Efficient terminal strip construction and mounting

Control cabinet builders face challenges in cost-effectiveness due to rising costs and a shortage of skilled workers. This article covers the production and mounting process of a terminal strip, from digital construction to marking and mounting, highlighting efficiency solutions for each step.

Despite increased automation in control cabinet building, mounting tasks are mainly manual. Automation is mostly used for material and work preparation, such as preparing the mounting panel and housing, cutting cable ducts and DIN rails, and preassembling wires. Manual tasks include picking components, mounting, wiring, and testing, usually done on the installed mounting panel by a qualified specialist.

To solve these problems, mounting processes must be thoroughly analyzed. The first step is shifting from direct mounting in the control cabinet to upstream module mounting.

Software-supported DIN rail assembly with worker assistance systems

In upstream module mounting, the DIN rail is fully assembled before installation in the control cabinet. Digital preparation of diagrams and optimized workstations with worker assistance systems enhance efficiency.

Data consistency from engineering to production underpins these systems. For instance, most ECAD systems can export data to engineering software like clipx Engineer from Phoenix Contact. Consequently, this software centralizes all components, functions, and marking information, ensuring a seamless digital workflow and eliminating paper-based media discontinuities. Furthermore, the worker assistance software provides only the necessary information for each production step, avoiding extensive documentation searches.

Efficiency can be further increased by using a workstation with an interactive worker assistance system and a pick-by-light system. Controlled by the software, it displays the correct shelf section for each mounting step, guiding the employee through the process. This reduces search times and errors, significantly boosting efficiency, and allows semi-skilled workers to perform mounting tasks.

Marking requirements

After assembling the DIN rail, it is marked for clear, permanent identification, enhancing safety and workflow efficiency. Uniform marking of components can save up to 30% of production time. Phoenix Contact offers a comprehensive range of marking solutions, including versatile materials and intuitive systems, supporting various technologies like thermal transfer, UV inkjet, and laser marking.

Simplifying the identification process with the aid of worker assistance systems

The construction and identification of a DIN rail involve various components and project variations. The worker assistance system simplifies selecting, creating, and mounting markings by using information from the engineering software, preventing errors. Employees use marking software to choose the right marking systems and materials, which are then printed. The system guides users step-by-step in applying the markings, reducing errors and enabling semi-skilled workers to handle complex projects.

Efficient mounting of terminal strips

After constructing and marking the terminal strip, it is mounted in the control cabinet. The challenge is that the elongated holes of the DIN rail are often inaccessible due to mounted components, making it difficult to secure the rail. This has led many builders to prefer the classic method of attaching the DIN rail first and then adding components.

Current methods to mount terminal strips include:

• Leaving spaces for fixing points, which reduces the rail’s capacity.
• Removing and remounting components around fixing points, which is time-consuming and poses a quality risk if components are not correctly repositioned.

Railfix adapters from Phoenix Contact simplify mounting fully assembled terminal strips without front access to elongated holes. The adapters are pre-mounted on the panel, and the DIN rail is placed into the locking clips with guide elements. Using a screwdriver, the rail is levered under the clips and secured with an M5 screw.

The mounting distances of Railfix adapters depend on the DIN rail pitch and the load from mounted components. The zinc die-cast adapters are electrically conductive, allowing shield currents to discharge to the mounting panel.

Read more control cabinet building.

Uncooled DC charging cables for realizing a wide range of charging solutions

With reliable DC charging infrastructure, charging electric cars on medium and long-distance journeys at semi-public and public stations is now practical for everyday use. Long charging times are a thing of the past.

Even with uncooled DC charging cables, charging currents up to 375 A and short charging times are achievable. Power transmission requirements vary by location and application, so optimizing the charging infrastructure makes sense for many operators. The robust Charx connect DC charging cables offer future-proof features and power versions from 150 A to 375 A.

The right power in the right place

Charging infrastructure should match application-specific criteria. For example, a DC home charger isn’t suitable for a highway parking lot, nor is an HPC quick charging station for a residential area. The key factor is the average time a vehicle spends at the location: HPCs are ideal for short stops at highway rest areas, charging parks, and interstates. Medium power stations (50-100 kW) are best for 30-minute to 2-hour stops, such as at shopping centers and supermarkets. Lower power DC charging is suitable for longer stays, like at tourist destinations, amusement parks, and sports stadiums.

DC charging is ideal for tourist destinations like amusement parks and sports stadiums. It also suits private and professional applications, especially with easy DC voltage access (e.g., large photovoltaic systems). Differentiating DC from AC charging requires careful consideration. Phoenix Contact’s charging cables support various DC applications, enabling cost-effective infrastructure. The new CHARX connect standard CCS connectors cover 150-250 kW. CHARX connect professional, with a 4 x 50 mm² conductor, operates HPC stations at 375 A without cooling up to 40°C and higher currents in Boost Mode.

Safe and robust in outdoor applications

The clever sealing concept of the CHARX connect standard DC charging cables ensures complete longitudinal water tightness. Protecting the live parts inside the housing against moisture. This maximizes electrical safety for the user while increasing the failsafe performance of the charging infrastructure.

The innovative two-chamber sealing system marks the next stage in the development of the DC charging cable sealing systems from Phoenix Contact: by physically separating the DC+ and DC- power contacts, short circuits can be completely ruled out.

High-quality materials also ensure the necessary robustness and long service life of the charging connectors – even in constant outdoor use under harsh conditions.

Prepared for four-conductor measurement technology

For reliable billing compliant with calibration laws, DC charging cables and connectors are prepared for four-conductor measurement technology, making them future-proof. This technology records power dissipation in the cable to precisely determine the energy transferred to the electric vehicle.

Sustainable, easy, and cost-effective: repair kits

Despite their robust materials, charging connectors at semi-public or public stations require regular maintenance due to improper handling. Damage often occurs on the mating face. Repair kits allow quick and easy replacement of mating face frames and power contacts, making Charx connect DC charging cables easy to maintain, saving time and costs, and increasing infrastructure availability.

This eliminates the need for costly and time-consuming complete cable replacements. This maintenance is more economical and sustainable.

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Single Pair Ethernet (SPE) enhances modern communication infrastructures. Phoenix Contact offers a comprehensive SPE product portfolio, providing technical solutions and cross-industry expertise.

Unlike conventional Ethernet, Single Pair Ethernet (SPE) uses just one wire pair to transmit data and power. It supports transmission rates from 10 Mbps over 1,000 m to 1 Gbps over 40 m, making it ideal for demanding applications like networked sensors and camera systems. SPE overcomes previous limitations in data rates, ranges, and seamless communication.

Connections of up to 1000 m

Conventional Ethernet is limited to 100 meters for point-to-point connections, requiring additional repeaters or switches for longer distances, which are prone to faults and maintenance. Single Pair Ethernet (SPE) connects devices up to 1,000 meters at 10 Mbps with one cable and supports Power over Data Line (PoDL) technology. SPE can replace specific fieldbus technologies and supports complex network topologies with speeds from 10 Mbps to 1 Gbps. New SPE standards being discussed could enable data rates of ≥10 Gbps for short distances (<15 m) and 100 Mbps for up to 500 m, opening new application fields.

Seamless and secure data communication

Classic industrial systems used Ethernet and many fieldbus systems. The Industrial Internet of Things (IIoT) is making these topologies obsolete, requiring more efficient communication systems. This shift is seen in all applications needing seamless sensor and network communication, where secure data connections are critical.

Cost-efficient factory automation

Factories generate about one terabyte of data daily, and this is increasing. Continuous communication is essential for effective data evaluation. Single Pair Ethernet (SPE) ensures consistent networking from sensors to the cloud. With more sensors and intelligent devices in industrial applications, SPE is the ideal cabling solution—simple, secure, compact, and cost-effective. SPE will be cheaper than current bus and Ethernet component combinations.

SPE and robots: Space-saving and high-performance

Single Pair Ethernet (SPE) benefits autonomous and collaborative robots with higher data transmission rates than conventional fieldbus systems, enabling better communication. It simplifies cabling by combining data and power in one line. Future hybrid SPE solutions will include data and power contacts in one connector. Fewer cables and connections mean fewer errors, faster troubleshooting, and easier maintenance. The smaller bending radius of SPE also optimizes robot handling system design.

Process automation with SPE

In process automation, such as in the oil and gas sector, large sites require complete status overviews and remote control with consistent data flow from sensors to the cloud or ERP systems. Single Pair Ethernet (SPE) provides efficient network structures without intermediary devices. Power over Data Line (PoDL) with SPE enables simultaneous data and power transmission.

Process automation with SPE

In process automation, such as in the oil and gas sector, large sites with massive buildings or tanks are common. Companies need a complete status overview and remote control of all locations with consistent data flow from sensors to the cloud or ERP systems. SPE enables efficient network structures without intermediary devices for signal modulation or gateways. PoDL combined with SPE allows simultaneous data and power transmission in these applications.

APL technology for explosion-protected areas

The Advanced Physical Layer (APL) standard meets high data and power transmission
requirements in explosion-protected areas (zones 0, 1, and 2), used in the
process industry. It combines the 10BASE-T1L standard with the 2-WISE standard
for explosion protection and intrinsic safety. APL covers large distances (up
to 1000 m trunks, 200 m spurs) and ensures interoperability between devices
from different manufacturers. It supports predictive maintenance and modernizes
existing systems cost-effectively using existing cabling and Ethernet protocols
like EtherNet/IP™, HART-IP, OPC UA, and PROFINET. APL benefits industries such
as oil, gas, and chemicals by enabling secure, efficient, and future-proof
networks.

Range advantages for the energy sector

Single Pair Ethernet (SPE) benefits renewable energy management, which requires intelligent data handling due to fluctuations. For wind turbines and photovoltaic systems, energy must be measured and fed into the grid intelligently. Modern wind turbines exceed 100 m in height, making conventional Ethernet insufficient. Operators use fiberglass or wireless solutions, but SPE’s increased range is advantageous for covering these distances in wind turbines, solar parks, and power-to-grid/gas systems.

SPE via connector or terminal block

SPE’s performance benefits devices with smarter, more compact, and complex functions in building technology and industrial applications. Device manufacturers need to consider connection technology, often requiring IP protection. Options include IP-protected connectors or cable glands. PCB terminal blocks suitable for SPE can be used inside devices, offering placement flexibility and ease of installation with familiar screw and Push-in connections. Clear color coding of SPE cables helps avoid installation errors, even in challenging environments.

Space-saving connection technology

SPE PCB terminal blocks excel in IP20 environments, like building technology, where space constraints limit connector use. They are ideal for distributor boxes and flush-mounted sockets, offering a space-saving alternative. These terminal blocks allow flush-mount and DIN rail devices to connect directly via an SPE installation cable and integrate into the network.

Discover more about SPE technology

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.

Explosion protection and functional safety included

Power-to-X technologies are  becoming increasingly important for the All Electric Society. Compact Ex i signal conditioners with SIL 3 are vital for their safe use.

Technically, the All Electric Society offers a solution to the climate crisis and sustainable development. This vision involves using renewable electrical energy as the main, inexpensive, and abundant energy source. Achieving this requires comprehensive electrification, networking, and automation across all sectors—industry, mobility, infrastructure, buildings, and energy. Sector coupling integrates power generation, distribution, storage, and consumption into a holistic system, allowing energy exchange and optimal control through data evaluation.

Society’s energy needs will continue to rise, while fossil fuel use must be drastically reduced to cut carbon emissions. This presents challenges and opportunities, such as increasing renewable energy production. However, renewable sources depend on external factors like weather, making energy storage systems crucial. These systems buffer surplus electricity and convert it back when needed. Power-to-X technologies offer solutions for energy storage and further carbon emission reductions.

Use of green hydrogen in heavy industry is essential

Power-to-X technologies convert electrical energy into chemical energy sources, with “X” representing various chemical products from electrolysis or other processes. Green hydrogen production from renewable sources is the foundation for all power-to-X applications. Hydrogen is used to produce ammonia (mainly for fertilizer) and methanol (a raw material for the chemical industry).

Besides energy storage, power-to-X applications are crucial for heavy industry energy consumption. Green hydrogen is essential for industries like steel, chemicals, and refineries, which rely on fossil fuels. Since substantial electrification isn’t feasible, power-to-X is the only alternative to reduce carbon emissions.

Power-to-X applications require modularity due to the use of many small decentralized systems and control boxes. Explosion protection and functional safety are crucial because of the combustible gases generated. Phoenix Contact offers a comprehensive range of products and solutions for explosive areas, including the new Mini Analog Pro intrinsically safe signal conditioners.

High level of operating convenience, even in limited spaces

In modern process and power-to-X systems, intrinsically safe explosion protection and functional safety are crucial. Limited control cabinet space often reduces product handling convenience. Phoenix Contact’s Mini Analog Pro offers compact, user-friendly devices for intrinsically safe and safety-related measuring lines. The new signal conditioners and transducers include SIL 3 1oo1 functional safety for all signal types—analog, digital, control, and measuring signals—within a 6.2 mm width.

The Mini Analog Pro family allows easy conversion to digital protocols via modular communication modules without extra space. Compatible with Modbus RTU, Modbus TCP, Profinet, and Profibus, up to eight signal conditioners can form Mini Analog Pro gateways. This eliminates the I/O level and specific input cards, ensuring direct digital network connection, channel-specific electrical isolation, and precise signal transmission.

Broad product portfolio for power-to-X applications

To achieve a sustainable future, significant carbon emission reductions are essential. Power-to-X technologies are crucial in the energy transition, replacing fossil fuels where electrical alternatives are limited. These applications are efficient and scalable due to their modular and decentralized structure. Safety aspects like explosion protection and functional safety are vital, and the Mini Analog Pro signal conditioners meet these requirements. Phoenix Contact offers a wide range of products and solutions for power-to-X applications, making them a reliable partner for system extensions.

Read more about power-to-X

Cost-effective and comprehensive inspection based on machine learning

Automating quality control with AI-based image processing requires a suitable network and automation concept. Phoenix Contact supports system evaluation and component selection, as shown in this example from an international automobile manufacturer.

The automobile manufacturer maintains high quality standards by inspecting and optimizing all car components. Automated quality inspection is crucial for cost-effective control, using sensors (like ultrasonic sensors or cameras) to detect defects, which are then evaluated and corrected by robots. In the body shop, weld quality is a major focus, as proper welding ensures vehicle stability and durability. Additionally, removing weld spatter is essential to prevent damage to cables laid later.

Previously, inspection involved manually swiveling car bodies and illuminating them with diffuse lighting, then removing weld spatter with a Dremel tool. To automate this, the manufacturer conducted a feasibility study using eight cameras for inspection and a robot-guided rotary tool to remove the weld spatter.

Flexible fields of application due to the generalization properties

Implementing automated weld spatter removal with cameras and robots requires additional software. Firstly, this software synchronizes cameras and lighting for brightness control. Next, it inspects images for weld spatter. Then, it converts the position into the robot’s coordinate system. Finally, it guides the robot to remove the spatter with its rotary tool.

In this system, industrial image processing detects weld spatter, implemented either rules-based or via machine learning (ML). The manufacturer chose ML for its flexibility with different component shapes. The pretrained ML model learns to detect weld spatter based on properties like shine, shadows, or shape, making it adaptable to various automotive parts and spatter appearances.

In the ML process, images of components with and without weld spatter are taken. The spatter is manually identified and described using coordinates or bounding boxes. This data trains the model, and the descriptions check recognition accuracy. The trained model is then tested on new images. Due to generalization, it can detect spatter on previously unprovided images, serving as an identifier for removal.

Joint evaluation of a coordinated automation and network concept

Besides the automated quality control solution, a coordinated automation concept is needed. This includes connecting and powering cameras and lighting, using a PLC to control the line and robots, execution units for ML processes, and a control station for human-machine interaction. Additionally, components must form an efficient, interference-free network. Phoenix Contact assisted in creating the concept and evaluating suitable ML hardware.

Proven systems from the Blomberg-based company, already in use at the automobile manufacturer, were utilized for automation, network connection, and control stations. For ML processes, the manufacturer provided pretrained models, which Phoenix Contact integrated into a machine learning runtime environment and tested on various industrial PCs (IPCs). CPU and RAM utilization were verified in endurance tests. The results helped select the most cost-effective hardware. Phoenix Contact also offers hardware, software, and services for other industries through its Digital Factory now campaign.

Future potential through virtualization, GPU extensions, and Time-Sensitive Networking

The chosen concept perfectly meets the automobile manufacturer’s current needs. Future ML technology developments will offer more optimization potential. Container virtualization will enable automation services and ML processes in IT or cloud environments. Model execution can be accelerated with industrial PCs using GPUs. Currently, automation and camera networks must be separate, but Time-Sensitive Networking (TSN) can combine them, reducing complexity. Phoenix Contact is working on TSN applications. Regular technology days and information exchanges help tailor these technologies to the automotive industry’s needs.

The automobile manufacturer already uses ML processes for automated quality control. Phoenix Contact supports evaluation, automation, and network concepts with its hardware, software, and services.

Read more about AI-based quality control in the body shop.

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).

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