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.

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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. 

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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.

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

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

Features of a floating connector

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

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Direct, on-site mobile marking for electrical installations

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

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

Digitalization of marking processes

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

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

Sector coupling

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

The role of energy storage systems in an All Electric Society

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

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High-speed data transmission for industrial applications

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

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

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

The advantage of fiber optics

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

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

Speed and distances

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

Reliability and security

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

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

Costs

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

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Simple implementation with the PSRmodular and AXL F series

Phoenix Contact offers two series of analog signals for monitoring physical variables in process engineering systems. These signals are standardized as either a (0)/4 … 20 mA or a 0 … 10 V signal, with current signals being more robust against electromagnetic interference and having high measuring accuracy over longer cable lengths. Furthermore, the concept considers whether the sensor is powered by the evaluation module or supplied by an external source.

Consideration of load and measurement information

The analog evaluation module distinguishes between active and passive inputs, requiring external supply for passive inputs. Load consideration is crucial when engineering analog signals, and signal conditioners are recommended if it exceeds active inputs. Moreover, NAMUR recommendation NE43 defines signal levels for failure information of digital measuring transducers with analog output signals, with current values outside these limits considered invalid or failure information. The evaluation unit must provide corresponding information or respond to deviations.

Design of functional safety

Single-channel analog signal generators can be used for safety-related circuits up to SIL 2/PL d. While two-channel signal generators can be used up to SIL 3/PL e. MTTFD values can be determined based on sensor manufacturer failure rates. Furthermore, Diagnostic coverage (DC) is required for safety-related analog signals, but plausibility comparison is difficult due to measurement inaccuracies and ambient conditions. Two-channel architectures should allow short-term deviations outside the tolerance range, without impacting functional safety.

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Overview

In this blog article, we will explain the magneto-optic effect’s principle for monitoring surge currents in lightning strikes. We will use the example of a lightning monitoring system in wind power plants, monuments, and power transformation substations.

Lightning monitoring on exposed objects

Lightning strikes can cause severe damage to buildings and systems, especially in residential or commercial buildings. One can quickly evaluate the extent of damage and immediately repair it, preventing consequential damage. However, employees cannot continuously monitor exposed objects or large surfaces like wind power plants or railway systems. That’s why the use of Intelligent monitoring systems is becoming more common to permanently monitor system function states and send results to a central control unit. This allows for immediate response in case of malfunctions and prevents consequential damage and long downtimes. Until now, no measuring system could reliably detect and evaluate lightning strikes.

New monitoring technology with the Faraday effect

A new monitoring system uses the Faraday effect and magneto-optic effect to analyze surge currents in lightning arresters. Moreover, a fiber optic cable transmits signals, preventing lightning currents from influencing the light signal. This ensures reliable and EMC-protected signals for the evaluation unit electronics, ensuring efficient and reliable monitoring and measurement.

Structure of the measuring section

The measuring section is a transparent dielectric with polarizers at either end, positioned 90 degrees to the current flow direction in the down conductor. Consequently, Ensuring that the propagation direction of a light wave is parallel to the surge current’s magnetic field.

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DC technology: Test facility shows potential savings

DC grids in the automotive industry are a key step towards climate neutrality. A production plant in Dingolfing, Bavaria, uses Phoenix Contact components to supply a unique DC grid system for robotic arms and automotive parts.

It was AC power supply in the beginning

In the late 19th century, Thomas Edison (DC) and George Westinghouse (AC) fought over large-scale power grid supply. Ultimately, choosing alternating voltage is due to AC voltage’s ability to be transformed up and down.

The advantages of direct current

DC technology offers efficient direct current usable at a low cost. Making it suitable for electronic devices, electric cars, and renewable energy. Furthermore, DC grids can eliminate lossy AC/DC conversion and integrate renewable energy systems efficiently. Moreover, Phoenix Contact provides solutions for intelligent control of power flow and networking, ensuring high availability and supply security.

Direct current as a key technology

Phoenix Contact, a family-owned company, has been supporting BMW in their research into using Direct Current (DC) technology in a production cell at their Dingolfing plant. The company, a member of the Open Direct Current Alliance, has been able to provide rapid support and optimize the existing DC product portfolio through practical applications. This move aims to use renewable energy efficiently and conserve energy and material resources in an All Electric Society.

From theory to practice

Phoenix Contact’s High Power Systems range converts public AC grids into DC grids with 19-inch devices connecting DC subnetworks. Moreover, the wide output voltage range allows gradual ramping up the grid. Furthermore, the performance parameters can be parameterized via the PLCnext platform. Phoenix Contact’s Contactron ELR HDC DC circuit breaker and ArcZero connector ensure safe plugging and unplugging under load.

Read more about DC grids in industry and Solutions for automotive manufacturing.