Supplement: Power
Graphic 2: Simplified depiction of an AI process based on power supply data.
the functionality and availability of the converter function in the power supply. However, if an external influence, such as an overvoltage due to a lightning strike, were to result in a fault in the power supply, the internal IO-Link module can immediately output an error message to the higher-level control. The protocol can then be queried from the outside to analyse the situation that caused the failure and to find a solution. The power supply data obtained are permanently stored in the integrated memory in this process, and this data can be queried via a standard IO-LINK/USB-Master, for example.
Additional advantages of the EtherCAT communication protocol The integration of the available PULS power supplies with EtherCAT interface into existing EtherCAT networks is very easy and works without additional gateways, which is a big plus for users who already rely on this field bus solution.
The biggest benefit of EtherCAT is its real-time capabilities, high-speed data transmission and easy integration, which outperforms any other industrial communication. This allows the power supply data to be used within real-time control loops. Based on the data, drives and other high-energy users can be optimally controlled to maintain overall dynamic power needs at their optimum level. The data enables improved system efficiency as power supplies can be used at the optimal operating point. This leads
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to increased system availability throughput, improved product quality, and reduced waste, ultimately benefiting end-users by delivering better results due to the consistent performance and minimal disruptions. Power supplies with EtherCAT interface are ideal for maintenance, logging and remote control in large-scale systems.
AI decisions in the factory based on
The data recorded by power supplies with IO-Link or EtherCAT forms the basis for the technical innovations of the coming years. Above all, PULS is thinking here of the importance of machine learning in combination with the ongoing progress in terms of artificial intelligence (AI). The power supply is already supplying precise measurements of the output current, in other words, the load current. Based on these very carefully measured values, it is possible to detect and describe digital load profiles. Based on information on the output current, for example, it is possible to determine whether or not a load changes across an extended period. This change can be an indication of signs of wear in the machine or plant. As an example, in the case of knocked out profiles, a sinus curve would be detectable in the load profile. As part of computer-aided data analysis based on artificial neural networks, this anomaly would be detected and reported. Data is also provided by many other system components in parallel. Certain patterns
can be recognised in these data sets and linked to operating states. The next step would then be a similarly automated decision-making process on the subsequent procedure using AI. This approach means that the power supply and other components as data sources open up entirely new options in the use of AI in the factory environment.
The use of current as a standardised data source in the production process plays an important role here. As a physical value, current supplies precise, interpretable and reliable data. This means that common big data problems in established company structures, such as incompatibility and inconsistency of data, or difficulties in networking and scaling, can be avoided.
Summary
In conclusion, leveraging a power supply unit as a data source offers significant advantages for both operating companies and system manufacturers. By integrating PULS power supplies with IO-Link or EtherCAT, customers gain access to valuable real-time information such as output current, voltage levels, temperature development, and load on the power supply. This data enhances system availability and reduces maintenance costs while supporting predictive maintenance and automation of industrial processes.
With the addition of communication interfaces, power supplies play a more
active role in system diagnostics and parameterisation. The integration of IO-Link and EtherCAT into PULS power supplies ensures compatibility with existing networks and provides robust, real-time data transmission. This enables remote diagnostics, automated parameterisation, and efficient maintenance, ultimately leading to improved system efficiency, reduced energy costs, and enhanced overall performance.
Moreover, these systems are ready for an AI-shaped future. The data recorded by power supplies with IO-Link or EtherCAT forms the basis for technical innovations, including machine learning and artificial intelligence applications. This opens up new possibilities for optimising system performance and predictive maintenance.
Explore the benefits of these advanced power supply solutions and discover how they contribute to the success of your smart manufacturing initiatives.
PULS is a leading manufacturer of DIN-rail power supplies, field power supplies and complementary units. The company was founded in Munich in 1980 by Bernhard Erdl and currently has around 1400 employees worldwide. The division Wiferion – a PULS brand – develops innovative technologies in the field of inductive charging systems for automated guided vehicle systems and mobile robots. PULS manufactures all its products in its own plants in Chomutov/Czech Republic, Suzhou/China and Drebach/Germany.
https://www.pulspower.com/uk/
Position paper: Shaping European Data Spaces for Smart Manufacturing | Author: Trilateral cooperation between “Alliance Industrie du Futur”, “Piano Transizione Industria 4.0”, and “Plattform Industrie 4.0” References
www.cieonline.co.uk Components in Electronics December/January 2025 25
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