Overcoming obstacles of industrial automation

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 The benefits that can be derived from Industry 4.0 adoption are to RS-422/RS-485 converter widely understood. Through this, it will be possible to transform module from Advantech 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. ADAM-4520-F is an RS-232 to RS-422/RS-485 converter module capable of delivering 115.2kbps data rates. By attaching one Advantages of Industry 4.0 and cost implications of these units to equipment that was originally fitted with RSThrough widespread implementation of Industry 4.0, elevated levels 232 interfacing, it is possible to convert the RS-232 signals into of efficiency will lead to better use of assets and increased output. isolated RS-422 or RS485 signals. Through its use, communication This in turn, means that orders can be fulfilled quicker to keep pace distances of up to 1200m can be supported and as many as 32 with customers’ demands. In addition, it will be possible to improve different nodes connected. There is no need to change any of the product quality and reduce wastage. software, thereby facilitating the upgrade process. As well as having 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 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. predictive maintenance activities too - so that any component parts Supporting the Modbus TCP protocol, the Brainboxes ED-588 that are in need of replacement can be identified before causing Ethernet gateway allows existing industrial equipment to interact costly interruptions in production workflows. with the enterprise infrastructure further upstream. It offers a robust 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. 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. Before embarking on migration to a smart factory arrangement of These units can be attached to a 24V supply and are housed in some form, the cost implications will need to be fully understood. insulated polyamide casings which are IP20 rated. It may be used In situations where there is only limited available budget to fund this to control fans, solenoid valves, reed switches, lamps, or motors. work, companies will need an alternative to wholesale replacement In addition, the gateway can deal with data coming in from a of existing machinery. They must therefore look for a means via multitude of different sensors. There is no software needed, as the which they can adequately upgrade it instead. unit can be accessed from a web browser. Since it is installed as Connectivity solutions and the attributes needed a COM port on a Windows PC, it has full backward compatibility 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 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. need to be considered. Likewise, it is paramount that this hardware Conclusion is aligned with the application environment into which it is being For a large proportion of industrial operations, there is still a major placed. It will need to exhibit the robustness necessary for it to disjoint between what happens on the factory floor and what takes cope with the uncompromising working conditions that industrial place at the higher levels. If the advantages of embracing higher applications are certain to subject it to. Extreme temperatures, degrees of automation are to be fully leveraged, then this needs shocks and vibrations, as well as the threat of electro-static to change. Through retrofit options, like the ones mentioned in this discharge (ESD) strikes and potential liquid ingress must all be article, the route towards Industry 4.0 does not actually need to safeguarded against. Only solutions that have these properties, and be that complicated or expensive. Using the industrial converter can ensure ongoing reliability, should be selected. modules and smart sensor plug-ins supplied by TME, it is possible Enabling convenient communication between items of equipment to renovate longstanding industrial operations and start bringing supporting different serial interface standards, the Advantech them into the next industrial era. tme.com/au