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INDUSTRY 4.0
Overcoming the obstacles of industrial automation implementation Arkadiusz Grzegorek, Head of Automation-Maintenance Division at TME sets out the solutions and implications of Industry 4.0.
The ADAM-4520-F RS-232 to RS-422/RS-485 converter module from Advantech
The benefits that can be derived from Industry 4.0 adoption are widely understood. Through this, it will be possible to transform the way in which factory production lines, processing plants and warehouse operations function daily. In many cases, however, the financial outlay involved is likely to prove problematic. Companies looking to employ such technology will need to do so while keeping the related expenditure to a minimum. The following article will look at how this goal can be achieved. According to leading analyst consultancy Statista, the worldwide industrial automation market is going to experience substantial growth over the coming years. Having already generated more than $175bn in revenue during 2020, it is expected to hit the $265bn mark by 2025 – which equates to a 9% compound annual growth rate (CAGR) over that period. Fortune Business Insights predicts that this 9% CAGR will remain beyond that timeframe, resulting in a total annual worth surpassing $355bn by 2028.
Advantages of Industry 4.0 and cost implications Through widespread implementation of Industry 4.0, elevated levels of efficiency will lead to better use of assets and increased output. This in turn, means that orders can be fulfilled quicker to keep pace with customers’ demands. In addition, it will be possible to improve product quality and reduce wastage. Another aspect of Industry 4.0 that is going to be pivotal is the ability to continuously monitor the key parameters of different items of machinery. This will allow any issues affecting overall performance to be investigated and addressed accordingly. It will support predictive maintenance activities too - so that any component parts that are in need of replacement can be identified before causing costly interruptions in production workflows. It must be acknowledged however, that industrial equipment will remain in service for protracted periods of time. Largescale investments that have already been made mean that such equipment cannot be replaced within a short timeframe. The question therefore is how to get the most out of Industry 4.0 while keeping the associated costs down. Before embarking on migration to a smart factory arrangement of some form, the cost implications will need to be fully understood. In situations where there is only limited available budget to fund this work, companies will need an alternative to wholesale replacement of existing machinery. They must therefore look for a means via which they can adequately upgrade it instead.
Connectivity solutions and the attributes needed Any hardware that is intended to bring next generation connectivity to legacy industrial equipment or instrumentation must be straightforward to install of course. Space constraints may also need to be considered. Likewise, it is paramount that this hardware is aligned with the application environment into which it is being placed. It will need to exhibit the robustness necessary for it to cope with the uncompromising working conditions that industrial applications are certain to subject it to. Extreme temperatures, shocks and vibrations, as well as the threat of electro-static discharge (ESD) strikes and potential liquid ingress must all be safeguarded against. Only solutions that have these properties, and can ensure ongoing reliability, should be selected. Enabling convenient communication between items of equipment supporting different serial interface standards, the Advantech
AMT AUG 2022
ADAM-4520-F is an RS-232 to RS-422/RS-485 converter module capable of delivering 115.2kbps data rates. By attaching one of these units to equipment that was originally fitted with RS232 interfacing, it is possible to convert the RS-232 signals into isolated RS-422 or RS485 signals. Through its use, communication distances of up to 1200m can be supported and as many as 32 different nodes connected. There is no need to change any of the software, thereby facilitating the upgrade process. As well as having 3kV galvanic isolation, this module has a built-in surge protection mechanism. An operational temperature range of -10°C to 70°C is covered. Supplied in a compact ABS enclosure (with 70mm x 122mm x 30mm dimensions) it can be DIN rail or panel mounted. Supporting the Modbus TCP protocol, the Brainboxes ED-588 Ethernet gateway allows existing industrial equipment to interact with the enterprise infrastructure further upstream. It offers a robust and intelligent ‘control side’ device that provide the interface to systems on the factory floor environment, commonly referred to as ‘process side’. It has eight non-isolated digital input and eight non-isolated digital output channels. The Ethernet port enables data to be transferred at 100Mbps rates. This DIN rail-mounted unit is supplied in a compact form factor (with dimensions of 101mm x 128mm x 22.6mm), so only takes up minimal cabinet space. These units can be attached to a 24V supply and are housed in insulated polyamide casings which are IP20 rated. It may be used to control fans, solenoid valves, reed switches, lamps, or motors. In addition, the gateway can deal with data coming in from a multitude of different sensors. There is no software needed, as the unit can be accessed from a web browser. Since it is installed as a COM port on a Windows PC, it has full backward compatibility with older equipment models. Short circuit and ESD protection features are incorporated, as well as over-temperature shutdown. An operational temperature range of -30°C to +80°C is supported.
Conclusion For a large proportion of industrial operations, there is still a major disjoint between what happens on the factory floor and what takes place at the higher levels. If the advantages of embracing higher degrees of automation are to be fully leveraged, then this needs to change. Through retrofit options, like the ones mentioned in this article, the route towards Industry 4.0 does not actually need to be that complicated or expensive. Using the industrial converter modules and smart sensor plug-ins supplied by TME, it is possible to renovate longstanding industrial operations and start bringing them into the next industrial era. tme.com/au
