Feature Communications & Networking Getting to the heart of automation
Many forward thinking companies are continuing to recover from the recession by creating more dynamic operations that respond flexibly and constructively to overcome obstacles and maximise opportunities. As Peter Croucher of Weidmüller explains, the key to this higher efficiency is automation
ower, raw materials, capital and time are key resources and for these to be used efficiently, I/O systems are essential - without them, it is not possible to automate any- thing. Today, a powerful I/O system must be fast, reliable and flexible. Dr Timo Berger, head of the Electronic Interfaces Division at Weidmüller commented, “The demands of an I/O system are anything but trivial. They need to feature freely selectable sensor connection options in 2-, 3-, ‘3 plus FE’ and 4-wire tech- nology. For example, our high speed system bus offers impressive elec- tronic performance and works with as many as 256 DI/DOs in 20µs. With an extremely short response time, the rapid display of processes and the high power reserves, we have designed our ‘u-remote’ to be equipped for the future.”
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Positively connecting, mechanically cross locked remote I/O systems should be designed to be robust and mounted on terminal rails to withstand vibra- tions. They should also be able to with- stand extended temperature ranges, such as -20°C to 60°C, as the wide vari- ety of potential locations could put them under considerable duress.
Development
Asked how the company had gone about developing its new module remote I/O system, Andreas Hoffmann, product manager, Remote I/O Systems at Weidmüller explained, “When working on its conceptual design, we focused all of its benefits specifically on user requirements. As a result, the ‘u-remote’ excels due to its high component density, top perfor- mance and high levels of efficiency and productivity. Significant features include lean planning, simple installa- tion, fast start-up and the avoidance of down-times. This means that the user (thanks to a very slim design with a module width of just 11.5mm plus a low number of power feed modules) can design the switch cabinet to be sig- nificantly smaller yet have extreme flexibility in its design.
“Due to the high 10A capacities of each of the module current paths - for both inputs and outputs - users will
need fewer power feed modules and, as already mentioned, also save space in the switch cabinet. Furthermore, less effort is needed for planning. In light of its full diagnostic capabilities, the system can also be maintained quickly, as the inputs and outputs can be turned off independent of each other. Furthermore, installation can also be carried out without the need for tools and the system also offers the option of pre-assembling cables, which makes installation in a switch cabinet or on a machine or system more reliable and much faster.” Commenting further on what users would be particularly excited about with the I/O system, he added, “On the one hand, ‘u-remote’ features a single row, modular plug-in connection level and is very attractive due to its clear, straight- forward structure. During cabling and servicing, the assignment of functions to the connection points is designed to be simple and error-free. In other words, the plug-in connection level ensures that sensors and actuators can be connected quickly and reliably with pre-assembled cables, while at the same time minimis- ing the error rate in system wiring. “In addition, the electronic unit can be replaced while the system is pow- ered-up and operating when there is no load (hot swapping), thus without the need to disconnect the bus connection and power supply. The I/O station remains functional and the machine or system continues to be available - expen- sive shutdowns and restarts are not nec- essary. When replacing the electronic unit, the cabling stays totally in place.
Automation NOVEMBER/DECEMBER 2013
Above and below: I/O systems are essential - without them, it is not possible to
automate anything. Today, a powerful I/O system must be fast, reliable and flexible
As soon as more than one electronic unit has to be replaced, the I/O station must be shut down and the machine or system put into a secure, defined state. The I/O station logs off from the fieldbus system and once the station’s corresponding module configuration has once again been restored, it logs back onto the field- bus automatically.”
For speed and efficiency in use, it is important that users can identify, at a quick glance, the status of modules and each channel so he/she can con- duct a precise diagnosis of the I/O system. This is where the importance of LEDs being positioned at the wire connection comes into its own. However, it is not just the LEDs that catch the user’s attention - other visi- ble markings can also be customised.
Summary
One might think that to accommodate every potential use, a wide variety of variants or range of interfaces would create a problem. This is not so as Dr Berger explained, “Weidmüller pro- duces a wide variety of variants for its modules not through a large assort- ment of parts, but instead through the ability to parameterise them - as a result, each module has only one part number but can handle a wide range of functions. This makes selecting mod- ules easier, as well as planning, and reduces the size of the inventory. In terms of the interfaces, our remote I/O system is equipped with both Ethernet and USB interfaces and is certified by accredited laboratories. This refers to the integration of the fieldbus into the PLC, the IEC 61131-2 product standard and UL certification.”
Weidmüller
www.weidmuller.co.uk T: 01162 823 470
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