High-speed data transmission for industrial applications

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

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

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

The advantage of fiber optics

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

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

Speed and distances

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

Reliability and security

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

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

Costs

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

Simple implementation with the PSRmodular and AXL F series

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

Consideration of load and measurement information

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

Design of functional safety

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

Overview

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

Lightning monitoring on exposed objects

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

New monitoring technology with the Faraday effect

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

Structure of the measuring section

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

DC technology: Test facility shows potential savings

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

It was AC power supply in the beginning

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

The advantages of direct current

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

Direct current as a key technology

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

From theory to practice

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

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

A key technology in the digitalization of our world

Digitalization and the Industrial Internet of Things (IIoT) are driving the demand for faster, seamless networking in various industries. Ethernet has proven effective in intelligent device networking, but Single Pair Ethernet (SPE) will replace serial fieldbus communication protocols in the future. SPE’s innovative characteristics make it valuable for advanced communication infrastructures. Phoenix Contact offers cross-industry expertise and an ideal product portfolio for SPE implementation in various fields. Ethernet solutions typically require two wire pairs, but Gigabit Ethernet may require four for increased data transmission rates. Single Pair Ethernet, which works with a single wire pair, can transmit data and power simultaneously. Its transmission rates range from 10 Mbps at 1,000 meters to 1 Gbps at 40 meters, making it suitable for demanding tasks like networked sensor technology. This technology is suitable for fields previously affected by limitations in data rates, ranges, and seamless communication.

Connections of up to 1,000 meters

Standard Ethernet solutions have limitations, such as a maximum of a 100-meter point-to-point connection distance. Furthermore, To cover longer distances in industrial systems, additional repeaters or switches are needed. SPE technology allows devices to be connected over 1,000 meters with 10 Mbps transmission speed and Power over Data Line (PoDL) technology with only one cable, potentially replacing specific fieldbus technologies in the future.

Speeds of up to 1 Gbps and more

Single Pair Ethernet (SPE) is a reliable solution for complex network topologies with gateways, offering transmission speeds ranging from 10 Mbps to 1 Gbps. Hence, IEEE 802.3 consortia is discussing further SPE standards for higher data rates and distances which will open up the spectrum for SPE for even more fields of applications.

Digitalization for more sustainability and productivity

Phoenix Contact has developed a solution for the energy-intensive pharmaceutical production industry to achieve the Net Zero Factory climate target. The solution uses the open IIoT framework from PLCnext Technology to digitalize all machines, systems, and processes. The Digital Factory from Phoenix Contact covers all stages of the value chain, addressing digitalization requirements in all stages. Rapid climate change, demographic development, deglobalization, and global political changes present opportunities for sustainable digital processes, new business models, and agile working methods.

Minimally invasive digitalization approaches

The All Electric Society envisions a world where renewable energy is the primary source of electricity, available abundantly, inexpensively, and carbon-neutral. Industry plays a crucial role in developing solutions for electrifying sectors like energy, infrastructure, buildings, and mobility. Addressing all factory areas, including raw material warehouses, production, power supply, packaging, and buildings, is essential for reducing greenhouse gases and complying with environmental and materiality analysis directives.

Less maintenance effort thanks to contactless data and power transmission

SHL AG has been developing systems for automated grinding, polishing, and deburring since 1989. The company uses NearFi contactless power and real-time Ethernet solutions from Phoenix Contact for wear-free and maintenance-free communication. SHL’s systems include flexible robot cells, grinding, polishing, and deburring cells, as well as complete production cells. The company supplies users from various industries, including faucets, automotive crankshafts, and titanium and ceramic for medical applications. With 95 percent vertical integration, SHL reduces production costs through better cycle times. However, shorter cycle times and movements can lead to more wear, resulting in downtime.

Data exchange via slip ring was previously prone to interference and wear

Surface processing requires workpieces to swivel 360 degrees, and rotary tables with swivel units are used. The system consists of three areas for the various processing steps: insertion onto the carrier, ithe initial processing of the workpiece by sanding robots with coarse grit, and finally processing by sanding robots with fine grit. The rotary table rotates the workpiece to the next processing station. Bernhard Mattes, Senior Director of Engineering at the Böttingen plant, introduced contactless NearFi technology for wireless data exchange, which is mounted on each rotary axis for the three endlessly rotating swivel units.

Simple startup without configuration effort

NearFi enables contactless data and power transmission using base and remote couplers that can be flexibly positioned without precise alignment. It reduces maintenance costs, enhances system availability, and simplifies startup with quick, configuration-free connection via 24V and Profinet cables, communicating Ethernet protocols at 100 Mbps full duplex.

Optimized processes and coordinated system solutions for greater efficiency in wire processing

Control cabinet builders face international competition, skilled worker shortages, and increasing labor and material costs. In-house production and cost structure are increasingly under spotlight. The process chain in control cabinet building offers potential for efficiency gains in engineering and production through the use of optimally coordinated systems.

Identifying time-consuming process steps

The continuity of the control cabinet building process chain is vital for efficiency and competitiveness. Untapped potential in wire preparation, identification, and wiring can be exploited through the use of optimally coordinated hand tools and automatic tools, as well as manual and automated marking systems.

Automating and bundling core processes

Automatic cutting devices, such as the Cutfox 10, can cut wires precisely and with repeat accuracy at high speed, saving time and allowing for easier stripping and crimping processes. These devices also offer flexibility in production by allowing for interchangeable dies for different types of contact. Bundling individual stripping and crimping capabilities can result in time and cost savings of up to 70%. Phoenix Contact offers a wide variety of marking solutions for wire identification, including thermal transfer printing, UV LED printing, and direct laser marking. The Thermomark E Series marking system from Phoenix Contact automates and combines the printing and applying of various marking materials in a single process step, resulting in time savings of around 60% in industrial identification. This system consists of three applicators for wire and cable identification, connected to a standard thermal transfer roll printer, eliminating the need for an additional device.

Efficiency and ergonomics

Phoenix Contact’s Clipx Wire Assist system offers a scalable, efficient, and ergonomic worker assistance system for semi-automated wire production. The system guides users through the process, controls automatic tools and printers, and displays necessary information on a monitor. The system is built around a height-adjustable workbench, allowing workers to switch between sitting and standing while working. Mounted on four industrial-grade castors, it is mobile, reducing unnecessary legwork. The modular workbench design allows users to arrange their workstation as desired, with guides attached for additional accessories.

Nothing works without data and software

Furthermore, the Wire Assist worker assistance system enhances productivity by controlling devices and guiding users through wire preparation, reducing manual effort and errors. Its intuitive graphical user interface features touch capability and a clear design. The system saves time and money by exporting necessary wiring information from CAE programs and importing it into Wire Assist. Filter and sort functions ensure efficient wire processing, eliminating unnecessary material changes.

Read more about control cabinet building.

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.