How migration works

Process engineering systems, often based on automation technology from the late 1990s or early 2000s, need an innovation boost to remain competitive. Digitalization offers opportunities for more efficient working, better insight into processes, and additional functionalities. Furthermore, the migration towards Ethernet-based communication promises greater openness and higher transmission speed. Consumers are increasingly thinking online. However, process automation still requires systematic thinking and a pragmatic approach. The NAMUR Open Architecture (NOA) allows for the installation of additional sensor technology and monitoring elements, such as machine learning, artificial intelligence, and cloud services, without disrupting ongoing system operation.

Cooperation between OPAF and NAMUR

Open Process Automation (OPAF) is based on the idea of a modular IT world with process-oriented systems and long-term availability. Moreover, it has developed into an internationally active consortium of renowned system operators, technology manufacturers, standardization organizations, and software companies, collaborating with NAMUR for pilot projects and industry expertise.

Axioline F I/O system for implementing the NOA side channel…

In addition, the Axioline F I/O product family and PLCnext Technology controllers are used in pilot projects. This modular system, originally designed for factory automation, can implement NOA side channels or data diodes. Since 2020, the portfolio has also included intrinsically safe I/O modules for NAMUR sensor technology, HART communication, and valve controllers.

…and Axioline P with proxy functionality

Phoenix Contact introduced the Axioline P, a high-availability I/O system for process automation, at Achema 2018. The system offers both conventional I/O modules and Profibus PA proxy functionality, allowing hot-swap and dynamic reconfiguration. Furthermore, it can integrate up to eight Profibus PA segments in one Profinet I/O station, supporting 10/100 Mbps Ethernet transmission. The Axioline P proxies also provide redundancy, shielding, and 14 watts of power per segment. The Phoenix Contact portfolio includes I/O modules with and without intrinsic safety for every applications.

Integration of the intrinsically safe power supply into the modules

Phoenix Contact has introduced intrinsically safe Axioline F and Axioline P modules in the XC Ex series, which eliminate the need for intrinsically safe power supply modules. The Axioline F system is used in NAMUR automation and PLCnext Technology controllers. The Axioline P module supports Profinet S2 redundancy and is used in zone 2 installations to connect field devices that are mounted in zone 2 or 1. The modules have a black power supply connector and partition plates. A Modbus/TCP version version of the Axioline P family will be launched in 2024, opening up new possibilities in open process applications.

Connection of up to eight Profibus PA segments

For migration, the Axioline P platform enables the connection of up to eight Profibus PA segments with high-power trunks and universal I/O connections into the field. It offers advantages in size and cost-effectiveness compared to previous designs. The intrinsically safe I/O modules provide greater flexibility. The first NOA and OPA pilot solutions were presented at the NAMUR Conference, and APL technology is predicted to be of great importance.

Learn more about process automation.

Customized solutions for classic point-to-point applications

Phoenix Contact offers a range of signal conditioners and measuring transducers for point-to-point wiring in industrial environments. These devices are used to safely isolate, filter, amplify, and convert electrical signals from field devices. The Mini Analog Pro series features intrinsic safety and functional safety, while the revised MACX Analog Ex device family and VIP I/O marshalling provide a comprehensive range of signal conditioners and measuring transducers. In addition, point-to-point wiring offers advantages such as easy installation, high flexibility, easy troubleshooting, and less interference. However, the wiring can be disadvantageous as each device must be connected to the controller. The Termination Carrier from Phoenix Contact eliminates this issue.

The main spectrum of tasks

Moreover, signal conditioners and measuring transducers are essential for safely isolating, filtering, amplifying, and converting electrical signals.

Signal amplification

Moreover, signal amplification is necessary when a weak signal and can therefore only be acquired in distorted or attenuated form. For example, adding an amplifier reduces the load connected to the measuring sensor to 70 ohms, preventing distortion and ensuring the measurement signal remains accurate.

Conversion to a standard signal

Depending on the measuring task, analog sensor signals can be converted into standard signals in an interface block. The conversion result should be proportional to recorded input values, to avoid distortion. Moreover, the standard signal converter adjusts the required signal between the transmitter and the evaluation unit.

Filtering

Furthermore, interference voltages in cables for measured value transmission can occur due to electromagnetic induction or high-frequency signals. Signal conditioners with filter functions detect and suppress these voltages, while twisted or shielded cables reduce induced voltage. To avoid interference, convert voltage signals into current signals.

Electrical isolation

An electrically isolated signal connection, referred to as a floating connection, is essential in the plant and process industry. It eliminates compensating currents between potential differences, ensuring the recording of identical signals. This is achieved by integrating a galvanic signal isolator into the connecting cables.

Line monitoring

Line monitoring is a crucial function in interface blocks, ensuring line interruptions and short circuits. It is detailed in NE 21 NAMUR recommendations. The figure illustrates line monitoring on the entire signal transmission path, with resistances ranging from 400 to 10 kΩ, ensuring maximum current and zero current in line breaks.

The diverse areas of application

Furthermore, the tasks described are required in various industries, including chemicals, oil and gas, infrastructure, cement, machine building, and renewable energies like wind and solar power.

Industrial process control

Signal conditioners and measuring transducers are commonly used in industrial applications to isolate, convert, and amplify analog signals from sensors or measuring devices for precise and reliable monitoring and control of the process.

Energy monitoring

Furthermore, devices are utilized for energy monitoring, accurately measuring and controlling energy consumption in buildings and industrial plants by isolating and amplifying electrical signals from current and voltage sensors.

Monitoring of process variables

Lastly, Phoenix Contact provides signal conditioners and measuring transducers for monitoring sensor signals, conforming to explosion protection standards, international approvals, functional safety certifications, and maritime applications.

Discover more about Signal conditioners and measuring transducers.

A reliable connection

Fiber-optic cables, often supplied by meters, the different types of fiber-optic cables require different connection technologies for field use. Additionally, they are commonly used for cabling data technology systems, with different fiber types like POF, PCF, and quartz glass. Moreover, suitable tool sets, connectors, distributor boxes, and cables are required for proper cabling and connection, with the fiber type planned for use serves as the starting point.

Use and connection of POF

Polymer optical fiber (POF) cables are often used in industrial environments with low data rate and range requirements. These cables have a plastic core and cladding, protected by a 2.2 mm diameter coating. They are typically used in breakout cables, which have two POF cores, filler material, and strain relief elements. Phoenix Contact offers a wide range of breakout cables with POF cores for different applications. In addition, specially adapted tool sets are the solution. They are used to connect connectors, making the assembly of POF fibers easy and safe.

Use and connection of PCF

Polymer-clad fiber (PCF) cables are used in industrial environments due to their robust design and high-quality workmanship. These cables have a 200 µm core and 230 µm cladding, enclosed in a plastic sheath with strain relief elements. 2-core breakout types are commonly used in harsh conditions. Moreover, different connector types are available for field assembly, with tool sets for each type. The cleaver, matched to the respective connector type, ensures a precise and optimally prepared fiber face. Additionally, Phoenix Contact offers PCF cables for various applications.

Use and connection of GOF

Pure quartz glass fiber (GOF) is increasingly used in industrial networks for fiber-optic cabling due to its high data rates, attractive cost, and easy management. Many specialist companies have established themselves in fiber-optic connection technology field, specializing in fusion splicing and large-volume connector assembly. Phoenix Contact offers the necessary cabling and connection technology products, including fiber-optic cables and fiber-optic splice boxes. However, if you prefer to perform GOF connector assembly in-field, a specially adapted tool set allows SC and LC connector assembly on site. Furthermore, The connectors contain factory-prepared fibers. All that remains to be done is to strip the cables and prepare the fibers. This results in a reliable, long-term stable connection with low attenuation values.

Learn more about Fiber-optic cables.

Wear-free wireless transmission of data and power

The Krah Group, a leading global supplier of power resistors for the automotive industry, has introduced a contactless NearFi power and Ethernet transmission solution. The company, based in Germany, has been manufacturing electronic components since 1970. It specializes in developing products with customers and employs around 2,000 people globally at sixteen production sites. The Krah Group is a founding member of the Automotive Center Südwestfalen e.V. association.

Contactless solution for mobile applications

Oliver Krause, team leader for automation and control technology at Drolshagen plant, explored alternatives to conventional connectors at Hannover Messe 2022. He discovered contactless NearFi technology for data transmission at Phoenix Contact’s booth. The laser welding machine processes workpieces in four steps. First, the workpieces are inserted, then, the workpieces are aligned with each other. The tolerances are then checked and the workpieces are welded. Finally, the finished workpiece is married and given a barcode. Sensors at each processing station are picked up by a Profinet I/O module, communicating machine states and workpiece positions to the controller. The data forwarding and power supply are contactless, making it wear-free.

Simple startup without configuration effort

NearFi couplers are a new solution for data and power exchange. Offering a flexible and customizable interface. These couplers can be positioned to face each other from any direction and rotate. Reducing the precision needed for mechanical movement. They also display operational readiness with bright LEDs, reducing service calls and maintenance costs. In addition, the contactless solution supports the Profinet Fast Startup function, preventing communication delays. The proximity couplers also offer a simple startup without configuration effort, making them a significant improvement over traditional inductive coupler solutions.

Protocol-independent Ethernet communication with no appreciable latency

Industrial automation relies on Ethernet with a 100 Mbps data rate, but NearFi technology offers contactless and protocol-independent Ethernet connections with low latency. NearFi couplers transmit 50 watts of power and real-time Ethernet data over a small distance, ensuring coexistence with existing wireless technologies like Bluetooth or WLAN. Moreover, Phoenix Contact’s IP65 housing and M12 connections make them suitable for demanding environments. NearFi couplers are ideal for moving applications with high interference risk.

Learn more about NearFi technology.

Control cabinet building can benefit from optimization through digitalization, lean management, and agility approaches. However, manual activities still dominate production, making automation difficult. Electrically skilled personnel are essential for wiring and adaptability, as they understand equipment requirements and can react to unforeseen challenges that cannot be mapped in a highly automated process.

The skills shortage exacerbates the problem

Traditional control cabinet building relies on well-trained electrically skilled persons for long-term success, and automation is limited. in addition, time is pressing to integrate the remaining electrically skilled persons into relevant production processes. Moreover, untapped potential in information flows and digital support exists, especially for small and medium-sized companies.

Weaken your weaknesses and strengthen your strengths

The saying “Focusing on strengthening your positive qualities and skills while trying to overcome your weaknesses” fits well the digitalizing of company processes. To implement this strategy, identify and categorize areas of the company based on their influence on the company’s success. These areas are typically technical and represent the company’s competitive advantage. The support categories include non-technical areas necessary for core competencies tasks, while organization categories include non-specific areas like HR departments. Introducing market-standard software can help digitalize these areas, addressing weaknesses. However, standard commercial software may leads to loss of unique selling points, impacting the company’s competitive advantage. The digitalization plan should consider practical requirements, employee needs, and company goals.

The role of detailed analysis

A thorough analysis of information flow is the first step towards optimizing. Understanding all work steps is essential to identify optimization potential. Digitalized worker assistance systems can help by directly supporting work steps with necessary data. However, ad-hoc integration and digitalization without prior analysis can lead to unnecessary data addition, making the problem worse. However, as humans, we are not good at processing large amounts of data quickly. More data is generally required for automation, but in manual production, it can lead to waste and inefficiency. The challenge lies in sorting and filtering existing data to make it more accessible to employees in a targeted manner.

Data is not always information

In digitalization projects involving people, it’s crucial to differentiate between data and information. The term data is used here as a generic term, regardless of its use, and information is the part of the data that is necessary or beneficial for the process. The implementation only considers data classified in the Information field, with redundant data included if necessary. Uniform implementation in the form of just a document, as is the case in production supported by paper documentation, is therefore not the optimal solution, as it can lead to the optimization of specialist processes. Paperless production is a welcome side effect of digitally supported optimization.

Learn more about control cabinet building.

Single Pair Ethernet (SPE) is a popular industrial communication technology that enables cost-effective and space-saving connection of sensors and extends the performance of classic Ethernet. It supports IP-based communication and Power over Data Line (PoDL) for IoT devices and other applications.

SPE continuity from IP20 to M12

Phoenix Contact has developed connectors for SPE environments with IP20 and IEC 63171-5 for M8 and M12 versions in IP67. These connectors are user-friendly, available as patch cables or freely assembled versions. They meet industrial requirements in terms of impedance, electric strength, return attenuation, and coupling attenuation necessary in industrial environments.

Simple design-in with uniform pin connector pattern

Phoenix Contact offers IP20 and IP65/IP67 connectors with a uniform pin pattern, simplifying handling and facilitates both servicing and installation. These connectors allow for easy assembly in the system field, and their standardized M8 and M12 housing screw connections allow for seamless transition from previous Ethernet or bus systems to the current standard. They are suitable for data transmission rates up to Gigabit and meet future SPE standards.

Advanced Shielding Technology – the shielding of the future

Phoenix Contact’s Advanced Shielding Technology replaces traditional zinc die-casting for crimp sleeves with a liquid metal shield connection. This innovative method increases mechanical robustness and prevents short circuits between the shield molding and contact carrier. The technology improves M8/M12 connectors by providing robustness, availability, durability, and overload resistance. It supports Industry 4.0 and the Industrial Internet of Things, supporting miniaturization in field and device cabling.

PNO supports SPE pin connector pattern of IEC 63171-7 for hybrid applications

The PNO guideline for “PROFINET Cabling and Interconnection Technology – Guideline for PROFINET Version 5.3” has defined hybrid M12 Single Pair Ethernet as the new pin connector pattern, marking the first time a user organization has opted for an SPE pin connector pattern..

M12 Hybrid – the perfect addition to PoDL

Single Pair Ethernet (SPE) offers the advantage of integrating power supply and data transmission via the same cable, making it ideal for supplying power and data in confined spaces. Phoenix Contact Group and TE Connectivity have developed SPE M12 hybrid connectors in accordance with IEC 63171-7, enabling hybrid interfaces with SPE and power contacts in M12 format. SPE is particularly beneficial in robotics, as it combines flexible and space-saving wiring with fast response times. SPE M12 hybrid interfaces integrate seamlessly into existing Ethernet infrastructures and offer simple plug-and-play connections.

Learn more about Single Pair Ethernet.

Into the green future with the Next Generation Control System

Phoenix Contact has partnered with ENERCON. A leading manufacturer of wind turbine generators, to develop future-proof automation solutions for their platforms. The alliance focuses on enhancing pitch, azimuth, and automation systems for new platforms with the e-nacelle. Moreover, Phoenix Contact, driven by the All Electric Society’s vision of renewable energy availability and affordability, focuses on electrification, networking, and automation technologies. The partnership aims to provide expertise in the field of automation technology.

High-performance hardware including the support of high safety requirements

The wind turbine generator uses a central control system and decentral I/O stations for data transmission. The Next Generation Control System (NGCS) uses Profinet protocol and Profisafe for safety realted communication. The BPC 9102S safety PLC is the highest-performance controller, with an Intel Core i7-10700TE processor and an integrated Profisafe safety controller. ENERCON chose the Axioline system for decentral I/O modules due to its robustness and compact design. Furthermore, the AXC F XT PMP 1000 V AC extension module is also developed, measuring current and voltage grid variables with high precision. Also, provide protective devices in accordance with the VDE-AR-N 4110 and VDE-AR-N 4120 directives.

Any combination of high-level language code and model-based tools

ENERCON and Phoenix Contact have partnered to develop an open PLCnext Technology ecosystem, allowing automation projects to be implemented without being subject to the restrictions of proprietary systems. The controller, based on a Linux kernel, offers real-time capability and patented task handling, reducing development time and effort. Continuous in-process testing on HIL test benches ensures system requirements are fully met. The control platform offers future-proofing and integrates technologies like OPC UA and TSN. The partnership allows for short paths to challenges and decision-making, with a support team providing active support remotely and directly at ENERCON locations and prototype construction sites.

Joint development of new technologies

ENERCON and Phoenix Contact’s partnership has resulted in the creation of innovative technologies that could significantly transform the wind industry.

Learn more about wind power.

The optimal network concept for artificial intelligence

Time Sensitive Networks (TSN) can revolutionize automation when combined with Profinet. Artificial intelligence (AI) in automation, such as ChatGPT, requires large amounts of data to be transported from the field to the AI system, affecting the control process. High-precision time synchronization is essential for processing and evaluating distributed data from the field level. TSN standards contribute to this, and the migration process is expected to be rapid. The combination of Profinet with TSN is ideal for meeting these requirements in a single network.

Currently separate networks for fieldbus and IT

Currently, requirements for optical anomaly detection using AI tools are implemented in separate networks due to limited transmission speed and high-precision time synchronization is also not currently available in IT networks and systems. This separation allows IT communication to maintain real-time capability, but also has costs and challenges in future extensions or changes. A “convergent network” can improve these functions by combining IT and OT disciplines in a single network, ensuring that the Ethernet structure, known as Time-Sensitive Networks (TSN), does not affect each other.

TSN as a tool box for special purposes

TSN can be compared to a tool box containing several tools. Each of these tools serves a specific purpose. Here is a brief explanation of the tools:

Quality of Service (QoS) is crucial for real-time-critical traffic, while preemption reduces data forwarding variance. In addition, precision Time Protocol (PTP) is used for high-precision time synchronization in AI applications, allowing for microsecond-range synchronization accuracies. Synchronous communication ensures that terminal-to-terminal response time remains consistent. Brownfield integration is necessary for Profinet with TSN, as it requires new hardware in all devices involved. However, a smooth transition from Profinet RT to Profinet with TSN is feasible, as any existing Profinet device can be used at the TSN area boundaries. By combining these tools effectively, Profinet with TSN offers advantages without changing the look and feel of the network.

Areas of application for Profinet with TSN

Profinet with TSN offers benefits in applications like optical anomaly detection, vibration data, 3D images, frequency synchronization, alarm messages, and firmware updates. These tools can be used for Profinet communication between controllers and field devices without changing the application view of Profinet. OPC UA with pub/sub communication is more suitable for data exchange between different controllers. The OPC Foundation is working on a usage concept for TSN in OPC UA Field Exchange.

Learn more about Time-Sensitive Networking (TSN).

Comprehensive protection of the network

The IIoT trend has increased the need for better production transparency and control, leading to higher demands on access security. Phoenix Contact offers a Secure Edge Box to address these challenges. Data acquisition solutions often have different interfaces and communication protocols, making them confusing and difficult to administer. In addition, the diversity of solutions requires a high level of expertise, which may require external help. For this purpose, a standardized and secure remote connection to the peer must be set up. At best, a secure edge interface is established between manufacturing and other networks. To support users, Phoenix Contact offers a Secure Edge Box that solves the challenges listed..

Signal light for checking VPN connections

The Secure Edge Box is a tool used to protect production from attacks and sabotage by controlling data traffic and dividing the network into small areas. It uses an industrial firewall router, the mGuard firewall, to separate the lower-level network from manufacturing. In addition, firewall rules can be entered or managed centrally using the mGuard Device Manager tool. The box also allows remote VPN access, allowing employees to monitor the VPN connection status.

Additional security settings via a managed switch

The box features a second switch controlling the DMZ port of the firewall router, allowing service technicians to access specific devices in the area via this port. The mGuard firewall records the configuration through digital inputs. Additionally, if the control cabinet door is opened and there is a potential risk of tampering on site, the mGuard firewall can send an alert to a configurable receiver. A managed switch with 16 ports from the FL mGuard 2000 series is used for networking. Additional security settings can be made when configuring the switches, including user administration and authentication on RADIUS or LDAP servers.

Edge PC for data acquisition and forwarding to a cloud

The edge PC with PLCnext Runtime in the Secure Edge Box can be upgraded via the PLCnext Store, a digital marketplace for PLCnext Technology. It can implement local data acquisition with visualization and anomaly detection. In this way, for example, energy data or analog sensor data is transmitted to the edge PC via MQTT or OPC UA. With the second approach, the data is forwarded to an online hosted cloud. The edge PC normalizes, compresses, and stores data temporarily, ensuring compatibility with almost all systems. Both approaches can be used in parallel to increase data availability, and additional apps for data anomaly detection can be installed. Regulatory intervention in the process is also possible.

Ready-made, functionally extendable control cabinet solution

Additionally, the Secure Edge Box can be ordered as a ready-made control cabinet solution. In addition to CE-marked it compiles with the UL 508A standard. It can be extended with additional switches or othr components. The box features a main switch, VPN tunnel, and DMZ port control, and a signal tower. Moreover, it can accommodate up to 60 cables using a cable entry system. The box protects against cyberattacks by controlling incoming and outgoing data traffic, allowing local and cloud data processing.

Learn more about Digital Factory.

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

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

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

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

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.