PHOENIX CONTACT | Eduline Smart Lab

PHOENIX CONTACT | Eduline Smart Lab – Description

Eduline SmartLab – description Table of contents 1 New quality requirements ..........................................................................................................................4 2 Smart Labs for education ............................................................................................................................6 3 Eduline Smart Lab ........................................................................................................................................8 4 Learning scenarios ......................................................................................................................................14 Appendix: Configuration of technical equipment .....................................................................................16 All rights are reserved, including (but not restricted to) those relating to photocopying, microcopying, film adaptation, duplication using data, image, and sound carriers of any kind, and the reprinting of extracts. TechEducation – powered by Phoenix Contact 3

New qualification requirements 1 New qualification requirements In recent years, the digitalization of production has been promoted globally under the term Industry 4.0. Industry 4.0 is regarded as the fourth stage of industrialization. It represents the intelligent networking of resources, information, objects, and people based on cyber-physical systems (CPS). In companies, this can be seen, for example, in the fact that processes are mapped digitally and “smart” systems ensure that entire process chains, including material flows, are coordinated and optimized, that these are operated with IT support, and that predictive mainte- nance and process intervention are possible. Professional world of Industry 4.0 In Industry 4.0, the professional and working world will change fundamentally and place new requirements on the qualifications and competencies of skilled workers. This applies in particular to those activities that deal with the automation of technical processes in machine building and systems manufacturing, electrical engineering, process engineering, and logistics. The skilled workers concerned must increasingly work in ever more complex, interdisciplinary, and networked contexts. Collaboration across company and domain boundaries is becoming more and more common. The requirements concerning the competency profiles of skilled workers are therefore also changing. Vocational and academic educational institutions must meet this challenge and adapt their curriculum and training format to keep pace with technological change. This requires not just new professional qualifications for an improved understanding of processes and systems; methodical, social, and personal skills for mastering networked systems are equally important. Complex digitalized production processes require interdisciplinary collaboration throughout the entire value added chain. The increasing complexity of networked systems also calls on the problem-solving and self-learning skills of all the skilled workers involved. New requirements With regard to the automation technology aspects of digitalized production and based on various analyses and studies, the following key qualification and competency requirements can be identified for future skilled workers in the context of Industry 4.0: Use of Web 2.0 and mobile devices Familiarity and proficiency with regard to the digital networking of virtual and real systems Cross-domain and cross-functional collaboration Ability to handle uncertainties and complexity (big data and artificial intelligence) Highly skilled at efficient problem solving Understanding the difference between the virtual representation (digital twin) and the real process Interdisciplinarity and mutual understanding of process chains Teaching and promoting innovation skills The individual qualification topics, such as planning and creating control programs, evaluating 4 TechEducation – powered by Phoenix Contact

Smart Labs for education 2 Smart Labs for education Smart Education Lab Smart in Industry 4.0 The term Smart Lab has been used worldwide for several years for different areas of application and with differing content. These include, for example, Smart Labs for education and training (Smart Education Lab). In these Smart Labs, the focus is on the pedagogical and didactic aspects in particular. Modern digital media and new forms of teaching and learning are used here, such as customized learning formats, new forms of interaction, and the comprehensive analysis of learning data. The term Smart Lab also often refers to learning scenarios that use virtual reality and/or augmented reality in the learning environment. The Smart Labs in the field of education are more a concept and guide for the implementation of Education 2.0, realized to some extent as learning platforms on the Internet or digital training ecosystems. They are not available as a direct product in the education market. With the increasing digitalization of production, the use of cyber-physical systems, and the concept of Industry 4.0, the term “smart” is often used as a synonym for the modern automation of technical processes. For example, the Smart Factory is a core element of Industry 4.0. It is characterized by a new intensity of sociotechnical interaction between all agents and resources involved in production. At the center is a network of autonomous, situationally self-controlling, self-configuring, knowledge-based, sensor-supported, and physically distributed production resources (production machinery, robots, conveying and storage systems, equipment) including their planning and control systems. In other application areas of automation, for example, you also have Smart Logistics (automation in the transport of goods and commodities), Smart Home (building automation), and Smart Farming (automation in agriculture) in the context of Industry 4.0 and the Industrial Internet. Smart Automation Lab To qualify skilled workers for the development, operation, and maintenance of a Smart Factory, educational institutions need to be equipped with appropriate laboratories. They illustrate the basic principles, methods, and objects of a Smart Factory in a realistic and practice-oriented manner for learning and teaching purposes. For this reason, suitably equipped laboratories are increasingly being set up as Smart Automation Labs at vocational and academic educational institutions worldwide. In these training laboratories, the focus is on the typical content-related concepts and structures for a production system based on cyber-physical systems. These include, for example, standard- ized, flexible, and open control systems, web-based operator interfaces, horizontal communica- tion in the field level, consistent networking in the automation hierarchy, cloud-supported analysis and diagnostics, and the integration of virtual controllers and digital twins. The design, function, and method of operation of these components and their use for typical applications from the production and manufacturing process are the focus of the training. 6 TechEducation – powered by Phoenix Contact

Smart Labs for education Smart Automation Labs are complex training systems that are developed and set up at educa- tional institutions as part of specific projects. They are neither reproducible nor available for purchase on the market. In some cases, machine building systems suitable for laboratory purposes, such as conveyors, processing stations, and assembly robots, are also marketed as Smart Lab systems. However, without the necessary electronic components and IT components for modern automation, such systems can only be used in the conventional way. Smart Labs are also used in chemical process engineering and the life science sector. However, in this case the term does not refer to training laboratories, but to automated analysis and diagnos- tic laboratories that are required for the production of various chemical and/or medical products. Other Smart Labs TechEducation – powered by Phoenix Contact 7

Eduline Smart Lab 3 Eduline Smart Lab The Eduline Smart Lab is an education solution from Phoenix Contact which is based on the hardware components in the Eduline product range. It provides a modular and flexible way of realizing new educational requirements in the age of Industry 4.0 for the digitalization of produc- tion. The Eduline Smart Lab provides all the automation and information technology components (including educational material) necessary to set up a Smart Factory in the learning laboratory for various industries. Existing electromechanical systems or system parts (conveyors, workpiece storage, processing stations, robots, etc.) available in educational institutions can be used together with the Eduline Smart Lab, and, if necessary, also combined with new stations, to realize an industry-typical Smart Factory for training purposes. Fixed investments in the educational institutions are kept within limits, making it possible to concentrate on the core automation technology components of a Smart Lab in training and teaching. Concept and structure The Eduline Smart Lab provides all the automation and information technology components required for setting up a Smart Factory in the laboratory (Smart Factory Lab). These include the following hardware components: Eduline Technology: Training board with PLCnext Control device Eduline HMI Board: Operation and visualization of the technical process Eduline PROFINET Board: Extension of the basic system with classic fieldbus systems and/ or Ethernet-based bus systems (e.g., PROFINET) and intelligent I/O interfaces (e.g., IO-Link) Eduline Switch Board: Local networking of all device components Eduline Power Supply Board: Power for the modules Figure 1 shows the hardware components for an Eduline Smart Lab. Figure 1: Hardware components for the Eduline Smart Lab Eduline PLCnext Technology Board Eduline HMI Board Eduline PROFINET Board Eduline Switch Board Eduline Power Supply Board 8 TechEducation – powered by Phoenix Contact

Eduline Smart Lab All hardware components are products from the Eduline range TechEducation – powered by Phoenix Contact. They are mounted on DIN A4 training boards and cabled ready for operation (for detailed device description, see Appendix). If required, the Eduline Smart Lab can be extend- ed with further modules from the Eduline product range for TechEducation – powered by Phoenix Contact. Figure 2 shows an example configuration of an Eduline Smart Lab for a less complex Smart Factory. The configuration shown in Figure 2 can be used, for example, to set up a system structure (technology model) for a Smart Factory Lab in which 48 digital and 10 analog I/O process signals and 16 I/O-Link process signals from sensors/actuators can be processed. The digital and analog I/O signals for I/O simulation (toggle switches, LEDs, potentiometers, LED bar graph) built into the PLCnext Board can, if necessary, also be used to connect technology systems/models. PLCnext Engineer as software for configuration and engineering Cloud (PROFICLOUD, AWS, MS Azure, etc.) Eduline Smart Lab with two IO servers Figure 2: Eduline Smart Lab for setting up a less complex Smart Factory PLCnext Board HMI web Ethernet panel switch Power supply IO server I IO server II PROFINET + IO-Link PROFINET + IO-Link Eduline Smart Lab According to the requirements of the educational institution Real station as a technological process, e.g., small robot, assembly, Smart Home, Smart Farming Smart Factory Lab With appropriate scaling, even extensive systems of a Smart Factory can be operated via the Eduline Smart Lab. In addition to the hardware, important components for an Eduline Smart Lab are the educational materials for teaching the core automation technology topics of Industry 4.0. The topics cover classic and advanced topics in automation technology. They are based on the Reference Architec- ture Model for Industry 4.0 (RAMI 4.0). Topics TechEducation – powered by Phoenix Contact 9

Eduline Smart Lab The training topics are structured as follows: Topic 1: Open- and closed-loop control technology Every automation solution for a Smart Factory is based on a high-performance, open, and standardized controller. PLCnext Control including the associated PLCnext Technology is used as the controller. The training topics are: Installation and configuration of PLCs Basic principles of PLC programming in accordance with IEC 61131 Integration of high-level programming languages (C++, C#) in PLC programs as a supplemen- tary topic Topic 2: Operation and monitoring Modern operating and monitoring systems (HMIs – Human Machine Interfaces) for process and production automation are increasingly based on web technologies and use the web browser as a stationary or mobile operator terminal. The training content in this topic covers: Basic principles of human-machine communication Configuration and implementation of operator interfaces for a PLCnext control system Visualization of process data for the operation and management of automated technical processes Topic 3: Field-level communication Ethernet-based real-time bus systems (supplemented by intelligent feeder interfaces) are increas- ingly being used for the communication and networking of distributed sensors and actuators at field level and in the factory. The training topics are: Basic principles of communication with PROFINET, Modbus/TCP, and EtherNet/IP at field level Basic principles of IO-Link for the connection of intelligent sensors/actuators Planning, configuration, and startup of industrial communication networks Diagnostics and analysis of communication networks in conjunction with PLCnext Technology 10 TechEducation – powered by Phoenix Contact

Eduline Smart Lab Topic 4: Vertical networking When it comes to the digitalization of production in the context of Industry 4.0, networking over vertical automation levels all the way to global networking plays a key role in the automa- tion of the entire value added chain. The training content in this topic covers: Basic principles and global networking with OPC UA and MQTT Using cloud gateways with PLCnext Control Networking with the RESTful HTTP protocol Using PLCnext Control as a cyber-physical system Topic 5: Cloud computing Cloud computing is a hot topic in industrial automation in the context of Industry 4.0, cy- ber-physical production systems (CPPS), and the Industrial Internet of Things. Data, services, and functions are stored, accessed, and executed in CPPS, providing significant advantages especially in terms of flexible production. The training content for this topic therefore focuses on: Basic principles of cloud computing for industrial automation Data analysis and visualization in PROFICLOUD Connecting PLCnext Control to cloud systems favored by the manufacturing industry (e.g., Amazon Web Service and MS Azure) The topic will be gradually extended with additional training topics as required, such as big data analytics, digital twins, and machine learning for predictive system maintenance and diagnostics. The Eduline Smart Lab is structured as an extendable Smart Lab in terms of the hardware components and topics that can be configured, and can be used flexibly according to require- ments. Table 1 lists the hardware components required for the corresponding configuration level. The topics that can be taught and learned in the respective configuration level are listed in Table 2. Configuration levels TechEducation – powered by Phoenix Contact 11

Eduline Smart Lab Configuration level PLCnext Technology Board Eduline Smart Lab components HMI panel IO server Switch Power supply Table 1: Configuration levels for the Eduline Smart Lab Primary Basic Standard Advanced The five topics correspond to those that are fundamentally required for the automation of technical processes in the context of Industry 4.0. With the Eduline Smart Lab and its thematic course packages, it is therefore possible to cover a large part of the required learning content in accordance with vocational training regulations with regard to Industry 4.0-relevant qualification requirements for industrial electrical professions and mechatronics engineers. Since the educational topics of the Eduline Smart Lab are not aimed at specific industries, but are geared towards the basic principles of automation and information technology, the Eduline Smart Lab and the associated training documents can also be used for Smart Home Labs, Smart Grid Labs, Smart Farming Labs, etc. - - - - - - - - Configuration level Primary Basic Standard Advanced - - - - - - - - - Training topics Open- and closed-loop control technology Operation and monitoring Communication Networking Cloud computing Table 2: Topics for the Eduline Smart Lab configuration levels Scope of training 12 TechEducation – powered by Phoenix Contact

Learning scenarios 4 Learning scenarios Smart Education Lab The Eduline Smart Lab enables the realization of Smart Labs of varying complexity and for different industries. In each case, it provides all the educational materials required for skills- and practice-oriented education and training for the digitalization of production. The range of possible applications for the Eduline Smart Lab is illustrated below using three learning scenarios from different industries. Learning scenario 1 In learning scenario 1, the following topics in particular can be covered: Basic principles of PLC technology (topic 1) Human-machine communication (topic 2) Just two hardware components are required here: the PLCnext Technology Board and HMI web panel. Many of the basic principles of automation technology for Industry 4.0 can be taught with just these two components. The IO simulations (toggle switches, LEDs, potentiometers, LED bar graph) on the PLCnext Board are used as the technology model (system). The PLC programs used for training are relatively simple and can be tested and operated with the help of the IO simulations. However, if the PLCnext Technology Board is connected to the local and/or public network (Internet), some basic principles from other topics can also be incorporated in the training. These include: Basic principles of networking with OPC UA and MQTT (topic 4) Basic principles of cloud computing (topic 5) Learning scenario 2 Learning scenario 2 can be used to provide practical training for almost all the individual topics from topic areas 1, 2, 4, and 5. From topic area 3 (field-level communication), the training focuses on these topics: Basic principles of communication with PROFINET Planning, configuration, and startup of a PROFINET communication network Diagnostics and analysis of PROFINET in conjunction with PLCnext Technology In the learning scenario, the Eduline Smart Lab is used to set up a Smart Factory Lab. The technology model used is a typical industrial production cell with two processing stations (rotary table for inspecting and drilling a workpiece) and a loading robot. Figure 3 shows the system model used. The robot feeds both processing stations so that they can process two workpieces simultaneous- ly. The processing stations and robots are synchronized so that both stations are constantly 14 TechEducation – powered by Phoenix Contact

Learning scenarios Tray with workpiece 1 and 2 Start by inserting workpiece 1 in Pos. 1/Station 1 and workpiece 2 in Pos. 1/ Station 2 Station 2 Pos. 1 Pos. 2 Pos. 3 Figure 3: Production cell with two processing sta- tions and a loading robot Station 1 Pos. 4 Pos. 3 Pos. 2 Pos. 1 Pos. 4 processing workpieces. The dashed lines in Figure 3 indicate the motion of the robot and the solid lines indicate the motion of the two rotary tables. All hardware components used are from the Eduline Smart Lab. The following are required: 21 digital inputs, 18 digital outputs, four analog inputs, and four analog outputs. PROFINET is used as the communication system at field level. Higher-level control functions are connected to the system via OPC UA. Learning scenario 3 can also be used to provide practical training for almost all the individual topics from topic areas 1, 2, 4, and 5. From topic area 3 (field-level communication), the training in this learning scenario focuses on these topics: Learning scenario 3 Basic principles of communication with PROFINET Planning, configuration, and startup of a PROFINET communication network Planning, configuration, and startup of IO-Link sensors TechEducation – powered by Phoenix Contact 15

Learning scenarios The learning scenario uses the Eduline Smart Lab to set up a Smart Farming Lab and uses a greenhouse as the technology model. Figure 4 illustrates the basic structure. Just the following hardware components are required from the Eduline Smart Lab: PLCnext Technology Board, HMI web panel, and switch. All the necessary I/O signals (16 digital I/Os and 2 analog I/Os) can be connected directly to the PLCnext Technology Board. To do this, the I/O connectors on the I/O modules with the cabled I/O simulation are replaced with new I/O connectors with the greenhouse I/O signals. SFN 5TX switch Ethernet Figure 4: Component structure of a Smart Farming Lab with the Eduline Smart Lab Ethernet Ethernet Cloud (data storage) I/O signals PROFINET is used as the communication system and is already available on the PLCnext Tech- nology Board. The PLCnext Technology Board is connected to the Internet in order to store process data in PROFICLOUD for analysis and visualization. Appendix: Configuration of technical equipment All Eduline Smart Lab modules are designed as DIN A4 training boards and come from Eduline modular, Phoenix Contact’s educational range of devices. The modules for an Eduline Smart Lab can be set up and connected horizontally on a lab bench, or they can be suspended in a vertical frame and connected there. 16 TechEducation – powered by Phoenix Contact

Appendix: Configuration of technical equipment The Eduline PLCnext Technology Board consists of the modules listed in the following table: AXC F 2152 PLCnext Control PLCnext Control for the direct control of Axioline F I/Os. With two Ethernet inter- faces. Complete with connector and bus base module. Data interfaces: Axioline F local bus, Ethernet (10/100 Mbps – full duplex) PROFINET: PROFINET controller, PROFINET device IoT capability: PROFICLOUD, MQTT Engineering tool: PLCnext Engineer, Eclipse, MATLAB® Simulink® Operating system: Linux AXL F DI8/1 DO8/1 I/O module 2 x The module is designed for use within an Axioline F station. It is used to acquire and output digital signals. The filter times of the inputs can be adjusted to increase immu- nity. The outputs are protected against short circuit and overload. 8 x digital inputs: 8, 24 V DC, connection technology: 1-conductor 8 x digital outputs: 8, 24 V DC, 500 mA, connection technology: 1-conductor AXL F AI2 AO2 1H I/O module The module is designed for use within an Axioline F station. It is used to acquire and output analog voltage and current signals. 2 x analog inputs: 2, 0 V ... 5 V, -5 V ... 5 V, 0 V ... 10 V, -10 V ... 10 V, 0 mA ... 20 mA, 4 mA ... 20 mA, -20 mA ... 20 mA, connection technology: 2-conductor 2 x analog outputs: 2, 0 V ... 5 V, -5 V ...5 V, 0 V ... 10 V, -10 V ... 10 V, 0 mA ... 20 mA, 4 mA ... 20 mA, -20 mA ... 20 mA, connection technology: 2-conductor AXL F BK PN bus coupler The bus coupler is designed for use within a PROFINET network. The bus coupler creates the link to the Axioline F I/O system and the industrial I/O signals connected to it. Up to 63 Axioline F devices can be connected to the bus coupler. Corresponding GSDML files are available for integrating the Axioline F station into other program- ming systems. 18 TechEducation – powered by Phoenix Contact

Appendix: Configuration of technical equipment Configuration level: Basic In this configuration level, the Eduline PLCnext Technology Board is supplemented with an HMI web panel. The HMI web panel is an Eduline training board for operating and monitoring a simulated or real system. Eduline HMI Board EDU HMI 4070 The most important element of the Eduline HMI Board is a touch panel with the following features: Touch panel with 17.8 cm / 7" TFT display (analog resistive (polyester)) 800 x 480 pixels (WVGA) and 65,536 colors Arm9™, 200 MHz 2x USB Host 2.0 1x Ethernet (10/100 Mbps), RJ45 Windows CE 5.0 and user software: Micro- Browser Configuration level: Standard The configuration level extends the EduNet Smart Lab with an IO server (EDU PN/EIP IO server) and a power supply unit. PROFINET or EtherNet/IP can be used as the communication system. In both cases, intelligent sensors and actuators can be connected to the IO server via an IO-Link master. The following table lists the modules for the IO server extension board. AXL F BK PN bus coupler for EDU PN IO server or AXL F BK EIP for EDU EIP IO server A bus coupler for PROFINET or for Edu-Net/IP can be used as the bus coupler. Up to 63 Axioline F devices can be connected to the bus coupler. Corresponding GSDML files are available for integrating the Axioline F station into other programming systems. Network protocols: PROFINET or EtherNet/IP, SNMP, TFTP, DCP, BootP, etc. 20 TechEducation – powered by Phoenix Contact

Appendix: Configuration of technical equipment Module carrier for Smart Elements – AXL F BP SE6 The module carrier (Axioline F backplane) is designed for use within a station that is opened by an Axioline F bus coupler. The backplane has six “Smart Element Interface” slots to accommodate Axioline Smart Elements. AXL SE DI16/1 I/O module (Axioline Smart Element) The Smart Element is designed for the input of 16 digital signals in 1-conduc- tor technology with 24 V DC. AXL SE DO16/1 I/O module (Axioline Smart Element) The Smart Element is designed for the output of 16 digital signals in 1-con- ductor technology with 24 V DC/max. 500 mA. AXL SE AI4 U 0-10 I/O module (Axioline Smart Element) The Smart Element is designed for the input of four analog signals in 2-conductor technology. Input signal: 0 … 10 V AXL SE AO4 U 0-10 I/O module (Axioline Smart Element) The Smart Element is designed for the output of four analog signals in 2-conductor technology. Output signal: 0 … 10 V AXL SE IOL4 I/O module (Axioline Smart Element) 2 x The Smart Element contains an IO-Link master with 4 IO-Link ports (Class A). The IO-Link master enables the operation of up to four IO-Link devices. Alternatively, a standard digital sensor or actuator can be connect- ed to each port. 22 TechEducation – powered by Phoenix Contact

Appendix: Configuration of technical equipment The Eduline Power Supply Board is designed to supply power to the IO server as well as the Ethernet switch, but can of course also be used to supply power to other modules. Configuration level: Advanced Eduline Power Supply Board EDU PS 24 DC The Power Supply Board supplies all Eduline modules with 24 V DC supply voltage. The module is assembled with a STEP-PS/ 1AC/24DC/4.2 power supply. In this configuration level, the Eduline Smart Lab is supplemented with an Ethernet switch, which allows all components to be connected to a local network or to the Internet, for example. Eduline Switch Board EDU FL SWITCH SFN 5TX An industrial Ethernet switch with the following characteristics is installed on the module: 5 TP-RJ45 ports Automatic detection of data transmission speed of 10 or 100 Mbps (RJ45) Autocrossing function TechEducation – powered by Phoenix Contact 23