Category Archives: Industrial Electronics

Wireless Technology: the Industry 4.0 Backbone

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Industry 4.0 is the 4th generation industrial revolution. This world-changing principle enhances productive efficiency in smarter and faster ways by utilizing the state of the art technology of data analysis software alongside powerful computerized hardware capabilities.

The key to the success of Industry 4.0 is to connect thousands of devices to the central system in order to allow exchanging of various parameters to the processing unit, such as humidity, temperature, status, level, etc. Not only is data transmitted, but devices also receive commands for further actions.

Actually, the powerful hardware and advanced software capabilities have existed for over 20 years. However, the increased number of devices connected to the system means a higher cost of investment. In the past, the only reliable connectivity was through wired cables, which investment cost was directly related to the complexity of the number of devices.

This key obstacle has been rapidly resolved by the advent of reliable wireless technology. Today, various applications of wireless technology have been proven and widely used, such as:

NFC: Near Field Communication

RFID: Radio-Frequency Identification

Wi-Fi: Wireless Fidelity

What makes people trust wireless technology?

Security: New advancements in data encryption technology protects data from intruders.

Speed: The new standard of network 802.11ac helps increase data transmission speed to 10 times faster than the old standard which is sufficient for industrial control systems.

Savings: All stakeholders follow the wireless markets trend. Therefore, new hardware for wireless technology has been introduced daily. This brings significant reduction in the price of wireless devices which mean tremendous savings during investments.

Phoenix Contact offers a huge portfolio of products under the category of wireless technology, as shown below.

Why Wireless?

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In the conventional method of data communication we often use wired systems. In the setting up of such systems involving data communication, we would need to plan the cable routes very carefully, and it is often very costly when the wires are required to be routed up and down such that obstacles are avoided in order to get connected. Usually the cost of the cables, labour, special tools for terminating etc. would be a considerably huge amount.

Besides the significant installation cost, physical degrading of the cable is a common issue faced (for example, wear and tear due to weather conditions, accidental cuts, scratches and bites by animals such as mice and ants). Especially when the system is down as a result of this, nobody would know which part of cable is broken or damaged.

In wireless technology, we could eliminate such worries and the less hardware used means that the risk of a breakdown would be lower. Aside from this, wireless technology has the following advantages:

  • More flexibility
  • Interference-free communication
  • Mobility and freedom of movement of participants/devices.
  • No wear and tear of the transmission medium
  • Able to bridge long distances and problematic areas
  • Neat looking

Applications of Wireless Techonology:

Some of our Industrial Wireless products are shown below:

An example of a typical setup:

Radioline Wireless Network

Wireless HART Network

Bluetooth Wireless Ethernet

CLOUD IoT GATEWAY – The Smart Gateway for IoT Solutions

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The CLOUD IoT Gateway is designed to allow users to integrate their existing systems into the cloud. Machines and physical infrastructures can now be connected to the digital world. This will allow users to implement applications such as big data, condition monitoring and comprehensive data analysis. With protocols such as Modbus/TCP supported, the IoT gateway enables an easy process of connection.  No additional engineering software is required as the parameter configuration can be easily carried out at the gateway using web-based management.

Key benefits to users

  • Direct connection to the cloud for data analysis
  • No learning of new software – configuration is done via web-based management
  • Existing devices with Modbus/TCP can be connected to cloud
  • Robust hardware for usage in industrial environment
  • Secured transmission using TLS encryption (Transport Layer Security)

Interested to see how this works? Feel free to request a demonstration by dropping us an email at marketing@phoenixcontact.com.sg!

OPC_UA SERVER for PC WORX-based Controllers

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Dynamic market changes make it necessary to solve automation tasks in line with Industry 4.0. The objective is always to produce more efficiently and intelligently. Uniform protocols, rules, and standards for communication are required to intelligently link machines and system components.

In the past, it was a very challenging task for any engineer to setup, access or share OPC classic remotely in a network but that has changed now, with Phoenix Contact’s OPC_UA Server.

The PC WORX UA SERVER from Phoenix Contact enables you to access all variables of PC WORX programmable controllers via the OPC_UA (Unified Architecture) standardized communication protocol.

Fig 1: System architecture with OPC_UA

Fig 1: System architecture with OPC_UA

Why you should switch to OPC_UA

The OPC Unified Architecture Standard, OPC_UA, is being adopted more widely across the market as the new market standard and provides the basis for open and standardized communication in the digital future.

OPC_UA Server capability:

  • Handle up to 200 controllers in a visualization or production control system
  • Variables are mapped via the standardized PLCopen profile
  • The OPC_UA server uses the binary protocol for communication, resulting in high data transmission speeds
  • A security concept based on certificates protects against unauthorized access
  • Status & Quality of connection for each individual items
Fig 2: OPC_UA VS OPC Classic

Fig 2: OPC_UA VS OPC Classic

In the end, the key feature that makes OPC_UA server the backbone for any IIOT system that uses PLCopen profile would be the fact that it allows customers to build extremely fast web/cloud base visualization even without a need to pay additional costs for licensing.

Fig 3 & Fig 4: Web/Cloud Visualization of data from monitoring a mini solar cell via OPC_UA

PLC Logic – The Better Smart Relay

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There are numerous smart relays in the market but PLC Logic is perhaps the only one that can have both control and monitoring capabilities while linked to an Apple iPad. This is done by using Bluetooth dongle, which turns the PLC Logic into a modern wireless control system.  The range of Bluetooth devices is 100 meters with unobstructed line of sight and this translates to a lot of cost savings for applications that require control and monitoring remotely without the need to spend money for installation of communication devices and cable installation. The best thing is that the app is free from the Appstore. An additional plus point is that the interface looks really cool and clean, similar to what you can expect from an Apple Interface.

The PLC Logic also has versatile communication options to any higher level control system. It can support protocols such as PROFIBUS RS-232 RS-485 Modbus/TCP DeviceNet™ CANopen® PROFINET EtherNet/IP™ with just a change of gateway. With so many protocol options, there is no need to worry if the PLC Logic can support any higher level controller in the market.

One of the advantages PLC Logic has over the many smart relays in the market is that the relays are pluggable and replaceable. This solves the problem of the need to change the whole smart relay module in the event of a faulty relay. This translates to lower replacement cost. More importantly, downtime is greatly reduced and one just needs to change a relay instead of reprogramming the smart relay if the unfortunate relay gets faulty.

Another game changer in the smart relay market is that the analogue cards, both input and output, can be inserted as part of the main PLC Logic module without the need to attach a separate analogue module. This translates into cost savings as well as space savings. The analogue card supports both mA and V in full ranges. Besides that, there is also an analogue input card that supports PT100 or PT1000 sensor.

Last but not least, the PLC Logic comes with an option of full Push In connection technology. This can be found on the PLC Logic controller itself as well as all the corresponding relays that can be supported. The advantage of Push In is evident in applications that are prone to vibrations – you are well assured that none of the wires from the PLC Logic will be loosened.

CBM – Protecting Your Application

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The Industrial Internet of Things (IIoT) is the use of Internet of Things (IoT) technologies in manufacturing. The fundamental driving philosophy behind IIoT is to build smart machines. The emphasis is placed on the topic of big data, sensor information and communications.

With data captured across all processes, it has enabled companies to analyse and anticipate on inefficiencies and issues immediately, thus saving time and money.

Typically in a switching system, its core function is to control and switch various kinds of devices and machines.

What’s common to all of them is that the demands placed on the components are very high. When a machine is running 24/7, the chances of the machine breaking down is very likely. Hence, extra attention is needed to ensure availability of the machine operations. In any case of the machines breaking down, the operation must be restarted in the fastest possible time.

Phoenix Contact’s CBM electronic multichannel DC device circuit breakers offer extended protection against over load and short-circuit currents on the connected applications.

Thanks to the integrated nominal current wizard, setting the right nominal current for your loads is hassle-free!

The selected settings are locked electronically to prevent any risk of unintentional adjustment.

The integrated early preventative warning system ensures fewer failures.

In the event that 80% of the set nominal current of a channel is reached, a warning is indicated via the associated on board LED. Furthermore, the separate signal output can be used for remote signalling.

Thanks to the active current limitation, the upstream power supply can be used optimally. This enables the use of smaller switched-mode power supply units and prevents undesirable voltage dips.

So what are you waiting for?

Ensure that your operations are running continuously and without fault.

Sleep with ease tonight, every night.

Switch to our CBM Electronic Device Circuit Breaker!

Radioline Signal Strength

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FAQ About Radioline

Question: Which wireless technology is used in the Radioline devices?

Answer: A proprietary wireless protocol is used in the Radioline wireless system. The wireless technology is called Trusted Wireless and is specifically designed for the reliable transmission of data and signals over long distances. The new Version 2.0 offers adjustable data rates, encryption, extended diagnostics, and parallel operation of multiple networks.

 

Question: Is Trusted Wireless really suitable for industrial use?

Answer: The frequency hopping spread spectrum enables reliable data transmission even in industrial environments and in the event of interference.

 

Question: What range can be achieved with the Radioline wireless system?

Answer: Depending on the set data rate and the antenna used, the following ranges can be achieved with a line of sight:

  • 4 GHz: up to 5 km
  • 868 MHz: up to 20 km
  • 900 MHz: up to 32 km

The above specifications is according to the product design, but sharing with you the test made in point to point configuration, having trees and structure as obstructions between two points.

At no line of sight, Radioline still transmits and receives analog and digital signals. Thus, Radioline works!

CCTV and Access Control in Indonesia

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Security Systems for the alternative energy source

Global oil prices have fallen sharply. From 2010 to mid-2014, world oil prices had been fairly stable at around $110 a barrel, but have now risen to around $50 per barrel. This influences future projects in the world. In Indonesia, the government postponed exploration projects (upstream). The government instead concentrated on developing projects downstream, such as TBBM (Terminal Bahan Bakar Minyak). At the same time, the Government develops project Refinery Unit, but focused on developing Security Systems.

The scope of work for a Security System is: CCTV, Access Control, Barrier Gate, Public Address/General Alarm (PA/GA) System and Radio. CCTV and Access Controls are more widely used in Indonesia today. For this project, we capitalise on the opportunities to provide components for CCTV and Access Control. CCTV and Access Control need a control panel. This control panel consists of Junction Box, Power Supply, Terminal Block, Cable, FO Converter and Surge Protection Device. Many brands exist in Indonesia, like Honeywell, Axis, Samsung and Pelco, to name a few. But for this project, the end user (pertamina) specifically needs a System Integrator, which is responsible for the design, installation, FAT, SAT and Commissioning.

We conducted a presentation for System Integrators in Indonesia where we explained the Junction Box, Terminal Block, FO Converter and Surge Protection Device. At January 2017 we received PO from System Integrator for Junction Box, Terminal Block and Surge Protection Device for project Refinery Unit at Pertamina Cilacap. The Integrator needed GRP Junction Box EXE standard. Phoenix Contact has SS and GRP. System Integrator needs SPD for power, Cat 5 and Cat 6. We can provide complete SPD. After that, we got PO for Surge Protection Device for project Refinery Unit at Pertamina Balogan. So for the next project we will try to offer a solution package. We will be offering complete Control Panel for System Integrator. The solution yields a lot of benefits for the customer as the system Integrator has time to focus on the other responsibilities. If the Control Panel has problems in the future, the engineering personnel would not be confuses as there is only one brand at the control panel. Imagine if one panel consists of different brands and the integrator has a lot of projects. The engineer has to check the old documents. Competitors don’t actively search for project related to Security Systems, they usually wait to get the PO from the System Integrator.

Smart Power Supply Unit – The Fourth Generation Quint Power

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The fourth generation of the high performance QUINT power supply units ensures superior system availability by means of new functions. Signalling thresholds and characteristic curves can be individually adjusted via Near Field Communication (NFC) interface.

The unique Selective Fuse Breaking (SFB) technology and preventive function monitoring of the QUINT power supplies increase the availability of your application.

QUINT 4 power supplies standard products are already equipped with comprehensive diagnostics that provide constant monitoring of the output voltage and output current. This preventive function monitoring visualizes critical operating states and informs the controller of them before errors occur.

Why are the QUINT 4 power supplies called a SMART power supply unit?

Selective Fuse Breaking (SFB) Technology

Even standard circuit breakers can be tripped reliably and quickly with SFB technology and withstand six times the nominal current for 15ms. Faulty current paths are switched off selectively, the fault is located, and important system parts remain in operation.

Example: Normal Power Supply Unit will take around 8-20 seconds to trip the circuit breakers. In this duration, the end device is drawing maximum power from the power supply unit which may cause the end device to be burnt. In this aspect, the QUINT 4 power supply unit ensures that the end device is well protected, thanks to the SFB technology.

Near Field Communication (NFC) Technology

With Near Field Communication (NFC), you are able to set the parameters for the power supplies easily by using a mobile phone or PC, adjusting signalling thresholds (current/voltage/power can be set differently depending on use). This saves time, minimises errors and facilitates customised applications.

Example: In a large scale project, the parameters of the power supply units can be easily set and also duplicate the rest of the QUINT 4 power supply units by using the NFC function. The parameters, MTBF (Mean Time between Failure) and serial numbers of the power supply unit can be displayed on the mobile phone or PC by NFC when it is online without interrupting the operation. Security passcodes can be set to prevent unauthorized personnel changing the parameters of the power supply unit.

Preventive Function Monitoring

Diagnostics on the bar graph help during operation and maintenance. The user is able to visualize the status of the QUINT 4 power supply unit during maintenance checks. The load current is able to be displayed as a percentage status on the bar graph. This enables the user to upgrade or maintain the panels in the future without using additional measuring tools like multimeters.

Critical operating status can be reported before errors occur. This flexible function is provided by a variety of contact configurations (relay contact, digital signal, analog signal, optical bar graph). These contacts allow the monitoring of output voltage, output current, output power, operating hours, prewarming derating, overvoltage protection and input voltage.

Power reserve

  • Easy system extension with static boost with sustained power of up 125% of the rated load current.
  • Increase of power for the future without additional power supply unit, which leads to a reduction of extra cost.
  • Reliable starting of heavy loads with dynamic boost with up to 200% power for 5 seconds – for components with high inrush current.

Example: When powering up a motor, the initial start will require high power from the power supply unit before going back to its nominal current state. The QUINT 4 power supply unit is able to start this application smoothly without disturbing the other components in operation.

High level of immunity to interference

  • Due to an integrated gas-filled surge arrester, the QUINT 4 power supply unit is protected from any transients from the incoming supply.
  • More than 20ms mains buffering time – in case of any power dip, the QUINT 4 power supply unit will maintain a suitable output.
  • High MTBF > 500,000 hrs – estimation of more than 50 years, assuming 24hours operation. 

Worldwide use

  • International approval – Class 1 Div 2, IECEX, ATEX, CE, UL, GL, EAC etc.
  • Input voltage of 100 – 240Vac or 110 – 250Vdc.
  • Automatic switch enables simple plug and play in any part of the world.

QUINT POWER 4 is the power supply that is truly a SMART Power supply. If you have any queries, feel free to contact us at marketing@phoenixcontact.com.sg!

Future Proofing Industry Seminar in Yangon, Myanmar

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Our slogan: “Inspiring Innovations”. It embodies what we do – Phoenix Contact never fails to come up with new and innovative products for the industry. As such, we are honored to be one of the market leaders and trendsetters of our industry.

Together with our partner in Myanmar, Synopsis Technology, we were proud to have brought you the “Future Proofing Industry” Seminar, held on the 31st of May 2018 at Lotte Hotel Yangon.

Seminar Poster

Alongside the topic of driving innovations, the main highlight of this “Future Proofing Industry” seminar was to introduce new applications and products for the education sector in Myanmar. It is of paramount importance to help the future engineers be ready for the industry.

Within the short time span of a day, we were elated that we had the opportunity to share our company history and actual success stories across South East Asia. Aside from that, we managed to introduce our innovative products as well.

First speaker: Mr Jiang

Our first speaker, Mr Jiang, who is also our Solution Manager, spoke about our new Industrial Cloud and Networking products for the first half of the seminar. Ideas and experiences were shared with the attendees.

Second speaker: Mr Maw Kon

The second speaker of the day was Mr Maw Kon, who is from Phoenix Contact Myanmar. He introduces our bread and butter products – the various connectors ranging from Terminal blocks to heavy duty connectors.

Third and final speaker: Mr Gary

Our last speaker, Mr Gary, never fails to draw the attentions of the attendees when it comes to introducing our surge protection devices. Live demonstrations and interactive activities were carried out and our attendees were all having a blast.

Last but not least, there was a mini competition held during the seminar.  All the attendees were encouraged to participate in the #futureproofingseminar and @phoenixcontactsea photoshoots. All they needed to do was to just take a photo during the seminar and upload them on their Facebook with the hashtag #futureproofingseminar together with a tag @phoenixcontactsea! The winner of the seminar was announced via our official Facebook page!