Factory automation is the basis for the promotion of Industry 4.0. One of the key elements for the success of Industry 4.0 is to build an Industrial Internet of Things (IIoT) and link factory production equipment to the network so as to obtain the conditions data of machines in real time. PoE (Power over Ethernet) technology can transmit power and data to equipment simultaneously in Ethernet, so it will be one of the best choices for machines to connect to the network and connect with the operating network in series. This article will show the development trend of factory automation and PoE solutions introduced by onsemi.
New generation of factory automation focuses on serial network connection
The traditional concept of factory automation is more inclined to the automatic production process of the machine itself, focusing on robot technology. However, machines are often independent of each other and not connected in series and cannot share information with each other. Driven by the wave of Industry 4.0, the definition of factory automation has been different, focusing on network interconnection and information sharing between equipment, and flexible and customized production can be carried out in a timely manner through the operation system in order to meet the changing market demand.
In existing factories, equipment and plant operation control system in the factory are all independent systems functionally. Due to different suppliers of machinery and equipment, different people in charge of management and other factors, they are not integrated technically or organizationally. Once cooperation or information sharing is needed between systems, they can only be handled manually, which inevitably leads to a time gap.
At present, factory automation has moved towards a smart factory, with the aim to linking all kinds of equipment in the factory into a network, obtaining data related to devices in the management point, and realizing visualization of all kinds of activity information in the factory, so as to find out the causal relationship between problems as early as possible, further improve the management quality, reduce the management cost, and achieve the goal of energy conservation and carbon reduction.
In order to achieve these goals, we must use network technology to connect in series all kinds of factory automation machines, equipment, power and other infrastructure, operation management system, etc. existing in the factory; that is, we must connect "control" systems and "information" systems in series. Of course, the series connection between different systems cannot be achieved overnight. It still depends on the opening of data and the establishment of standards between various systems to achieve data sharing.
PoE technology meets the requirements of factory automation
The ethernet is the most commonly used network architecture for information systems at present. Therefore, if Ethernet technology is also adopted in factories, it will help to reduce the complexity of the systems and the construction and deployment cost is expected to be greatly reduced. PoE system is based on Ethernet architecture. In combination with the power transmission, the complexity of network deployment is further reduced. PoE system includes power cord of power grid, power sourcing equipment (PSE) providing power source, Ethernet cable, and power device (PD) for load work. As PD does not need additional power supply and uses global standard power supply, the construction and deployment of PoE system is relatively simple and convenient.
PoE system architecture and standards have evolved over the years, from 15.4 W PSE output of IEEE802.3 af (PoE) to 30 W of IEEE802.3 at (PoE+), and the latest IEEE802.3 bt (PoE++) can support up to 90 W, making PoE technology can support more and more applications. The new generation of high-power PoE devices can also support the power demand of factory automation systems.
Multiple PoE protocols and high power applications supported
onsemi has launched a variety of product portfolios for PoE applications. Considering the demand of high-power equipment, it has also introduced devices supporting up to 90W and with higher rated power. For some proprietary high-power PoE applications, up to 100 W can be supported. With a low on-resistance hot swap switch, they have higher efficiency and energy saving effect, and support auxiliary power supply options and an open-drain power good indicator, which is quite safe and reliable, and is suitable for application in related fields such as factory automation.
onsemi's NCP1095/NCP1096 are PoE-PD interface controllers compliant with IEEE 802.3bt, IEEE 802.3af and/or IEEE 802.3at, which can be used to develop high-power applications, including factory automation equipment, interconnected lighting devices, security cameras and USB Type-C devices. The NCP1095/NCP1096 integrate all features required for PoE system, such as inrush phase detection, classification, and current limiting (110 mA), support for up to five events in the physical layer classification, short maintain power signature (MPS), overcurrent protection, overtemperature protection, junction temperature range from −40℃ to +125℃, in 16-pin TSSOP packages, and are Pb-free and RoHS compliant devices.
The NCP1095/NCP1096 use external transfer transistors that provide output voltages of up to 90 W to support high power applications. In order to improve energy efficiency, NCP1095/NCP1096 also support Autoclass function, to allow the power supply device (PSE) to efficiently allocate power to each powered device (PD) and optimize power allocation, and also ensure interoperability between PoE devices. In addition, the NCP1095/NCP1096 has an auxiliary power supply detection pin for applications powered by PoE or wall adapters. Unlike the NCP1095, the NCP1096 also provides an internal hot-swap FET for higher integration.
Evaluation board speeds up PoE application development
NCP1095/NCP1096 are suitable for applications such as PoE devices, the Internet of Things and IIoT, supporting various communication protocols such as IEEE 802.3bt (up to class 8/90 W), IEEE 802.3at (up to class 4/30W) and IEEE 802.3af (up to class 3/15W). Power-good pins ensure proper disabling/enabling of adjacent main DC/DC converters. The classification result pin allows operation according to the assigned power class (up to class 8). They can be widely used in end products such as factory automation equipment, digital signage, satellite data network, connected lighting, video and VOIP phone, security camera, pico base station, multi-band access point, USB Type-C device, etc.
In order to speed up the development of PoE products by customers and evaluate the characteristics of NCP1095/NCP1096 devices, onsemi has also introduced the NCP1095GEVB/NCP1096GEVB PoE-PD interface controller evaluation board, which is used to evaluate NCP1095/NCP1096 controllers and includes RJ-45 connectors, power transformers, Greend Bridge2 and other fixtures to help end users carry out tests.
Conclusion
Driven by Industry 4.0, factories are fast developing towards intelligence. The new generation of high-power PoE technology can just meet the needs of networked smart factories and reduce the complexity of factory network construction and deployment. It is expected to further promote the demand of factory automation and PoE equipment and has great market development potential. onsemi's PoE solutions will play a more important role in factory automation network construction and deployment.
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