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.

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.

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.

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.

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

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 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.

Learn more about CHARX technology.

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.

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.

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.

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.

Learn more about PLCnext Technology.

Significant cost savings

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.

Evaluating the requirements on connection technology holistically

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

The challenges in practice

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

Standardized basis for safe connectors

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

Failure causes and starting points

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

Selection criteria

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

General conditions are decisive

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

Learn more about Phoenix Contact’s PRC series.

Full speed ahead

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

Structure of private cellular networks

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

Low cabling overheads in wide-area networks

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

Forwarding small data packets quickly and reliably

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

Falling costs as the number of private 5G networks increases

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

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

Urgent need for action for all stakeholders

The EU Cybersecurity Strategy, published in December 2020, focuses on resilience and attack blocking for major manufacturing companies. The strategy aims to implement security by design in products and systems, addressing the increasing attack area for cyberattacks and the increasing professionalism of attackers. Cyber security focuses on securing a company’s value creation and individual security objectives, including protecting know-how and complying with legal regulations. Significantly, the EU is now extending legal requirements for cybersecurity to include more companies.

Implementation in the automation sector

Based on ISO 27001/2, the information security management system (ISMS) in IT is being extended to operational technology (OT). Measures in the IACS environment can be applied by incorporating organizational and technical criteria, as part of this expansion. These measures include network configuration, data protection, user authentication, monitoring, device security hardening, and system management. The IEC 62443 series of standards addresses specific measures for the IACS environment, covering components, systems, operators, and service providers. The comprehensive security-by-design approach, known as the “defense-in-depth” concept, makes access more difficult for attackers.

Upvaluation of regulations through NIS 2

The EU’s NIS 2 directive, mandating cybersecurity measures for public and private entities, is changing the landscape. Specifically, it applies to companies with over 50 employees and more than 10 million euros in sales, focusing on essential and important facilities. Commencing from January 16, 2023, this directive must be transferred into national law by October 18, 2024. However, implementing security-by-design in products is challenging, and the EU has introduced the Cyber Resilience Act (CRA) to address this issue.

Development of security-by-design products in accordance with the Cyber Resilience Act

The Cyber Resilience Act (CRA) mandates manufacturers to create security-by-design products, ensuring they receive a CE mark if they comply with regulations. Minimum security measures must be demonstrated through conformity tests or manufacturers themselves using a harmonized standard. The CRA includes access protection, confidentiality protection, integrity, availability, and a secure delivery state. It also includes vulnerability management and regulations for manufacturers to provide security updates. The draft text of the CRA is in trialogue, expected to become EU law in 2024. To meet vulnerability management requirements, products must have a standardized Software Bill of Material and known vulnerabilities must be available in a standardized digital format.

Consideration of security in the new Machinery Directive

The Machinery Directive 2006/42/EC mandates machines to be equipped with functional safety technology, ensuring the protection of people and the environment from injuries or contamination. However, this standard requires updates due to new technologies and product safety regulations. Looking ahead, the Machinery Directive 2023/1230, set to be published by mid-2023, combines functional safety with cybersecurity.

360-degree security based on IEC 62443

Phoenix Contact, a German company, has implemented IEC 62443 since 2017. In this time frame, it has focused on a 360-degree security concept throughout its products and solutions. The company follows a secure development process, ensuring security-by-design and defense-in-depth. Additionally, It actively monitors vulnerabilities and provides regular security updates. Moreover, the company’s secure products comply with IEC 62443-4-1 and IEC 62443-4-2, including denial-of-service protection, user management, and data confidentiality. Furthermore, the company’s security services are certified by IEC 62443-2-4. The Phoenix Contact Security Team has developed templates for various solutions and markets, and the Product Security Incidence Response Team (PSIRT) manages security issues. Importantly, all certifications are monitored by TÜV Süd through annual audits.

Learn more about Industrial security.

Who still needs fossil fuels?!

Phoenix Contact aims to support national and international users in implementing an All Electric Society (AES) by 2030. The All Electric Society Park in Germany demonstrates this by demonstrating the path from renewable energy production to distribution and consumption. The park covers over 7,800 square meters and uses advanced battery and hydrogen synthesis systems to store energy for future use. Visitors can see the efficient use of energy at charging stations, production facilities, and transportation infrastructure. The park’s interactive glass cubes provide a self-explanatory view of energy availability and demand.

Solar panels on trackers and roofs, on the facade, and on the sidewalks

The All Electric Society Park utilizes 550 solar panels, solar trackers, and automation technology to generate 155,000 kilowatt hours of green electricity annually. Furthermore, Solar pavers and wind turbines are integrated into the park, ensuring renewable energy from the sun and wind.

Storage system as a battery booster for e-vehicle fast charging

The All Electric Society Park has two battery storage systems, one with a 1.2 megawatt-hour capacity and the other 281 kilowatt-hour capacity. The smaller system, located in the charging park, functions as a booster battery for electric vehicle charging.

Energy management system for evaluating energy flows

The transformer station is the central electrical hub of the All Electric Society Park. Distributing energy generated by solar systems and wind trees to loads like charging stations, cubes, pavilion, outdoor lighting, and irrigation. IoT-capable EMpro energy measuring devices record outgoing flows, allowing efficient park control. The park connects to the Phoenix Contact corporate grid via a smartRTU, a modular wireless solution designed for monitoring distribution grids and decentral power generation systems.

Sustainability even with the construction and cooling materials

The transformer station houses medium and low-voltage switchgear with transformers, disconnectors, and fuses. Sustainability was prioritized, using air instead of SF6 as an insulating medium and biodegradable ester fluid for cooling. Notably, carbon concrete was used instead of reinforced concrete. which led to a reduction in wall thickness by around one-third. Greenery on the facades and roof contributes to microclimate and small animal habitats. Looking ahead, future transformer stations will be located in cities for better air quality and cooling.

Creating awareness of the technical possibilities

Phoenix Contact is implementing an electrical energy management system using PLCnext Technology control technology to ensure reliable power supply to park devices. The system integrates park devices like inverters, storage systems, and charging stations into the system. Allowing data and values to be accessible. With a broader perspective, All Electric Society Park aims to raise awareness about the company’s future vision and technical capabilities, showcasing real applications and educational presentations. The park opened to the public on September 1, 2023.

Learn more about All Electric Society.

Innovative inner workings ensure the safety of DC connectors.

Phoenix Contact offers the ArcZero series DC connector to address safety risks associated with DC power grids. Despite its efficiency improvements and simplified installation, direct current is prevalent in electronic devices and production machines. Despite the decline of DC technology, direct current is making a return in the form of intelligent DC grids in an electricity-led energy revolution.

Into the future with direct current

Countries worldwide are actively working to reduce net carbon emissions to zero by enhancing both renewable energy availability and energy efficiency. To achieve this, there is a concerted effort to modernize power stations, upgrade motors, optimize industrial processes, and renovate buildings. In parallel, the adoption of direct current loads is rising in diverse devices such as lighting, IT infrastructure, and electric motors. Notably, the transition to energy-efficient LED lighting is replacing traditional incandescent lamps, while inverters in intermediate circuits contribute to heightened efficiency. Direct current, pivotal in power generation and consumption, assumes a central role across various societal areas.

Requirements on DC connectors

Direct current displaces alternating current, changing component requirements and grid behavior. Protection concepts cannot be adopted one-to-one, and grid behavior varies significantly. The electric arc during switching and disconnecting operations is crucial in DC applications, as zero crossings occur 100 times per second. Phoenix Contact has conducted test programs to understand DC electric arcs, developing technologies and prototypes for safely connecting and disconnecting connectors in DC power grids. ArcZero is a new connector for DC power grids.

ArcZero tames the arc

The ArcZero connector features integrated electronics that actively quench the electric arc, providing the same level of safety as AC connectors. This reduces wear and increases connector longevity. It allows safe connection and disconnecting under load, ensuring high availability. The connector is designed for IP69 protection, high-impact strengths, and long-term outdoor suitability. It can connect end and distribution circuits up to 20 amps and 400 volts or 800 volts. It is user-friendly and cost-effective, with numerous insertion cycles.

Learn more about the DC connector.

The use of battery energy storage systems in power-to-X applications

The All Electric Society concept describes a future where renewable energy is the primary source of electricity worldwide, affordable, and abundant. Energy storage technologies, such as power-to-X and battery systems, are crucial for this vision, with the greatest potential in battery energy storage systems and green hydrogen production.

Power-to-X as an energy storage technology

Hydrogen is stored in renewable energy through electrolysis, breaking down water into hydrogen and oxygen. This gas is compressed and stored in tanks. When electrical energy is needed, hydrogen reacts with air in fuel cells to form water, We refer to this process chain as power-to-X technology.  The term generally refers to the conversion of surplus renewable energy into other energy carriers.

Battery energy storage systems

Battery storage efficiently stores electrical energy through chemical conversion in galvanic elements, allowing current to flow through electrodes connected via an electrical load.

Short and long-term storage

Battery storage differs significantly from power-to-X processes, as batteries require large, expensive batteries with precious materials. Unlike hydrogen storage, which is less expensive and has a higher energy density, power-to-X technologies have lower conversion efficiency due to waste heat generation. However, battery storage has over 90% efficiency, making it suitable for shorter storage periods, such as hours or days. This makes battery energy storage more economically viable for long-term storage.

In combination lies strength

The hydrogen process and battery differ in inertia, with batteries storing energy quickly and electrolyzers and fuel cells requiring power proportional to reactor size. Both operate at maximum efficiency within a small process window, avoiding major fluctuations. Combining these technologies can provide hybrid solutions for stationary or quasi-stationary electricity generation, covering consumer base load and battery for short-term load fluctuations. Electrical connection technology ensures efficiency and reliability.

The role of electrical connection technology

Electrical connection technology is crucial for efficiency and reliability in batteries, electrolyzers, and fuel cells. It requires power, signal, and data connections, with analog signals controlling sensors and digital communication systems.

Examples of faults in the connection technology

Inconspicuous components like power wiring, signal connections, and data connections are crucial for system safety. Classic screw connections can loose in unfavorable conditions, leading to increased contact resistance and heat loss. Signal connections, such as sensor cables, can be soldered directly, resulting in cold solder points and incorrect temperature measurements being too low. Data connections, often created using patch cables, can also cause faults during transmission, leading to system malfunctions and hardware damage.

Recommendations for selecting connection technology

To avoid financial losses, system operators should use plug-in connectors for power connections when installation conditions cannot be guaranteed. Innovative connection technologies like insulation displacement connections offer convenience and reliability. For data connections, ambient conditions dictate requirements, with IP-protected data connectors ideal for high pollution or humid environments and industrial-grade connectors for tough mechanical conditions.

The importance of modular automation systems in energy storage applications

Battery-based and hydrogen-based energy storage solutions are complex systems with functional safety, IT security, and explosion protection requirements. Automation systems aim for optimal control of subsystems, considering user objectives, minimum operating costs, service life, and availability. Compliance with grid connection conditions is also crucial. Simulating system design in advance is advantageous. A modular, scalable automation platform with relevant certifications reduces development times and costs for energy storage applications. Automation suppliers offer comprehensive services, including safety concept creation, IT security considerations, and programming.

Learn more about Solutions for electrification, networking, and automation in the power-to-X and hydrogen industry. and Connection technology for energy storage systems.