces wiring work and errors and offers fast-connection technology, RJ45 communication interfaces, and a wide range of mounting materials. This system saves considerable system and installation costs, allowing a fully functional charging station to be set up in just a few minutes. Phoenix Contact’s experience as a leading charging infrastructure component supplier further benefits the customer.

The DC fast charging station for everyone

The 19″ system modules in detail

The Charx system, 19″ format, incorporates 30 kW power modules available in AC/DC or DC/DC versions. Along with a power control unit and an AC distribution unit. Achieving up to 96% efficiency, these high-quality modules offer flexibility for charging powers up to 1.5 MW. Ideal for large vehicle batteries, utility vehicles, and solar systems, the system enables the entire power flow from the grid to the vehicle. The AC distributor module allocates AC power to a maximum of five power modules. The power control module oversees up to five 30 kW modules, facilitating charging powers of up to 150 kW with a maximum current of 500 A. Preconfigured for easy installation and remote access, the charging controller ensures user-friendly operation.

The 19" system modules in detail

Learn more about CHARX technology.

Low-cost automation with PLCnext Technology

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Reaching into the box – simply explore new paths

Berlin-based Sikora GmbH has developed a proprietary robot controller (SRS) to automate manual tasks in the automotive industry. The company, founded in 1999, has been instrumental in shaping laser welding and soldering in the automotive industry. The SRS allows for easy programming of robot movements, and the first series used was in an application that “reaches into the box.” The solution for positioning bulk goods does not involve high-precision robotics or special drives and components but uses simple physical methods like magnetism and gravity. The low-cost automation system is energy-saving, with many components coming from the company’s 3D printers. This approach balances individual system elements according to demand, requiring less drive power and less waste heat. Additionally, mechanical wear is optimized and service life is increased.

Reaching into the box – simply explore new paths

Transparent processes – fast learning – easy operation

Sikora systems offer a self-explanatory process sequence for operation and maintenance, simplifying maintenance work. They are designed for limited operation in emergencies and quick fault identification without software-intensive configuration. The system’s interfaces between the user and controller are easy to handle, with a haptic interface for easy operation. A small robot with axes moved manually and a two-line display completes the unit, which can be taught using a 3D printer. The system’s simplicity makes it a valuable solution for skilled workers.

Transparent processes – fast learning – easy operation

IT and OT on the same hardware

Sikora GmbH has developed a robot controller using C++ programming on Linux-based computers, but it requires appropriate hardware for use in harsh industrial environments. Ralf Sikora discovered PLCnext Technology from Phoenix Contact, which meets all industrial use requirements, including real-time capability and data consistency. The controllers enable the use of high-level language programs like C++, C#, and Python. PLCnext Technology also meets IT security requirements in automation, as per IEC 62443 standards. This allows for sensitive banking transactions on smartphones in public WLANs, reducing the risk of network attacks or unsecured data transmission.

IT and OT on the same hardware

Intuitive operation by the user

Sikora’s automation solution, PLCnext Technology, is easy to use and gaining popularity among IT sector users due to its open ecosystem, which supports high-level language applications, database connections, cloud communication, artificial intelligence, and apps.

Industrial tasks have evolved from technical feasibility to user preference. Smartphones, for example, are intuitive and easy to use, but complex technology is still present. Automation systems must be quick and trouble-free for operators and maintenance personnel, increasing application availability. Open-source IT solutions make app interfaces on smartphones easier to use.

Intuitive operation by the user

Learn more about PLCnext Technology.

Compact box PCs for edge applications

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Significant cost savings

Compact box PCs

The Industrial Internet of Things (IIoT) is a forward-thinking technology in industrial automation. Focusing on high-performance applications that process and transmit data. Traditional automation systems use wired or wireless communication protocols to concentrate data in a central location. However, the lack of a common network in distributed applications, such as water pumping stations and oil fields, poses challenges and costs. Maintenance personnel often travel to remote stations to collect or update data, causing data delays or latency.

Significant reduction in network traffic

Applications require high-performance engines that capture, store, analyze, and preprocess data, with connectivity for efficient transmission. Small IIoT-capable industrial PCs distribute computing power to the edge of the Internet. This allows data analysis by a physically built device. This reduces network traffic, storage capacities, and costs while ensuring data is communicated immediately, forwarded at predefined intervals, and stored locally as backup information.

High availability even under harsh conditions

The VL3 UPC from Phoenix Contact is an example of an embedded computer design that ensures reliable operation year-round, even under harsh conditions. The compact box PC features a dual-core or quad-core Atom processor, fast DDR4 RAM, and NVMe solid-state memory modules. It is passively cooled, enabling high connectivity, and features a DisplayPort interface for high-resolution displays with Multi-Stream Transport capability. The design also includes easy maintenance options and passive cooling, reducing power consumption and heat generation.

A variety of extension options

The box PC has two Gigabit Ethernet and USB 3.1 interfaces. additionally, it can be extended with serial ports and WLAN configuration. Equipped with a DIN rail and mounting brackets for wall mounting, it offers versatility in installation. Furthermore, two extension modules increase system height by 30 millimeters, incorporating Gigabit Ethernet ports and M.2 interfaces for mass storage as well as accommodating 4G/LTE modems. This flexibility in WAN/WLAN connectivity is crucial for cloud computing installations.

Learn more about industrial PCs.

Learn more about HMI panels and industrial PCs.

Connectors for all weather conditions

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Evaluating the requirements on connection technology holistically

PRC series

Industrial systems require high-performance installation connectors to be robust, reliable, and flexible. These connectors must not become weak points, especially in extreme ambient conditions like cold water systems. These systems, often modular, must withstand moisture, frost, heat, and UV light for years without problems. Outdoor components, like cooling coils, require high IP protection and weather resistance. Connectors should enable intuitive operation during installation, commissioning, and maintenance, and ensure fast, error-free connections for power supply, signal transmission, and data transfer. These connectors are suitable for various industrial installations.

The challenges in practice

Device and system developers face challenges in creating reliable connection systems for IIoT and Industry 4.0 applications. Phoenix Contact’s PRC series offers high-performance power, signal, and data connectivity, IP6X protection, and UV resistance. The series includes circular connectors and assembled cables, with special housing inserts for a defined terminal point on the field device.

Standardized basis for safe connectors

Phoenix Contact's PRC series

Standardized connectors are advantageous in everyday life, smartphone market developments, and electric vehicle introductions. Standards like IEC 61984 and IEC 61535 define safety requirements and tests for connectors, while application-specific standards ensure permanent connections in fixed installations. These standards form a solid basis for power distribution, ensuring user safety and reliable connections.

Failure causes and starting points

PRC

The reliability of a system depends on its weakest link, and follow-up costs often outweigh the cost of materials or spare parts. Minimizing system failure risk is crucial, considering maintenance costs and intervals. Low-investment components often lead to failures, while quality upgrades can reduce costs. Cutting costs on connection technology can make error diagnostics difficult due to sporadic problems.

Selection criteria

Selection criteria

Planners should consider key characteristics like current, voltage, and conductor cross-sections, as well as seal tightness. The IP degree of protection, as per IEC 60529, defines protection against contact, foreign bodies, and water ingress. Higher IP degrees result in better seal tightness, with groups like IPX6, IPX5, IPX8, IPX7, and IPX9 forming groups.

General conditions are decisive

Repairs, maintenance, or inspections on existing systems can cause damage if connectors are loosened or the terminal box is opened. This can be due to inadequate design or incorrect selection of connectors and mounting materials. Environmental conditions, such as humidity, temperatures, UV irradiation, and wind, can affect the materials used, causing brittleness or corrosion. Substances in the environment, such as ammonia, sulfur, and salts, can also affect the materials. Environmental simulations and tests, such as ISO 4892, DIN EN 60068-2-52, 2 PfG 1911, and ISO 6988, are essential for material resistance. Impact and vibration tests are also necessary for mechanical load resistance. The Phoenix Contact product portfolio offers PRC series connectors for energy technology applications, such as lighting, infrastructure, and power distribution. These connectors are designed for fixed and permanent installations and feature high stability even with frequent plugging and unplugging. The PRC 20 series supplements existing products for up to 35 A and can be used indoors and outdoors.

General conditions are decisive

Learn more about Phoenix Contact’s PRC series.

Profisafe transmission over 5G networks

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Full speed ahead

The next generation of 5G standard promises significant advancements in wireless industrial data exchange. Historically, cellular technology focused on consumer communication, but now it takes industry interests into account. The standardization also includes requirements for the Industrial Internet of Things (IIoT), such as Massive Machine Type Communications (mMTC) and time-critical communications (Ultra Reliable and Low Latency Communications). The Third Generation Partnership Project (3GPP) standardization organization has released several specifications, with the current functions expected in Release 18, set to be published in 2024. However, developing semiconductors, network technology, and products is expected to take at least two years.

Structure of private cellular networks

Private cellular networks, similar to public networks, use wireless communication between end devices and radio towers. These base stations connect to a central data center, which manages and authenticates connections. The network core, consisting of local 19-inch equipment, acts as the central communication element, routing user data and forwarding it to the internet. This ensures reliable communication with low latencies and high failsafe performance.

Low cabling overheads in wide-area networks

Private 5G networks use a licensed frequency band, allowing better control, efficiency, and prioritization of communication devices. This technology is beneficial in small areas with a large number of wireless devices and outdoor applications with fewer base stations. 5G can serve various applications across one infrastructure, including eMBB, video application, remote maintenance, AR, logistics, and on-site facility management. It also offers uRLLC functions for field communication, allowing robots to reassemble without adapting communication cabling. Automated guided vehicles can exchange data and outsource the intelligence of these devices to a central server system, reducing equipment costs and increasing scalability.

Forwarding small data packets quickly and reliably

The examples discussed above involve reliable data transmission from an AGV to safety sensors and other AGVs, allowing them to traverse hazardous areas at full speed without collisions. This is achieved through Profisafe protocol, a safety profile for the Profinet fieldbus. This communication is based on Layer 2 of the OSI reference model, with data exchanged via MAC addresses in a closed network. In a 5G network, routing is required due to the separate network of AGVs, robot cells, and production networks. Data is transmitted via a Layer 2 tunnel connecting the AGV’s network with another AGV’s network, encapsulating data into IP packets.

Falling costs as the number of private 5G networks increases

5G technology is promising for wireless industrial data exchange, but challenges remain. Current hardware is not suitable for uRLLC communication, and Profisafe transmission is feasible but not reliable. Hardware for later releases is under development to address latency spikes in AGV applications. As costs decrease, private 5G networks will increase for customized applications. However, wide-ranging projects demonstrate the variety of applications 5G can create, especially in uRLLC applications in AGVs and robotics, highlighting its potential in industrial communications.

Learn more about Industrial 5G and Safety-related PLCs for Profisafe.