Supplement: Power
Graphic 1: Benefits of power supply data. Continued from page 22
decentralised applications feature IO-Link as well, and another variant supporting EtherCAT is under development. With all these new tools at hand customers profit from a future-proof solution that, alongside a highly efficient and reliable energy supply embedded in a compact housing, also provides completely new insights into the performance requirements and physical processes of their systems or machines. This valuable information can be used to better understand what is really going on in the application in order to optimise the availability and capacity utilisation of the system. In addition, the data helps to reduce energy costs, permits needs-oriented preventative maintenance and provides valuable information for sustainability reports.
Remote diagnostics and automated parameterisation
The connection via IO-Link or EtherCAT also facilitates remote diagnostics and parameterisation via the user software being applied in the automation system. The system engineer can set the output voltage via the configuration software and the devices can be switched on and off remotely assuming remote access is enabled in the user software.
The settings made by the user, as well as critical process values, are saved on
24 December/January 2025
the automation system with full resistance to voltage failures, and simultaneously on the built-in non-volatile memory in the power supply. If a device exchange becomes necessary, rapid, automated parameterisation of the new device is carried out during ongoing operation – in accordance with the parameters stored on the automation system. Downtime due to maintenance work is therefore avoided in the long term.
The data sent by the power supply also provides information on the cause of the fault and simplifies problem-solving. This data is categorised in cyclical data, acyclical data and events.
The output current is included in the process data, for example, and is communicated to the master in a cyclical data telegram. The acyclical signals include device information such as input and output parameters that can be queried at all times. Special events are also reported by the power supply. These events could be warnings or error messages, such as too low or too high input voltages, an overload or too high temperatures. If an abnormal condition arises, the power supply sends a message to the IO-Link or EtherCAT master and displays to the user the need for action, even before a failure actually occurs. Maintenance is therefore preventative and needs-oriented. This means that rigid cycles of regular servicing work are no longer required. In turn, this saves costs
Components in Electronics
on new purchases and maintenance. Additionally, events or warnings can trigger application reactions. In the simplest case, this can establish a safe state of the system. Furthermore, it is even possible to completely avoid system downtime based on the communicated events and therefore prevent insufficient product quality. Now let’s dive deeper into the advantages of IO-Link and EtherCAT.
Advantages of the IO-Link communication protocol IO-Link is based on serial, bidirectional point-to-point communication. The system is very robust overall and has a high level of security – two factors that PULS pays particular attention to in the development of its industrial power supplies. The devices are often exposed to the harsh environments of the lower automation level and at the same time need to be protected against sabotage from outside. Data transmission via IO-Link is tried and tested for this usage.
The component costs for an IO-Link port in the power supply is relatively low in comparison to more complex communication protocols. Due to the low number of additional components, the MTBF value (Mean Time Between Failures) is almost as high as for the products without IO-Link. E.g. the MTBF for the QT40.241 (without IO-Link) is 375,000 h and for the QT40.241-IOL (with IO-Link)
350,000 h. This means that there are no compromises in terms of the reliability of the devices.
The same also applies to the long lifetime of 62,000 hours – at 3AC 480V, continuous full load and +40°C ambient temperature. This makes the IO-Link- compatible power supplies particularly well suited to failure-critical applications, such as in the automotive industry, factory automation and process industries. In addition, IO-Link has been designed from the ground up as a user-friendly plug and play solution. Installation and operation are simple and can be realised cost-effectively. Standard shielded IO cables are all that are required for the cabling. Integration capability in all standard field bus and automation systems is ensured, offering flexible usage options.
IO-Link – reliability first In the development process, PULS engineers pay particular attention to reliability when selecting the components and designing the layout. The internal integration of the communication interface into existing power supply electronics has also been optimised in terms of reliability aspects, however. For example, the integrated PULS IO-Link module works autonomously from the actual AC/ DC conversion in the device. This means any failure in the IO-Link communication module would not have any effect on
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