FEATURE Smart factories/software
A NEW GENERATION OF I/O SYSTEMS
Reaching smart factory status means different things to different businesses, but one thing they all have in common is a need for input/output (I/O) systems, says Dave Sutton, Product Marketing Manager for Industrial Automation, Schneider Electric
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ince the introduction of digital transformation, manufacturers have been steadily advancing towards smart factory status. A basic definition of a smart factory is a digitalised facility which continuously collects and analyses data to improve operations. However, as businesses move towards more advanced forms of digital transformation, more assets like devices and sensors will be digitally connected. At the same time, data analysis will be more granular and carried out at the edge of the network. These factors are driving a need for more data, and future-ready I/O technology to handle that data. Typically, manufacturers need I/O solutions that provide benefits in six areas: ease of integration to save time; flexibility and scalability to reduce stock levels; high performance in terms of speed and accuracy; high availability to minimise downtime; integrated cybersecurity; and physical size or compactness. A new generation of I/O module is now available that achieves this. In turn, manufacturers, machine builders and system integrators can provide future- proofing for I/O systems.
One way to achieve high availability is by choosing an I/O with hot-swap capability, where one or more modules can be removed and replaced from a system without powering it down. This enables maintenance to be carried out while avoiding costly minutes of downtime.
For maximum effect, hot swapability can be used alongside power supply redundancy and ring topology. In practice, this means that a single failure in one system doesn’t necessarily mean a stop to production as problems are isolated and processes rerouted. In the past, there were limitations on the number of modules that could be removed at once. However, with the latest breed of I/O, it’s possible to remove as many modules as needed without restrictions. Another important aspect of protecting
18 October 2025 | Automation
uptime is robustness. As standard, the new- style I/O modules meet or exceed industry standards for electromagnetic compatibility (EMC), mechanical shock and vibration, humidity performance, and achieve arduous compliance for use in Marine and Railway applications (certification pending). In addition, an environmentally hardened (harsh) range goes even further with extended protection to corrosive atmospheres and supports operating temperatures from -20 to +70°C. A barrier to digital transformation is
the growing awareness of cyber threats. Interconnectivity across previously siloed operations brings new cybersecurity concerns. Any data breach could lead to significant disruptions but too often in the industrial environment we can see cyber-attacks through ransomware and in the worst cases creating safety issues for the onsite operators. This challenge can also be addressed at the I/O level. Modern state-of-the-art I/O solutions offer built-in cybersecurity features that help protect both the infrastructure and data being shared throughout a smart factory. Facility managers can build cyber resilience into their networks by specifying an I/O system that complies with IEC 62443-4-2, the standard that governs security for industrial automation and control systems (IACS), with Part 4-2 covering technical security requirements components. By complying with this standard, the latest type of I/O system provides advanced security features. These include encrypted communication and secure processes so that only authorised users can access sensitive information, with the I/O taking responsibility for isolating compromised devices and potentially
containing breaches before they can spread. It’s worth specifying an I/O that complies with the IACS security standard to ensure future-proofing for systems that are going into operation today. The latest breed of I/O system offers flexibility to configure an I/O island with a communications link back to a controller over Ethernet/IP, Modbus TCP, OPCUA, and a wide variety of slices, supporting simple standalone machine applications, through to large scale process control systems with up to 250 slices per island, consisting of digital and analogue I/O, motion, counting, fieldbus connectivity- HART, IO Link, CanOpen, in both standalone or redundant architectures. Industrial companies need only to source and stock a smaller number of spares to cover a wide range of applications. A challenge when specifying and
configuring a system on this scale is that system integrators and OEMs typically need specialist tools and software to ensure they are building up I/O islands that will work as planned. To support them, Schneider Electric has developed an online configurator for its new Modicon Edge I/O NTS. This is an example of new-generation I/O system that provides the full range of benefits that companies need to underpin their digital transformation. The online configurator tool makes it straightforward for integrators to understand the range, select and configure the right modules, then purchase all the required components for a complete system. Visit the online configurator to see how the Modicon Edge I/O NTS can provide future- proof data handling for your smart factory.
Schneider Electric
www.se.com
automationmagazine.co.uk
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