2|16 The customer magazine from Phoenix Contact | June 2016 Consistently digital The Internet of Things revolutionizes automation
02 Editorial UPDATE 2|16 Ulrich Leidecker, President Industry Management and Automation (IMA) The best of both worlds Dear readers, At the last Hannover Messe, more attended than ever before: many well- known names in the IT world showcased their range of products and services for machine building and systems manufacturing at the industrial fair. The message? Jump onto the digital train with us, the IT specialists, so that you do not miss the connection to the business of the future. At this year's Light & Building as well, it was the buzzword par excellence: the Internet of Things – IoT – which entices with its billion dollar turnovers in building and infrastructure automation. You get dizzy just thinking about it. Time to determine our position. It is indisputable that we in the industry are at the brink of an epochal change in technology. But that does not mean that knowledge about the industries and specifi c technologies in the industry as well as their approach to challenges is suddenly obsolete. On the contrary – only through the experience with the industry's requirements can a "Big Data" solution or an Internet-based automation platform take its power to the streets. That's why we from Phoenix Contact off er solutions that combine the best of both worlds. This allows you to benefi t from automation solutions that exploit the potential of web technologies that are, however, simultaneously embedded in a familiar environment and thus precisely tailored to the industry's needs. Only through the synergies of automation and IT, the "disruptive shift" becomes invaluable, business processes can be consistently optimized, consumption of resources reduced and comfort increased. See for yourself how easy it is to reap the rewards of web technologies with Profi cloud or our new Building IoT Ecosystem. I hope you enjoy our magazine. Editorial 02 Ulrich Leidecker Interview 03 Dr.-Ing. Gert-Ulrich Vack, Sysmik GmbH Cover story Automation 04 Automation technology from Phoenix Contact ensures effi cient fl ood protection Technology Safety technology 08 Easily integrate functional safety into existing networks with SafetyBridge technology 12 Connection technology Smart Wiring for fl exible production facilities Automation 16 Automate across borders with Profi cloud On site 10 14 18 Safety technology SafetyBridge technology in grinding machines Automation The Building IoT Ecosystem in use at Phoenix Contact Electronics The AXC 1050 small-scale controller on the Erasmus Bridge in Rotterdam New products 21 Profi net bus coupler for Axioline KNX installation terminal block Modular electronics housings Quint Power power supply News 22 Smartfactory OWL inaugurated 22 Digitization laboratory in Schieder tests Industrie 4.0 23 New specialist book on the functional safety of machinery phoenixcontact.com
UPDATE 2|16 Interview 03 One platform – many languages Web-based solutions for Building IoT and infrastructure are fit for industrial application Sysmik GmbH is a leading provider of web- based solutions for Building IoT (Internet of Things) and infrastructure. The Dresden-based company has been part of the Phoenix Contact Group since October 2015. The editors at UPDATE asked Managing Director Dr. Ing. Gert-Ulrich Vack about where automation in building technology is heading. UPDATE: Dr. Vack, you are one of the first in Germany to have picked up the technology for Building IoT and successfully offered it on the market. How did that happen? Dr. Vack: In 1991, we started using LON* technology for networking in buildings. The vision was to network all switches, lamps, climate controllers – that is, sensors and actuators – with one another. The highest energy efficiency class requires network-wide data exchange for optimal building operation. I got to know Tridium in the United States in 2004 and decided to choose their software technology, the Niagara Framework. UPDATE: You saw it and immediately thought: that's it? Dr. Vack: Yes, because merely selling devices – that's only half the story. The software makes all the difference! Tridium had piqued my interest because it had developed an Internet-based software technology for a major energy company. It was used to centrally manage all the dispersed branch offices. UPDATE: What was so special about it? Dr. Vack: Systems from different manufacturers were installed in the properties. The ingenious idea behind Tridium's Niagara Framework is to standardize the various communication protocols and data types on a common web-based platform: an "Esperanto of automation". This concept was so fascinating that we have been working with Tridium as a Value Added Reseller and development partner since 2004. Dr.-Ing. Gert-Ulrich Vack, Sysmik GmbH UPDATE: What does that have to do with the Internet of Things? Dr. Vack: IoT triggers a radical change in the business world. The Niagara Framework optimizes resource consumption through the continuous evaluation of building data, thereby reducing operating and service costs. Many hundreds of drug stores belonging to a well-known chain have installed this technology. Our products and services provide an important basis for implementation. UPDATE: Why was the partnership with Phoenix Contact interesting to Sysmik? Dr. Vack: We have been successfully working together in projects as the product supplier since 2004. With the Scalibur controller, which, as ILC 2050BI, expands the modular Inline controller for IoT, we now offer an embedded platform that unifies the automation of buildings, infrastructure and the world of industry. Scalibur is unique in the world and was just launched to great success together with Phoenix Contact at the Niagara Summit in New Orleans. UPDATE: Thank you very much for talking to us! "Thanks to the Scalibur controller, which, as ILC 2050BI expands the modular Inline controller for IoT, we now offer an embedded platform." * Local Operating Network (LON): Fieldbus standard, mainly for decentralized building automation
04 On site UPDATE 2|16
UPDATE 2|16 On site 05 So that the polders stay dry Automation technology from Phoenix Contact ensures efficient and reliable flood protection The Dutch water authority Rivierenland has, as part of its modernization measures, replaced obsolete technology with automation components from Phoenix Contact. The new equipment helps contribute to cross- border flood protection. It also helps reduce engineering expenditure while increasing system availability. As part of a project by the International Water Association (IWA), a total of 165 weirs and 135 channel pumping stations will be converted to modern technologies. This also affects the landmark pumping station in Nijmegen, built in 1932 and operated by the Dutch water authority Rivierenland in Tiel. The authority is responsible for the water regime of an area roughly located between the Rhine/Lek and Maas rivers, extending from the German border to Kinderdijk, 15 kilometers southeast of Rotterdam. 194 polder pumping stations maintain the water level in the river basin ditches at the desired level. The larger pumping stations can pump up to 60,000 liters of water per second from a lower to a higher watercourse. This permits precise coordination of the water demand required by the individual regions. In Nijmegen's pumping station, the relay technology previously used has been replaced by automation technology from Phoenix Contact. The centrally installed RFC 470 PN 3TX controller regulates up to three large pumps with a total capacity of up to 16 cubic meters of water per minute. This corresponds to about 80 filled bathtubs per second. The central controller reads the big frequency inverters of At Rivierenland, the larger pumping stations can pump up to 60,000 liters of water per second from a lower to a higher watercourse the various pumps via the Profinet protocol so that the power units are constantly monitored. Profinet bus couplers distributed across the system permit various sensors and actuators to be connected via digital and analog signals. The bus system used here permits all signals that occur in the system to be read, processed and output again quickly. Simple diagnostic options assist employees during a fault when troubleshooting. The pumping station in Nijmegen, built in 1932, will likewise be retrofitted with modern automation technology Convenient visualization and operation via touch panel In addition to a quick diagnosis, employees must be able to intervene at any time in the process during operation. A panel with touch capabilities has therefore been built into the control cabinet door which permits continuous operation and surveillance of the building and the power units on site. All measurement and operating data are displayed at all times on the easily legible display and manually changed by the staff when required.
06 On site UPDATE 2|16 Due to the high investment and service costs incurred when using a SCADA system for updates and regular maintenance, the Rivierenland water authority management have opted for the web-based visualization software WebVisit from Phoenix Contact. This results in low costs over the entire service life of the system. In addition, the solution opens up a high degree of flexibility when creating operator-specific visualization interfaces. The visualization solution on site in the pumping station communicates via an Ethernet connection directly to the RFC 470 PN 3TX central controller. It displays the current state of the power units as well as metrics and operational data via web pages on the panel. Internet access lets the staff retrieve the current values of all pumping stations and weirs via a secured VPN tunnel (Virtual Private Network). Another advantage for the staff is the uniform design of the individual websites, which permits intuitive operation. Likewise, a similar standard was developed for programming the controllers and the documentation. Doing so lowered the engineering costs for the water authority Rivierenland. Reliable data transmission Constant monitoring of remote distributed outdoor systems requires a connection to a superordinate control system. That's why a permanently manned control room was set up in the control room of the Rivierenland water authority. The most important measurement and operational data are now exchanged in a fail-safe and reliable manner via a special remote control protocol. Communication between the decentralized buildings and the control room is via secure ADSL Internet connections. With IEC 60870-104, the water authority uses a standard specialized in requirements relating to remote control that permits safe and loss-free data exchange between the individual stations and the central control system. The central controller installed in the pumping station processes the control The pumping stations installed in Nijmegen are regulated by a high- performance RFC 470 PN 3TX controller
UPDATE 2|16 On site 07 commands, which are prompted by the control room staff and sends the current operating data via the VPN connection to the control room. Should data transmission be interrupted, all information is issued with a time stamp and is stored in the memory of the RFC 470 PN 3TX. Once communication is restored, the controller transmits the data in the correct order to the control room. This way, no event that has occurred in the remote stations is lost and the staff is able to view all of the operating data. Resource-saving supply of smaller external buildings Besides modernizing the relay technology, which was previously installed in the pumping stations and weirs, the Rivierenland water authority is seeking a neutral energy balance by 2030. To achieve this goal, renewable energy sources, for example, are being used on smaller weirs. Solar panels and small wind turbines locally produce the energy that is necessary to supply the external buildings. In order to have enough renewable energy to operate each system, electrical components with a low power consumption are required. Built-in equipment that is less energy efficient is therefore replaced Johan van IJmeren with the 8113 industrial tablet PC, which is suitable for indoor and outdoor use by economical automation products from Phoenix Contact. This kind of swap permits the resource-efficient operation of all weirs and thus contributes to protecting the environment. Joel Stratemann phoenixcontact.com HMIs and industrial PCs from Phoenix Contact for marine and outdoor applications that are specifically designed to meet these requirements. The panel PC with touch functions is built into the control cabinet Phoenix Contact offers robust and reliable technology for operation and monitoring: starting with HMIs (Human Machine Interfaces) and powerful industrial PCs right through to customized solutions for specific industrial requirements. The requirements placed on the user interface, functionality, and system coupling determine the right visualization system and HMI device – from the simple operational data indicator up to high-end visualization. Industrial PCs are indispensable in industrial environments. Touchscreen monitors and attractive panel and tablet PCs are also part of the portfolio as well as powerful 19" box and rack PCs. For use under extreme environmental conditions, Phoenix Contact offers devices
08 Technology UPDATE 2|16 SafetyBridge technology supports the I/O systems Inline and Axioline F Safety for each controller Easily integrate functional safety into existing networks With SafetyBridge technology (SBT), Phoenix Contact has developed a distributed safety solution for automation networks. The certified SBT modules transmit secure data packets. They thereby use the standard controller and the existing automation network to transport these. Since the Hannover Messe, the I/O system Axioline F has also been supported. In many applications, conventional safety technology based on electromechanical components such as relays and contactors is still frequently used. However, this means that the safe signals must be wired in parallel and the flexibility in terms of their function is low. Safety controllers based on microprocessors are increasingly being used by design engineers when dealing with a medium to large volume of safe signals. But not every controller manufacturer offers a safety controller and not every user wants to pay the corresponding surcharge. In addition, numerous machine builders are developing their own controller. However, they often lack the expertise to design these as a safety version so that they have to use remote solutions. The SafetyBridge technology was created against this background, which, in the first step, was based on the hardware of the Profisafe modules of the Inline I/O system. Secure in each network An SBT system consists of secure input and output modules and logic modules. The secure input and output modules record the secure signals or output these. Besides this main task, they continuously perform self-diagnosis. The logic module is a central part of the installation of SafetyBridge. It generates and controls the safety-oriented SBT transmission protocol and processes the logical operators of the parameterized safety logic. The logic module is also equipped with secure outputs. The secure signals that are received and output with the SafetyBridge I/O modules can be transmitted across almost all automation networks. These include, for example, Interbus, Profibus, Profinet, Ethernet/IP, Ethercat, CANopen, Sercos III or Modbus on all common controller types. The respective network and the controller used are only employed as a
UPDATE 2|16 Technology 09 means of transport. Therefore, they do not need to be taken into account in the safety appraisal. Secure even without cables The SafetyBridge protocol identifies all possible communication errors and detects these. When an error is detected, the SBT system immediately uses the substitute values. If, for example, a transmission error occurs with an input module, the system assumes an actuated emergency stop button and switches to the safe state. The SafetyBridge protocol can also communicate wirelessly – no matter whether the user uses WLAN or Bluetooth as the transmission standard. The standard controller handles data exchange between the modules using function blocks. The blocks are also responsible for transferring the secure logic into the logic module and provide extensive diagnostic information. Besides the module diagnoses, the PLC programmer also has access to the status of all the secure inputs and outputs. Without additional hardware, wiring or programming effort, it thus receives information about which safety door was opened or which emergency stop button was pressed. In combination with a visualization solution, the machine operator thus receives instructions to eliminate the fault. Downtimes that result from the functional safety are thereby reduced. Simple configuration of the safety logic via drag and drop The safety application is configured with the free Safeconf software. The tool provides all the necessary functions on the user interface. Here the user can configure the entire safety logic using drag and drop without having to jump between different windows Due to the great demand for SafetyBridge, Phoenix Contact has now expanded the technology for use in the block-modular I/O system Axioline F. Since the 2016 Hannover Messe, one logic module and one digital input and output module are available. All modules comprise of four secure digital inputs or outputs each for two-channel assignment as well as eight secure digital inputs or outputs for single-channel assignment. Lutz Rahlves phoenixcontact.com The SafetyBridge system is easy to configure using the Safeconf software
10 On site UPDATE 2|16 Safe without Safety PLC SafetyBridge technology in grinding machines Safety-related functions need to be executed without an additional safe controller in the machines from Ulmer Werkzeugschleiftechnik GmbH & Co. KG. The SafetyBridge technology from Phoenix Contact fulfills these requirements with flying colors. Ulmer Werkzeugschleiftechnik GmbH & Co. KG develops and manufactures grinding machines used to make precision tools. For many years, the company from Ulm-Einsingen has specialized in high-performance multi-axis machine tools and cylindrical grinding machines. NUM AG's CNC control platform is used in all machine types. That's why the design engineers at Ulmer searched for a concept that implements safety-oriented functions without an additional safety controller. The safety signals are thereby to be transmitted via the standard CAN bus system. Another requirement was that both the safe and non-safe signals are visible in NUM's standard controller. The SafetyBridge technology (SBT) from Phoenix Contact was ideally suited. Handling all safety-related functions SafetyBridge technology is used for data protection in all machine types. The SBT components handle all safety-related functions. In addition to the conventional emergency stop monitoring functions, safety doors and loading doors have to be monitored, locked and unlocked. Moreover, the controller should safely call up the setup and service functions. Another requirement is in various enable signals for the pneumatics and hydraulics, as well as for the coolant. As these safety- related functions are sometimes connected
UPDATE 2|16 On site 11 The SafetyBridge components are connected via an IL CAN Inline BK module to NUM's CNC machine chronologically, flexible configuration via the Safeconf software tool is easier than a hard-wired solution with safety switching components. To ensure the supply voltage for servo drives, hydraulics and coolant is potential- free, Ulmer also uses a decentralized output module with a built-in safety relay. Access to all diagnostic information Deep integration of all SafetyBridge modules in the CNC controller is particularly advantageous. Here, CAN proves to be an easy-to-handle, cost- effective, and high-performance bus system. Since SBT can transmit safety signals without a bus, the corresponding components are merely connected via an IL CAN Inline BK module to the bus system. The safe SafetyBridge modules can then be flexibly arranged in the Inline station next to the standard I/O modules. The integration of SafetyBridge via software is just as easy. A special Operate function block for SBT, which can be imported from the Codesys library, provides the standard application with all the diagnostic and status information of the SafetyBridge components. In addition, the states of all the safe output channels for standard inputs are restored so that the otherwise usually complicated back-wiring is no longer necessary. The standard controller is also kept informed about the current status of all the safety functions at all times since it has direct read access to the diagnosis flags of the SBT logic module. At the outputs, the CNC controller can control the enable and reset signals within the logic module. If the enable principle is used, it even has write access to all the safe output channels. Administering the Safety projects on the standard controller The safety logic is created with the Safeconf configuration software. It is stored as an X.export.xml file and imported as a POE (program organization unit) into NUM AG's Flexium software. There it can then be saved as part of the overall project on the NUM type used. The program specifically requests this only when required. Another advantage of security project administration on the standard controller is its ease of use. Consequently, no software tool or memory card is required to replace the modules. The deep level of integration described here not only works with Codesys-based controller types such as Flexium/NUM, but can also be used for all other common controllers. The implementation of SafetyBridge technology at Ulmer proves that the comprehensive integration of the safety solution need not be contrary to the practice of a clear separation of standard and safety functions. controller. Moreover, a number of different Steffen Horn security projects can be configured and tested in advance based on the machine phoenixcontact.com
12 Technology UPDATE 2|16 Heavycon Modular and M12 connectors enable efficient cabling for complex systems Efficiency that can be plugged in Smart Wiring for flexible production facilities Intelligent production facilities are becoming increasingly networked, which increases the total number of cable connections. Modular and standardized connectors are helping to make automation more flexible and efficient. The industrial connectors Heavycon Modular and M12 circular connectors are central to the Smart Wiring concept. To modularize machines and systems in a highly integrated way, it makes sense to combine the transmission of data, signals and power in a single connector. Thus only one connector needs to be connected or disconnected in order to install or retrofit systems with minimal effort. Modular all-rounder: Heavycon With Heavycon Modular, Phoenix Contact provides a solution for transmitting power, signals and data via a single connector. The connector is assembled from a number of modules that are clicked into place in the newly developed snap-in frame with spring. Depending on the size of the connector, two, three, four or six modules can be fastened in a single frame. The modules are securely attached in the correct, designated position without becoming loose. Due to the frame, it is impossible to tilt or move the modules. With the variety of usable modules available, the application knows no limits. The data is transmitted via shielded copper conductors or fiber optics. Modules for attaching RJ45 connectors are available for this purpose. Preassembled and tested RJ45 patch cables may be deployed. For assembly on site, the user can make use of the IDC (insulation displacement connection) connection technology based on RJ Industrial. An additional module can accommodate an RJ45 connector with crimp connection. In a CAT6 module for Gigabit transmission, the wire pairs are also shielded in the connector. Thanks to the full copper shield in the module, interference-free data transmission is ensured even if energy is transmitted at the same time. If the EMC load is extremely high, then fiber optics, such as the SC and LC contacts from Phoenix Contact, can also be used. You can thereby use a variety of preassembled fiber optics. The field of application extends continuously from systems to network technology. Signals from sensors and actuators are also connected by means of Heavycon. Individual
UPDATE 2|16 Technology 13 simple locking mechanism, the M12 is suitable where space is limited. Many new applications are possible, thanks to the new internationally standardized coding that comprises the product range from Phoenix Contact. The K and S-coded versions of the M12 power connector are designed for an AC power supply with 630 V AC and 16 A. They permit the space-saving connection of AC motors and drives as well as frequency inverters, motor starters, power supplies or lighting systems. The L and T-coded M12 power connectors were designed for the low-voltage DC power supply for up to 63 V and 16 A. These reliably supply I/O modules, networking devices or motors with power, for example. Hybrid connectors for transmitting signals, data and power reduce the number of interfaces in the field. The optional fast locking system Speedcon minimizes cabling times. Hartmut Schwettmann/ Thomas Wolting phoenixcontact.com modules with up to 25 contacts are available. Since a basic signal connector has up to six modules, a packing density of 150 contacts per connector results from 25 contacts per module. For a universal connection: circular connectors M8 and M12 circular connectors offer an integrated solution to reliably connect automated production communication participants. Thanks to their versatility, they are suitable for the modular and scalable automation concepts of Industrie 4.0. They can be conveniently adapted to different applications and simultaneously transmit signals, data or power. The M12 circular connector in particular has become the leading connection system for sensors and actuators. The components are robust and user-friendly, the pin assignments are internationally standardized, and special internationally harmonized coding prevents incorrect insertion. The time-saving concept behind the connectors speeds up initial startup. System diagnostics in case of failure is simplified, due to clearly arranged installations. The M12 connector has evolved not only for data transmission – many new application possibilities arise when it comes to voltage and current. Thanks to its small designs and Heavycon Modular is the modular connector system for data, signals and power
14 Technology UPDATE 2|16 From a cost center to a profi t center Phoenix Contact uses Building IoT Ecosystem as standard If you want to operate commercial properties cost-eﬀ ectively today – whether they are apartments, offi ce buildings or industrial buildings – one thing is required, above all: data. Even at Phoenix Contact, those responsible for the operation of properties face the challenge of obtaining, evaluating and using the information from the technical facilities with the least possible eﬀ ort and applying it as the basis for new business models. With its own Building IoT Ecosystem, this is now being made a reality at Phoenix Contact. Initial tests were so convincing that this system will be introduced as a standard for the building infrastructure in the Phoenix Contact Group. With traditional automation, the concepts of networking facilities and technical equipment in buildings soon reach their limit in terms of feasibility or cost. Numerous, diff erent communication protocols that have developed over time have so far made a cross-facility approach and the systematic use of data almost impossible. The Building IoT Ecosystem from Phoenix Contact now combines all data streams in the building, regardless of protocol, starting with facility-based data and going right through Quality ISO EN 50.001 Integration Industrial Niagara Innovation Solution Open Modular System Functions Visionary Green Building Compact IoT Controller (ILC 2050BI) Smart Flexible
UPDATE 2|16 Technology 15 to usage-related data, such as that gained from production, logistics or office spaces. This results in consistency, right from the sensor to the higher-level control system. The programming effort required is massively reduced, thanks to the Building IoT Ecosystem. Different protocols and functions are integrated into the system with a few clicks, thanks to an extensive software library. Quick results When the system was first put into practice at Phoenix Contact Power Supplies GmbH in Paderborn and at Phoenix Contact Electronics in Bad Pyrmont, the benefits became apparent. In Paderborn, an existing fieldbus system installed in the purchased property was connected to the Building IoT Ecosystem with little effort. This brought together the current operating values from the uninterruptible power supply, the fire alarm system, heating and air conditioning in a web-based user interface. The information derived from this is now visualized in a customized cockpit control. It can even be retrieved from mobile terminal devices. What used to keep several programmers busy, in each individual project, is now accomplished by a single facility management employee in a matter of days. The objective: holistic building services management However, the combined depiction of values in the browser of a terminal device is only the first step. Broader objectives are pursued when implementing the IoT building infrastructure in the new building of the Solution Center in Bad Pyrmont. The office building, which is connected to the existing properties at Phoenix Contact in Bad Pyrmont, offers the opportunity to install the entire technical building equipment based on the Building IoT system. This results in new usage scenarios: facility and energy managers can work with the system independent of terminal device; right from the server through to smartphones or tablets. The energy flows are controlled and monitored by the building's active energy management. The photovoltaic Powerful functions, easy operation The special feature of the Building IoT system is the abstract depic- tion of all data points in a building as a software object, regardless of the fieldbus and communication protocol used. This way, a BACnet data point, for example, can be "captured" on the software interface without additional programming effort and connected to a data point from LON, KNX or other bus systems. This is made possible by a large library of driver modules for all common bus systems that transport the device-specific information in a universal format. This kind of universal software object is used to create system schematics, control processes, monitoring or visu- alization and to connect these to the building's ERP and accounting system. system with energy storage is also integrated into this. This avoids peak loads and significantly reduces energy costs. To reduce the building's operating costs even more, the Building IoT system is used for proactive maintenance concepts. This extends from conventional HVAC infrastructure right through to the three installed elevators, from which data is continuously recorded. Thanks to these functions, such a building can be operated in a networked way. This turns facility management from a pure cost center into a profit center. Christoph Manegold phoenixcontact.com
16 Technology UPDATE 2|16 Just get started with the IoT Automate across borders with Proficloud For many who program machinery and systems in automation technology, the idea to integrate services from the Internet into their programs or plan projects across locations is still a bold vision, to say the least. Proficloud expands the local Profinet network with Internet- based services in the familiar programming environment and permits communication across locations. Profinet is one of the fastest growing communication standards in automation technology. In order to combine the advantages of the real-time Ethernet protocol with the numerous possibilities of cloud technology, Phoenix Contact developed Proficloud. Where complex programming interfaces and function calls were once a must, now new virtual devices simply appear in the bus overview within the PLC programming environment, such as PC Worx or the TIA portal from Siemens. It can be called up by the programmer just like any other Profinet device and linked to a program. Phoenix Contact demonstrated what Proficloud can do at this year's Hannover Messe. The exhibition stand boasted a system for automatically mounting PCB terminal blocks that was connected to the Proficloud. By linking the process data inside the PC Worx programming environment, a Smartwatch was easily integrated into the Profinet system, which was then connected to the Proficloud. The system sent push messages to the display on the employee's wrist when the machine started up or stopped, and provided information on the operating condition. Moreover, real production facilities at the Bad Pyrmont site were integrated and live data retrieved from the cloud. However, easily setting up mobile retrieval data from the system is only one aspect. New operating and analysis concepts With Proficloud, it is also easy to send machine data to big data computing centers in the cloud, to have complex calculations done there and restore the results. This opens up interesting prospects; new condition-based maintenance concepts, for example. The data from the system is recorded by the virtual Proficloud device via the Profinet protocol, analyzed in the cloud and then reported back to the system and its operators with the respective recommendations for action.
UPDATE 2|16 Technology 17 Finally, a weather device is available which can be used to link current or future meteorological data with program sequences, which is relevant to wind turbines or solar systems, for example. or going to the Proficloud is encrypted by TLS (Transport Layer Security). This is a generally accepted security standard that is also used for online banking, for example. In terms of an additional security mechanism, Interfaces for new business models In collaboration with IT service providers, Phoenix Contact is currently developing additional services that are accessed via an open data interface. It is the starting point for many exciting opportunities to introduce innovative business processes, which are often referred to as Business Intelligence. During the course of the year, Phoenix Contact will provide Software Development Kits that allow users to program their own virtual Proficloud devices. A virtual device could, for example, just be a link between Proficloud and other clouds and thereby use MQTT* as the mechanism. Comprehensive protection against unauthorized access the Proficloud devices are programmed so that they only make an outbound connection and do not respond to unauthorized requests from the Internet. A major focus for Phoenix Contact during its development was to store as little data as possible. What was also taken into account was that the applications comply with the German Data Protection Act. All data that is transferred as part of the cloud solution is therefore located in Germany. Even the Proficloud device itself, a Box PC, was designed to provide the highest possible security. Unnecessary interfaces that can be used to manipulate, such as USB ports or serial ports, were omitted and a special, safety- optimized software was installed. Even the web application for parameterizing and configuring the Proficloud is forwarded via HTTPS (Hypertext Transfer Protocol Secure) to the user. It is thereby protected against unauthorized access. In order to make data exchange and storage as safe as possible, all Proficloud coupler and Proficloud device communication coming from Christoph Manegold phoenixcontact.com * Message Queue Telemetry Transport (MQTT) – an open messaging protocol for machine-to-machine communication (M2M), a de facto standard in the communication of the Internet of Things (IoT) € Sample configuration of a cloud solution a 0 1 2 3 4 5 6 7 DI32/1 2688035 X1 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 D UI 00 10 20 30 01 11 21 31 02 12 22 32 03 13 23 33 04 14 24 34 05 15 25 35 06 16 26 36 07 17 27 37 a1 00 01 02 03 04 05 06 07 a2 10 11 12 13 14 15 16 17 b1 20 21 22 23 24 25 26 27 b2 30 31 32 33 34 35 36 37 R W P F C I E N L N O R O R R E C C D D V V 4 4 2 2 R R W W P P : : 1 1 X X 3 2 1 I T E N F O R P : 2 X t e n r e t n I : 3 X B S U : 4 X B S U : 5 X PC RFC 460 PN 3TX Ord.No 27 00 784 LNK LAN 1.1 ACT USB LNK LAN 1.2 ACT LNK LAN 2 ACT SYNC 24 V 24 VDC + – Profinet controller RUN/PROG STP MRESET DISPLAY LINK ACT ACT X1 X1 X2 X2 2 2 6 6 8 8 8 8 0 0 2 2 2 2 I I D D 1 1 6 6 4 4 / / LINK ACT ACT PROFICLOUD RUN FAIL DBG BF SF D UI X3 X3 SD-CARD RUN/PROG STOP MRESET Local Profinet I/O station Cloud coupler Secure TLS encryption LINK LINK ACT ACT ACT a 0 1 2 3 4 5 6 7 a 0 1 2 3 4 5 6 7 LINK LINK ACT ACT ACT a 0 1 2 3 4 5 6 7 a 0 1 2 3 4 5 6 7 X1 X1 X1 X2 X2 X2 LINK LINK ACT ACT ACT 2 2 2 6 6 6 8 8 8 8 8 8 0 0 0 2 2 2 2 2 2 I I I D D D 1 1 1 6 6 6 4 4 4 / / / DI32/1 DI32/1 2688035 2688035 X1 X1 X1 X2 X2 X2 LINK LINK ACT ACT ACT 2 2 2 6 6 6 8 8 8 8 8 8 0 0 0 2 2 2 2 2 2 I I I D D D 1 1 1 6 6 6 4 4 4 / / / DI32/1 DI32/1 2688035 2688035 X1 X1 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 X1 X1 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 BF BF SF SF ONL ONL RUN RUN FAIL FAIL DBG DBG D D E E UI UI X3 X3 X3 SD-CARD SD-CARD PROG PROG CLOUD CLOUD DREG DREG UL UL a1 a1 b1 b1 bb11 a2 a2 b2 b2 bb22 D D UI UI 00 00 10 10 20 20 30 30 01 01 11 11 21 21 31 31 02 02 12 12 22 22 32 32 03 03 13 13 23 23 33 33 04 04 14 14 24 24 34 34 05 05 15 15 25 25 35 35 06 06 16 16 26 26 36 36 07 07 17 17 27 27 37 37 a1 a1 00 00 01 01 02 02 03 03 04 04 05 05 06 06 07 07 a2 a2 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 b1 b1 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 b2 b2 30 30 31 31 32 32 33 33 34 34 35 35 36 36 37 37 Distributed Profinet station BF BF SF SF ONL ONL RUN RUN FAIL FAIL DBG DBG D D E E UI UI X3 X3 X3 SD-CARD SD-CARD PROG PROG CLOUD CLOUD DREG DREG UL UL a1 a1 b1 b1 bb1 a2 a2 b2 b2 bb22 D D UI UI 00 00 10 10 20 20 30 30 01 01 11 11 21 21 31 31 02 02 12 12 22 22 32 32 03 03 13 13 23 23 33 33 04 04 14 14 24 24 34 34 05 05 15 15 25 25 35 35 06 06 16 16 26 26 36 36 07 07 17 17 27 27 37 37 a1 a1 00 00 01 01 02 02 03 03 04 04 05 05 06 06 07 07 a2 a2 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 b1 b1 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 b2 b2 30 30 31 31 32 32 33 33 34 34 35 35 36 36 37 37 Distributed Profinet station
18 On site UPDATE 2|16 A Rotterdam landmark boasts a folding bridge
UPDATE 2|16 On site 19 Getting the bridge going AXC 1050 small-scale controller in operation on the Erasmus Bridge in Rotterdam Not every ship can pass under the Erasmus Bridge at all times. To avoid damage to the vehicle and the building, display panels visualize the current maximum clearance below. The panels receive the necessary data from an AXC 1050 small-scale controller via the Radioline wireless system – both from Phoenix Contact. The Erasmus Bridge measures a total of 802 meters long and weighs 6800 tons. Its southern ramp folds out and permits higher ships to pass. The result is the largest and heaviest folding bascule bridge in Europe. The maximum clearance below, which is dependent on the actual water level, is thereby depicted for the crews on six screens. Construction of the Erasmus Bridge began in 1994. Two years later it was completed. The Dutch company, ÆVO B.V., was involved in the project the entire time. ÆVO was awarded a four-year contract from the city of Rotterdam to maintain the electrical system of the bridges, locks and the Maas tunnel. Richard Hecker, Project Manager at ÆVO, is responsible for modernizing the control technology and transmitting the current maximum clearance height on the displays. On the strength of many years of fruitful collaboration with the Dutch subsidiary of Phoenix Contact, he was able to develop a solution that fully meets the operator's requirements. Maintenance of display panels and control center A project for recording and depicting the current maximum clearance height had already been planned and implemented in 2000. Following this, captains of passing ships should easily have been able to decide whether to pass under the closed bascule bridge or best wait for the bascule to open. The bascule is raised twice daily at predetermined times and as required. The system installed at the time was cable-stayed and failure-prone, as well as time-consuming and expensive to maintain. Following several lightning discharges, and the resulting surge voltage, this solution was destroyed in 2014. The Department Manager Maintenance of the City of Rotterdam then commissioned ÆVO to modernize the system. The ÆVO staff analyzed the existing concept together with the automation team from Phoenix Contact and developed a solution based on the latest technology. However, the existing on-site displays were to remain. Moreover, a connection to the new control center was also requested. Serial communication to the six visualization elements became a challenge during the course of the project. As such, no meaningful documentation was available on the existing concept and on controlling the displays. That's why it was necessary to determine, bit by bit, how the visualization elements could be controlled. The specialists then deduced which components from Phoenix Contact were best suited to the task. Wireless forwarding of calculated values The current sea level is recorded by two pressure sensors, converted to an analog value and relayed from there to the analog AXL F AI4 input terminal. As part of Axioline station, the input terminal subsequently transmits the data to the AXC 1050 small-scale controller, which it evaluates it. The maximum bridge clearance, which is then shown on the display panels, is calculated from the difference between the sea level and absolute height of the Erasmus Bridge. For serial data transmission to the visualization elements, the AXC 1050 was extended by the AXL F RS UNI serial communication module, which transmits the calculated bridge clearance value as a serial signal to the six display panels. Richard Hecker works at ÆVO as the Project Manager in charge of integrating measuring and display systems
20 On site UPDATE 2|16 ÆVO and Phoenix Contact opted for the Radioline system, which is based on the Trusted Wireless 2.0 technology, in order to redirect the serial signals to the visualization elements. Trusted Wireless 2.0 technology has been specifically designed for the reliable exchange of data and signals over long distances. It is In addition to the AXC 1050 small-scale controller, the Axioline system's I/O modules were also installed in the control center's control cabinet therefore suitable for use on the bridge. The Radioline system is also easy to handle. The inputs and outputs of the radio modules are assigned by turning the thumbwheel located on the devices. Consequently, there is no need for the user to program. Radioline transmits both I/O signals as well as serial data, which is why the wireless system can be used in many ways. Another advantage is that different network structures can be implemented from point-to-point connections up to mesh networks. Fault tolerance, thanks to intelligent surge protection For each display panel affixed to the Erasmus Bridge, ÆVO has set up a point-to-point connection, with each panel having a respective directional antenna on the roof of the control room. Directional antennas were also installed on the six visualization elements to receive the serial signals, so that the calculated bridge clearance can be displayed. To prevent surge damage – from lightning strikes for example – and thus increase failsafe operation, the coaxial signal interfaces were secured by attachment plugs with Lambda/4 technology. The equipment was used to reliably protect the transmission devices against surge voltage, whereby the transmission signal is not affected due to the high bandwidth of the attachment plug. The automation specialists from our Dutch subsidiary, Phoenix Contact BV, took over all the programming tasks according to ÆVO's specifications. The AXC 1050 small- scale controller was programmed with a standardized language in line with IEC 61131-3. The international standard for programmable logic controllers (PLCs) standardizes programming languages, command sets, and structures for automation systems. That's why the programs created can be simply ported to various platforms and used there. The employees of the Dutch subsidiary of Phoenix Contact also configured the Radioline wireless solution and connected it to the control system. Know-how for infrastructure applications Different components and systems from Phoenix Contact's portfolio were used to visualize the maximum bridge clearance. The right solution was developed for the task in Rotterdam, thanks to the combination of extensive employee expertise regarding infrastructure applications and the ÆVO team. Following the Site Acceptance Test, the entire application was integrated into ÆVO's regular maintenance and 24/7 emergency service. Arno Martin Fast phoenixcontact.com
UPDATE 2|16 New products 21 KNX installation terminal blocks The distribution board quickly becomes overcrowded, especially when it comes to star-shaped cabling on the KNX bus system. The color-coded, double-level terminal blocks from the PTTBS 1,5/S family are just 3.5 mm wide and permit clear visual assignment of the terminal points to the wire colors. Although the PTTBS 1,5/S is a double-level terminal block, it fi ts comfortably under the distributor cover. The white base color of the terminals distinguishes the KNX bus wiring from the load wiring in the installation distributor. Profi net bus coupler for Axioline F The Axioline F portfolio has been expanded by two products, the Profi net bus couplers. The AXL F BK PN SC-RJ module permits communication via fi ber optics (FO) in environments that are susceptible to disruption. The FO technology lets you cover longer distances with high EMC protection. An XC version of the Axioline F bus coupler is now available for use in special ambient conditions and in potentially explosive environments. In Profi net applications, the AXL F BK PN XC is the link between the Axioline F and the higher-level Ethernet system. Modular electronics housings Confi gurable power supply The ME-IO electronics housing off ers new enclosure versions and accessories for designing a complete system consisting of controller, bus coupler, and individual I/O modules. Various designs and connection technologies permit highly fl exible system solutions. The 37.6 mm and 75.2 mm wide housings can accommodate PCBs vertically and horizontally and off er a large area on the front for optional displays, operating elements or data interfaces. The L-design versions also permit the easy integration of RJ45 or D-SUB connections. For the Quint Power power supplies, signaling thresholds and characteristic curves can be confi gured wirelessly via the integrated NFC interface using a smartphone or tablet. The integrated Selective Fuse Breaking (SFB) technology delivers six times the nominal current in up to 15 milliseconds and thereby selectively trips standard circuit breakers. To extend the system, a static boost with up to 125% of the nominal current is used. The dynamic boost with up to 200% of the nominal current is also available for up to fi ve seconds in order to start heavy loads. phoenixcontact.com
22 News UPDATE 2|16 Smartfactory OWL officially inaugurated Research lab wants to bring digital production to companies On the initiative of the Fraunhofer Society and OWL University of Applied Sciences, a factory demonstrator was created in Lemgo for around five million euros, which vividly demonstrates the benefit of intelligent automation. On 12 Experience Industrie 4.0 in the Smartfactory OWL April 2016, a ceremony was held to celebrate the opening of the Smartfactory OWL. Equipped with a real IT and production environment valued at five million Euros, it is both a test and demonstration platform as well as a learning environment for both scientists and students. The system is intended to serve as an example small and medium-sized companies on their way to digital production. "We have made it our mission to not only be a pioneer in the field of Industrie 4.0, but to bring these technologies into companies as well," said Professor Dr. Jürgen Jasperneite, Director of the Fraunhofer Application Center (IOSB-INA) in Lemgo and the initiator of the Smartfactory OWL. "Project areas let you temporarily set up machinery or system parts for a pilot run, equip it with Industrie 4.0 solution components and put these through their paces. These can be used when assessing potential and making necessary investment decisions early on," explains Jasperneite. Industrie 4.0 in practice Work out the benefits of digital production for the customer In order to test components, systems and solutions for Industrie 4.0, Phoenix Contact opened a digitization lab on 10 June 2016. The The Industry 4.0 Demonstrator is used to test application scenarios technology and technology know-how surrounding digitization are to be learned and applied in practice on 130 square meters in the newly inaugurated Phoenix Contact Training Center in Schieder. The focus is on transferring, as well as applying and testing results from various committees and working groups for Industrie 4.0. The objective is to also test scenarios where Industrie 4.0 can be used, that serve to digitalize the value creation networks of customer applications. The benefits can thus be validated and demonstrated.