End-to-end safety from the sensor/actuator to the controller

IO-Link technology has become crucial in machine and system integration due to its ability to enhance data collection from sensors and actuators. In 2021, over 6.3 million IO-Link devices were installed, totaling more than 27 million to date. However, while IO-Link offers benefits, it previously lacked a safety solution for integrating safe sensors and actuators. The release of IO-Link Safety expansion V1.1.3 in March 2022 addresses this by allowing the use of IO-Link Safety masters and devices for a standardized and integrated solution in automation systems.

Manufacturer-independent use of IO-Link Safety devices

Since 2016, automation has witnessed safety-over-IO-Link solutions dominated by manufacturers, which deviate from IO-Link’s core principles. For instance, PROFIsafe-over-IO-Link devices are limited to matching masters and the PROFIsafe system. In contrast, IO-Link Safety offers benefits like network independence, standardized connections, configuration via IODD, and interchangeable devices. It’s versatile, as IO-Link Safety devices, following specifications, can be used with any manufacturer’s IO-Link Safety master, giving users flexibility in device selection.

Flexible use of the IO-Link Safety master even for the standard IO-Link

IO-Link Safety solutions provide flexibility with the master functioning in classic IO-Link mode. Future developments may enable mixed operation for additional information transmission, especially useful in complex control units. This emerging standard envisions a single device combining IO-Link and IO-Link Safety, simplifying functions and data transmission through the IO-Link Safety master. This concept is expected to expand to devices like light grids, laser scanners, and IO-Link Safety hubs, offering similar advantages.

Various configuration options for the IO-Link Safety ports

The IO-Link Safety system expansion offers extensive configuration options for each IO-link safety port through “Feature Levels.” These ports can handle safe and non-safe digital signals with modes like IO-Link, IO-Link Safety, and a mixed mode, enhancing flexibility. For instance, users can configure a Class A port to support IO-Link, IO-Link Safety, or both, Digital output (DO), and Two-channel safe digital input (FS-DI). The system expansion also includes Class B ports that will supply higher current to IO-Link devices in the future. This standard enables a smooth migration of existing safety solutions in the field and ensures a future-proof approach for implementing their digitalization strategies.

Easy parameterization with IODD

Introducing the new IO-Link Safety standard has integrated functional safety into the benefits associated with IO-Link technology. Users can easily configure parameters using IODD, and they can align device replacement with IO-Link’s core advantages. IO-Link Safety is emerging as a crucial element in connecting sensors and actuators to the control level in machine building. Multiple suppliers are expected to introduce IO-Link Safety masters and devices in 2023. Ultimately, this standard offers a manufacturer-independent pathway for users in the realm of machine and plant digitalization.

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Data-driven analysis options for the factory

Data-driven analysis of production systems enables predictive insights for machine condition, energy use, and performance. Furthermore, As a part of the “Digital Factory now” concept, Phoenix Contact offers modular hardware and software solutions for independent data acquisition. Control cabinets like Data Collection Box and Secure Edge Box integrate with existing infrastructure, with adaptable source code. Moreover, open-source tools like Grafana, Node-RED, and InfluxDB enhance flexibility.

Creating, training, and executing machine-learning models with MLnext

Once the data has been stored in a database, the user can use the MLnext software portfolio from Phoenix Contact to create, train, and execute machine-learning models. With the MLnext Framework, developers can evaluate time series data, while the MLnext Creation app offers ready-made templates for model creation and testing. The MLnext Execution app allows model creation without programming, supporting the entire application cycle for uncovering potentials and issues.

Planning needs-based maintenance measures

The condition-based maintenance system uses energy and process data to plan maintenance based on the condition of the system, creating a digital system representation. Furthermore, data is collected by the Data Collection Box, standardized, and sent to the Secure Edge Box. A time series database archives the data, which can be visualized via a web app. Users can then use MLnext Creation to build a machine-learning model for comparing normal behavior during production.

Visualization of the actual health, process, and consumption data

The created machine-learning model is stored and used for predictions. MLnext Execution on the Secure Edge Box evaluates system data in real time. If the model detects an anomaly, alarms are triggered via email or message. This proactive approach helps prevent downtime and enhances maintenance planning, ultimately increasing production availability.

Reducing or preventing system downtimes

At Phoenix Contact PLCnext Factory, a condition-based maintenance system monitors energy usage in production, tracing anomalies and reducing downtime. MLnext also analyzes critical supply units to prevent wear-related downtimes. The “Digital Factory now” concept predicts product quality and reduces rejects during restarts.

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Solving the challenges of the future with swarm intelligence

The significance of interdisciplinary collaboration between a company’s internal and external experts is increasingly recognized as essential for solving complex tasks efficiently. The PLCnext Community from Phoenix Contact exemplifies this approach in the open PLCnext Technology ecosystem. Just as collaboration is crucial in building a house with various specialists, it’s similarly vital in today’s digitized work environment across industries. Challenges like skilled worker shortages highlight the importance of cooperation among employees. In the automation industry, developers and engineers face intricate technological problems, often requiring collaborative efforts. This is especially valuable in new business areas where a company lacks experience. Online forums and digital communities facilitate information exchange and experience sharing among developers.

Reducing travel and office costs

In the 1970s, digital exchange methods existed even before public Internet access. In 1979, students from Duke University created Usenet, a virtual platform for cross-border forum-based collaboration, using the UUCP protocol. Organizational psychologist Prof. Dr. Guido Hertel from the University of Münster highlights the benefits of internet-based collaboration, such as international teams working across time zones and involving experts with minimal costs. Virtual collaboration reduces travel and office expenses, and the rise of online meetings due to COVID-19 has made web-based video conferences normal. With increasing home office adoption, network-based collaboration tools like Slack, Wire, and Rocket are gaining importance.

Increasing sales growth

A notable trend is the increasing reliance on cross-functional collaboration by large, globally operating companies as part of their digital transformation. A 2020 Accenture study found that companies using this approach achieved more than double the sales growth compared to those that didn’t. Effective collaboration across functions reduces costs and leads to measurable returns. Companies benefit even more in innovation and speed when they involve external partners in their development processes, alongside internal efforts. This shift turns a closed company system into an open ecosystem, tapping into external knowledge and creativity. Deloitte highlights this openness as a critical competitive advantage in the fast-paced digital economy.

Platform for subject-oriented exchange

The terms “collective intelligence” and “group/swarm intelligence” refer to intelligent decision-making through collaboration among individuals, often observed in decentralized systems with non-hierarchical cultures. Phoenix Contact exemplifies this with PLCnext Technology in industrial automation. It reimagines automation for digital transformation, using a Linux-based real-time-capable PLCnext Runtime System that’s open to various protocols and tools. The PLCnext Store, an online marketplace, enables exchanging reusable blocks and apps, fostering collaboration. The PLCnext Community supports this ecosystem, aiding users in using the hardware and software, sharing experiences, and enabling project success. Notable examples include students using community resources to measure social distances and companies benefiting from shared insights for automation app development.

Project for protecting bees

The PLCnext community is working on a sustainable project with the “Beehyve” campaign to protect bees using advanced automation. ChatGPT, an AI-based system, represents a new form of collaborative technology. Phoenix Contact has been working in collaboration with its customers, the science community, and society ever since it was founded 100 years ago.

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Easy qualification of time-sensitive networking (TSN) solutions

The Linux OS, especially with PREEMPT-RT, is widely used in automation devices, with growing popularity. Recent Linux versions support Time-Sensitive Networking (TSN). Phoenix Contact’s PLCnext Tech ecosystem, based on RT Linux, supports TSN on suitable Ethernet hardware.

Testing hardware uniformity in Linux for easy integration into systems like PLCnext Control is the next step. Linux-based automation devices consist of hardware (CPU, TSN-capable MAC, PHY), kernel (core functions, network driver), network interfaces, industrial middleware (e.g., Profinet, OPC UA), application, and synchronization.

TSN’s key feature is precise application synchronization. Recent kernel versions integrate Ethernet TSN mechanisms in RT Linux, benefiting manufacturers by enabling neutral TSN solutions without specialized hardware. The presented test environment validates implementations, promoting TSN’s simple and robust use in Linux-based devices across manufacturers, driving wider Time-Sensitive Network adoption.

Testing on widely used TSN-capable network chips

The responsibility for TSN implementation under Linux has shifted from device manufacturers, like Phoenix Contact, to chip manufacturers. Consequently, an automation device’s performance and quality hinge on the underlying TSN hardware and software. This shift has prompted device manufacturers to develop their network drivers to ensure the desired quality. In some cases, specific hardware, like FPGAs, is required, adding expenses and making hardware changes during a product’s lifespan more complicated.

Hence, the opportunity for independent hardware and driver validation from chip manufacturers before device development and hardware setup is particularly appealing to device manufacturers. Chip manufacturers with TSN solutions not tied to specific automation applications also share this interest.

With Linux now incorporating essential TSN functions, the need for an autonomous TSN test environment has arisen. In response, Phoenix Contact collaborated with chip manufacturer Intel to design appropriate test tools, testing them on widely used TSN-capable network chips. These tools will be eventually released as an open-source solution within a suitable organization, serving all interested parties. This approach enables chip and device manufacturers to validate their respective TSN products. Additionally, the tools can aid in comparing solutions and educating customers or research entities about TSN.

Performing highly accurate measurements of runtimes and deviations

To independently qualify a chip manufacturer’s TSN solution, an emulation replaces the industrial middleware and application. This emulation simulates the behavior of an automation device. After successful testing, the emulation is substituted with the manufacturer’s middleware and device application.

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Smart device connections

Fire alarm systems play a critical role in ensuring building and occupant safety against fire hazards. These systems involve numerous connection points and interfaces, making intuitive and time-saving conductor connections essential during development, alongside connection security considerations.

Standards like DIN 14675-1, DIN VDE 0833-1, and DIN VDE 0833-2 define the planning, installation, operation, and maintenance of fire alarm systems. The fire alarm control panel serves as the central hub, connecting signal lines from fire alarms and internal alarms. Interfaces automate device and air conditioning control, manage extinguishing, voice alarms, smoke, and heat ventilation, and assist transmission units.

Diverse fire alarm types are installed based on building size, layout, and environmental factors. Elements such as the fire’s nature, room structure, and disruptive influences impact selection. To minimize false alarms, appropriate fire alarms like point heat detectors or manual alarms must be chosen and configured.

Specialized applications utilize air intake and linear smoke alarms, equipped with features for reliable detection. These smart device connections allow fire alarm systems to be tailored precisely to specific building circumstances, enabling swift and dependable fire detection in early stages.

Developers and product managers are in control

Examining connection ergonomics during the initial stages of field device development is undeniably advantageous. This process entails evaluating the choice between fixed connections and connector solutions, while also taking into account factors like installation location and protection requirements. Moreover, developers should proactively tackle technical considerations such as connection sizes, voltages, currents, and pitch at an early stage. By anticipating installation conditions and future maintenance needs, developers can intelligently guide device customization, thereby efficiently streamlining the entire installation and upkeep process.

Smart device connections make work easier for everyone – from the installers to the operators

Phoenix Contact offers PCB terminal blocks and connectors for fire alarm systems, notably incorporating advanced lever-Push-in and Push-in connection technologies such as PTS, SPT(A), LPC, and LPT(A) series. This facilitates easy and tool-free connections, accommodating both flexible and rigid conductors. Furthermore, the availability of THR variants serves to enhance automated assembly processes, effectively reducing associated costs.

Secure – you can count on it

Phoenix Contact’s LPT and LPC PCB terminal blocks and connectors feature spring-actuated contacts for reliable connections. Furthermore, an indicator lever shows clamping status, effectively preventing errors. Moreover, the preprogrammed spring force ensures stability without torque-related issues. Notably, these components meet international standards, including UL 1059, greatly simplifying approval for global markets.

Phoenix Contact’s cutting-edge smart device connection technologies simplify fire alarm system installation, reducing costs and ensuring global reliability. Push-in connections benefit manufacturers, installers, integrators, and operators by boosting reputation, expediting work, and enhancing system availability.

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MORYX is a software platform that enables the digital transformation of manufacturing processes. It connects different systems and devices, creates digital twins, and provides flexible and intelligent control options. MORYX is used in 45 applications worldwide. In the following use cases, we want to show which tasks MORYX takes over in practice and which advantages result.

USE CASE: SYSTEM PROTECTION TECHNOLOGIES FACTORY

The “System Protection Technologies Factory,” operated by Phoenix Contact, utilizes MORYX since 2017 for the digital integration of ERP, MES, and PLM systems. MORYX serves as a higher-level digital instance, enabling seamless operation of all systems. The integration has resulted in significant improvements, including zero makeready time for one product line and reduced setup time from 10 to 5 minutes for other lines. The advantages and successes of MORYX’s implementation include parallel production of orders, automated machine setup, handling high product variance, flexible process definition, and accelerated production due to MORYX’s adaptability to changing production environments.

USE CASE: DEVICE CONNECTORS FACTORY

Phoenix Contact’s Device Connectors Factory uses MORYX since 2020 to generate digital twins for product, process, and machine, resulting in increased flexibility, control options, and lower scrap.

The advantages of using MORYX’s digital twins include; 10% reduction in production time with optimized first-pass yield, changeover times under 1 minute through parallel production and automatic article management, and the ability to configure production without the need for extensive PLC knowledge. The implementation of digital twins has led to improved production efficiency, reduced scrap rates, and simplified production processes.

USE CASE: MACHINE INTERACTIONS APPLICATION

Phoenix Contact utilizes machine interaction applications, such as smartwatches to enable seamless communication between machines and skilled workers in one of their plants since 2019. MORYX records real-time machine conditions and messages, sending support requests to plant personnel via smartwatches if problems are detected. The smartwatches provide location-specific details, issue types, severity, and potential solutions, allowing one employee to supervise multiple machines, even across different production halls. The advantages of this system include optimal time utilization, stress reduction for employees, and access to real-time information for efficient decision-making and support.

We accompany you on the way to the Digital Factory

MORYX is a powerful and versatile software platform that can help you achieve your digital factory goals. Whether you want to integrate different systems, create digital twins, or develop interactive applications, MORYX can provide you with the right solution. Feel free to contact us if you have any further questions.

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Quick and easy programming, visualization, and diagnostics

The Smart Production Library for PLCnext Technology by Phoenix Contact enables companies to meet changing market needs, customized buyer demands, energy sustainability, and labor shortages through digitalization efforts. The library simplifies programming, visualization, and diagnostics in the engineering environment, making code generation and commissioning faster and easier.

Adapting to each application via drag-and-drop

The generator configuration file enables fully automatic visualization creation. The library includes functions for diagnostics, operating modes, and various technologies. The HMI web server handles visualization without data storage on display devices. Function blocks combine logic, visualization, and diagnostics, simplifying configuration. The interface features generic animations, easily customizable by adjusting parameters. The library supports extensions, drag-and-drop objects, and multiple languages.

The Library is divided into three functional areas: Basic functions, Operating mode functions, and Technology functions.

Basic functions: Diagnostics of the controller and client access control, including exclusive mode and alarm management.

Operating mode functions: Support for various operating modes and safety features.

Technology functions: Control for actuators, sensors, and energy measuring devices, with the ability to add more technologies as needed.

Creating visualizations in just a few minutes

A clear application program structure aids visualization generation. The HMI generator features two methods: a comprehensive overview and selective visualization for stations. It quickly creates visualizations, saving time. Changes are immediate, ensuring error-free operation and consistent data management between PLCnext Engineer and the PLC.

Cloud integration via app from the PLCnext Store

The Smart Production Library is part of the PLCnext Technology ecosystem, enabling the integration of standard PLC programming with high-level languages for real-time execution. Cloud connection is facilitated through apps like “Node Red for PLCnext,” ensuring system availability without impacting automation processes.

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Greater efficiency and time savings of 60 percent for wire and cable identification

The Thermomark E Series marking system combines printing and application in one step, saving approximately 60% of the time in industrial marking tasks. It improves efficiency by enabling clear and uniform marking of components throughout the product lifecycle of a control cabinet. The system reduces the previously time-consuming process of printing, separating, and mounting markings on cables, wires, and components. It enhances safety and simplifies workflows with visible and permanent identification.

Automated identification

The Thermomark E Series marking system by Phoenix Contact automates printing and applying of marking materials in a single step, resulting in 60% time savings. It offers an efficient and user-friendly identification process with high-quality markings, improving longevity and durability.

Modular marking system

The Thermomark E Series is a modular marking system with applicators connected to a thermal transfer roll printer. It offers flexible wire and cable identification solutions without additional devices, saving resources and space.

Efficient wire and cable identification

Thermomark E Series provides three applicators for automated wire and cable identification. The E.Wire creates movable cable markers, the E.Sleeve processes shrink sleeves, and the E.Wrap applies wire-wrap labels. Each applicator offers specific features for efficient and precise marking based on different cable diameters.

Seamless software-supported marking processes

Standard IEC 61439 requires clear and permanent identification of devices in control cabinets. The marking software by Phoenix Contact allows for efficient data import from digital circuit diagrams, enabling the automatic transfer of marking information. Intuitive functions facilitate wire and cable identification, reducing errors. The Marking System software provides an overview of the project, guiding users through the identification process. The information can be displayed on a separate monitor or the Thermomark E Series device.

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Protection and supply – the intelligent way: The communicative 24 V supply system with everything in view 

The power supply is vital for control cabinets as it provides power to 24 V components. In industries where system availability is crucial, the Quint Power 24 V supply system from Phoenix Contact offers communication capabilities, increasing data transparency and system availability. Operators can access operating and diagnostic data to monitor the network and optimize costs through preventive function monitoring.

Raising optimization potential – maximum system transparency for maximum availability  

Data collection is essential for system availability. The Quint Power communicative power supply from Phoenix Contact offers two options: connecting to the Caparoc fuse via a proprietary data bus or using the IO-Link interface to connect to an automation system. Both options allow for data transmission and monitoring of power supply and UPS system data.

Monitoring and parameterization

The Quint4 power supply ensures complete data consistency, enabling early warning of malfunctions. It offers targeted maintenance, remote diagnostics, and cost savings. Data collected includes remaining service life and network surges, aiding preventive maintenance. Fieldbus interfaces and a web server provide system transparency. Parameter configuration is easy, avoiding user errors. Centralized configuration saves time and costs.

Integrated phase monitoring 

The Quint4 communicative power supply with IOL interface features integrated phase monitoring, providing information on three-phase availability. It can run at full power on two phases and constantly monitors rotating field direction and input voltage.

Power supply and electronic circuit breaker system grow to become a single system 

The Quint Power communicative power supply combines with the Caparoc circuit breaker system for monitoring fuse channel characteristics. It enables preventive maintenance, accurate remote maintenance, and cost savings. The system offers automatic configuration and optimization based on operating data, simple integration, and complete data consistency.

The communicative 24 V supply system from Phoenix Contact allows for monitoring load currents and operating temperature, providing optimal system monitoring. It enables preventive measures to be taken, reducing downtime and optimizing costs. The system offers extensive data for maintenance and early warnings for heavy equipment utilization.

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Achieving higher energy yields with new processes

Phoenix Contact is taking steps to maximize energy production by implementing new processes. Firstly, installing lightweight modules on buildings. Moreover, these films, weighing only three kilograms per square meter, directly adhere to the roof surfaces. Additionally, with their specialized surface design, they optimize light refraction and achieve energy yields comparable to standard modules. This approach not only increases efficiency but also reduces the amount of mounting material required.

Combination of conventional and flexible modules

Phoenix Contact is implementing a mix of conventional and flexible modules in its photovoltaic systems. Building 34 will have lightweight modules generating 750 kWp, while Building 60, currently under construction in Blomberg, will use conventional modules only with over 1,000 kWp capacity. They aim to install solar systems across all German sites by 2030. Their international subsidiaries in the USA, China, Austria, and India are also expanding their solar initiatives

Weather station for calculating the performance ratio

Phoenix Contact offers a range of components and solutions for cost-effective operation of photovoltaic systems. The string combiner boxes provide protection and efficient distribution of DC currents. They use weather stations to evaluate system performance and make adjustments as needed.

Grid stability by using certified power control units

Phoenix Contact utilizes in-house data loggers to collect and analyze data from their photovoltaic systems. These loggers connect various system components for easy data integration and storage. Additionally, their power control unit ensures grid compliance by monitoring voltage and reactive power and adjusting inverters as needed. Compliance with certified feed-in controllers is mandatory for larger photovoltaic systems since 2018.

Amortization after one-third of the service life

Phoenix Contact’s photovoltaic systems will have a total output of around six megawatts, meeting 5.5 percent of their electricity demand. Solar power proves to be cost-effective, with production costs one-third of procurement costs. This aligns with their climate neutrality strategy and vision for an All Electric Society. The photovoltaic systems are expected to pay for themselves within one-third of their service life.

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