Using existing infrastructures for SPE

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SPE

Phoenix Contact tested various cable types in building automation to determine if existing cables can be reused for Single Pair Ethernet (SPE). The investigation compared the technically relevant sizes of the cables with the limit values of ISO/IEC 11801-3, IEEE 802.3cg, and IEEE 802.3da. In addition, the quality of signal transmission over different cable lengths was examined using parameters to assess signal integrity.

Determination of the cable types

Determination of the cable types

The KNX protocol is widely used in building automation in Europe, particularly in Germany. J Y(ST)Y 2x2x0.8 type cables are used for bus signals, power installations, and process data processing. The YV 2×0.8/1.4 jumper wire, also known as a bell wire, is used for point-to-point connections. These cables were examined for their reuse in SPE connections.

Selection of suitable measured variables and measurement methods

Selection of suitable measured variables and measurement methods

The Fluke DSX 8000 field tester was used for cabling measurements, qualifying Ethernet cabling, and testing patch cables. In contrast, comparative measurements were conducted using the ZNBT vector network analyzer. Cables with good transmission properties meet limit values for RL, IL, and TCL and require constant independence of the cable. Phoenix Contact SPE connector was used for easy connection.

Investigation of realistic cabling structures

Investigation of realistic cabling structures

Moreover, existing bus line infrastructures can have unknown topologies, making it difficult to dismantle the installed cables. The transmission path has branch lines of varying lengths. A T-shaped line arrangement with master cables and branch lines was examined. The results showed that short cable lengths and non-terminated cable ends were problematic. Long cables were found suitable for SPE transmission.

Signal-based investigations

Signal-based investigations - SPE

The KNX bus line and jumper wire’s Signal-to-Noise Ratio (SNR) and Slicer Maximum Absolute Error were measured using two evaluation boards. The KNX bus line achieved a maximum range of 420 m with a minimum SNR of 30.1 dB and a Slicer Maximum Absolute Error of 0.15, while the jumper wire reached a maximum range of 910 m.

Learn more about Single Pair Ethernet.

Push-X: Tool-free connection increases efficiency

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Push-X technology

New connection – yet proven a billion times over

Phoenix Contact has introduced the Push-X technology, a tool-free connection method that enables flexible conductor connections without pretreatment. This innovative technology uses the Push-in connection from Phoenix Contact, which has been used for years and is primarily found in the terminal block sector. Additionally, the new technology uses a trigger inside the terminal block, triggers a pre-tensioned spring, and has been redesigned for vertical connection.

One connection compatible with all conductors

The Push-X system is suitable for all types of conductors, including rigid and flexible ones. It uses a pretensioned spring on delivery, releasing the locking mechanism with light pressure. Eeven the smallest flexible conductors can be connected without tools. The orange actuating push button signals the connection and audible feedback. The system is easy to release and reuse, with any tool being used to return the button to its original position.

Push-X technology

New to the market, but already a whole family

The Push-X family has also introduced new XTV terminal blocks, available in nominal cross-sections of 6 mm², 10 mm², and 16 mm². These terminal blocks are part of the Clipline Complete system, offering advantages such as vertical connection, lateral entry, and easy-to-read terminal point marking. Furthermore, the XTV technology is compatible with other systems and can be combined with other accessories. So, switching to using terminal blocks with Push-X technology will not be a problem. The terminal blocks are similar to spring-cage and Push-in terminal blocks.

Save a lot of time with Push-X technology

The All Electric Society is transforming infrastructure for renewable energy distribution and storage, increasing demand for switchgear and controlgear systems. To improve efficiency, tool-free connection technologies like Push-in and Push-X are being used. Push-X eliminates the need to change tools and requires no further checks, making it quick and easy to switch.

Learn more about Push-X technology

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

Learn more about System cabling for controllers.

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
Learn more about data connectors.

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.