Reduction of downtimes while increasing process quality
Targeted optimization during operation
The more efficiently systems and process chains operate, the greater the improvement in the cost and margin situation, regardless of whether this involves production lines, thermal processes, food industry facilities, or critical infrastructure. Modern, data-supported solutions create transparency from the sensor to the cloud and enable intelligent, resource-saving, and highly flexible processes. Continuous condition monitoring, AI-based analyses, and seamless OT-IT integration can reduce downtimes, improve quality, and increase output. At the same time, hidden optimization potential becomes visible, leading to greater operational safety and more sustainable use of resources. This results in efficient, future-oriented system operation that strengthens cost-effectiveness, availability, and sustainability in equal measure.
AI-based production optimization: From condition monitoring and predictive maintenance to time savings of 30%
With our solution portfolio, we combine robust automation technology with intelligent AI functions. This enables data-based control and decision-making that significantly increases the effectiveness of machines and systems.
Podcast
Podcast on the subject of AI-based production optimization
In the podcast, Tom Hammerbacher explains how his team uses machine learning to improve their customers’ energy consumption. The podcast also looks at how artificial intelligence is being used in practice. Automation technology from Phoenix Contact plays an important role here. You will also learn more about how these modern technologies and solutions are tested and used in our in-house factory.
Fast, modular digitalization and automation of decentralized machines and systems for greater efficiency
Improved production quality through AI-based process monitoring and optimization with machine learning and artificial intelligence (MLnext)
Faster decision-making with condition-based monitoring and predictive maintenance
Increase output volumes with the open, high-performance PLCnext Technology Ecosystem – from edge solutions and Virtual Control to intelligent analysis with MLnext
The correct design and efficient operation of pump systems can cut energy use by up to 50%
Practical example: Optimization of pumps and three-phase motors in the context of an All Electric Society
Efficient and cost-saving: Reduce energy consumption and operating costs through data-driven solutions and open systems
Devices such as the EMpro and sensors for temperature, vibration, and pressure can be used to record important data regarding the operation of three-phase motors. The collected data is analyzed in the MLnext software app in order to monitor and optimize the energy consumption and performance of the motors.
By integrating data-driven solutions and open systems such as MLnext and PLCnext Technology from Phoenix Contact, three-phase motors can be optimally monitored and controlled. PLCnext Technology is an open and flexible ecosystem that enables the integration of machine learning models and other modern technologies. This enables continuous monitoring and optimization of the motors by making predictions their condition and initiating maintenance measures in a timely manner.
In critical areas such as thermal processes in the glass, chemical, and steel industries, redundant pumps often run for years in the wrong applications, performance classes, or are incorrectly dimensioned from the outset. This results in high operating and storage costs. By continuously monitoring and analyzing the operating data, such inefficiencies are detected and eliminated at an early stage. Through data-based monitoring, defective seals and diaphragms are detected early on. This saves costs and increases safety and efficiency.
Increase the level of automation intelligently from an economic point of view
Between 30 and 50% cheaper than a classic MES approach: targeted automation, analysis, and optimization of processes for greater efficiency while reducing costs at the same time
The compact Smart Production Cabinet controls machines, monitors systems, and provides important diagnostics. With the modular design, you can select your ideal combination of pre-engineered and individual configurations. Moreover, you can implement your own solution based on this design.
The Smart Production library is a collection of function blocks and visualization elements for creating your own open automation standard. Important control, monitoring, and diagnostic functions can be implemented and suitable visualizations used with little programming effort. The visualization based on the integrated PLCnext Web HMI server is automatically generated in a rule-based manner from the application program and can also be individually expanded.
Appropriate training and clear descriptions help you to implement an automation standard for your systems that can be used worldwide.
Due to the changing role of humans, it is necessary to create suitable Human Machine Interfaces for interaction between people and machines. The Modular Operator Station from Phoenix Contact combines requirements for robustness and slim ergonomic designs, adding intelligent and powerful operating options into the mix. The Modular Operator Stations can be installed in systems without any further engineering effort. Just a power supply and network connection are required. The Modular Operator Stations are equipped with an IPC-65 PC as well as an integrated web client (also with open Windows operating system as an option). They offer flexible performance, different screen sizes, and multiple operating options such as a keypad, keyboard, mouse, or RFID reader.
With our Smart Production solution, we were able to implement the safety requirement of system safety for the robot application in our production quickly, simply, and with a minimum of effort.
Compact and open to your individual requirements
Operator Station
The modular Operator Station from Phoenix Contact is the ideal MMI solution. It combines the highest requirements on robustness with a slim ergonomic design and combines these with intelligent and powerful operating options. The modular Operator Stations can be installed in systems without any further engineering effort. In addition, they are characterized by scalable performance, screen size, and various user interfaces (push button box, keyboard, mouse, RFID reader).
AGVs
Flexibility at the highest level:
We provide solutions for the electrification and automation of your AGVs: Control, safety, navigation, electrification, communication, and energy. For an automated guided vehicle system in which components are coordinated with each other and functions can be flexibly and easily adapted or extended.
Smart Production Cabinet
Simple and cost-effective automation: The combination of the compact Smart Production Cabinet and intelligent Smart Production Library enables the control and monitoring of systems and machines as well as the creation of relevant diagnostics. With the modular design, you can select your ideal combination of pre-engineered and individual configurations, tailoring it perfectly to your particular application.
Cloud
Worldwide data availability implemented easily and securely: Cloud-based production facilities can be networked worldwide and across locations. With Digital Factory now, the openness of our solutions gives you the choice to use the high-performance plug-and-play Proficloud.io IIoT platform from Phoenix Contact or any other cloud platform.
With an open, scalable automation and data platform: Our standard connectors, edge intelligence, and analytics combine system, station, and machine data with business data – with security in accordance with IEC 62443 providing peace of mind. The result: Real-time transparency and rapid rollout across entire lines.
Precise PID and cascade control makes processes particularly stable and efficient. Functions such as auto- and pretune as well as flexible ramp profiles support a fast approach to the setpoint and shorten startup times. In practice, this leads to significantly more stable processes. In addition, machine learning-supported analyses enable the early detection of deviations and the identification of additional savings potential, for example through the intelligent evaluation of process and energy data and predictive optimization.
PL-capable switches and a secure remote access concept in accordance with IEC 62443 create a robust basis for protected, fully transparent system connections. In addition, safe I/O modules up to performance level e and SIL 3 in accordance with IEC 61508, PROFIsafe integration, and validated start and operating logic ensure a significantly higher level of system availability and process reliability. Comprehensive CE and standards services as well as international approvals, including UL and NFPA standards, enable end-to-end compliance from specification through to development and validation. In this way, we support OEMs and system manufacturers in providing machines and systems that are efficient, compliant with standards, and globally deployable.
FAQs from machine builders and systems manufacturers
The asset management shell (AAS) from Phoenix Contact serves as a digital twin and enables standardized data exchange between different systems. Benefit from improved data transparency, data security, and more efficient processes with seamless integration.
Phoenix Contact provides automation solutions such as PLCnext Technology, which enables flexible and scalable control. This technology supports the integration of renewable energies and optimizes energy consumption through intelligent control. This reduces energy consumption and operating costs in the long term and enables you to operate more sustainably.
Industrial security solutions from Phoenix Contact, such as the certified controllers from the PLCnext Control family, provide comprehensive protection against cyberattacks. You can therefore increase your system security and protect systems against failures and data loss.
FAQs from factory operators
Energy storage systems and feed-in management from Phoenix Contact enable the efficient use and storage of renewable energy. For reducing energy costs, stabilizing energy requirements, and contributing to sustainability.
Modular automation solutions and 5G campus networks from Phoenix Contact offer flexible and fast customization options. For increased production flexibility and faster response times to market requirements.
Sector coupling and key carbon emission figures via the asset administration shell enable a holistic approach and the optimization of energy flows. For reducing the carbon footprint while complying with environmental standards for sustainable production.
