With the rapid development of technology and the rise of the concept of Industry 4.0, factory automation has become a hot field in rapid development. This article will show you several current technologies and solutions to promote the development of factory automation for your better understanding of the relevant markets and applications.
IO-Link optimizes complex industrial processes
As the key technology of series factory automation equipment, IO-Link is a communication system that is independent of the communication standards of factory automation fieldbuses and is dedicated to connecting smart sensors and actuators to automation system. It uses the single-drop digital communication interface (SDCI) for small sensors and actuators in the IEC 61131-9 standard to standardize the electrical connection modes and digital communication protocols, according to which smart sensors and actuators can interact with automation systems.
In factory automation applications, it is easy to integrate with the communication protocols commonly used in factory automation systems through dedicated interfaces or bridges, which is a simple solution to expand existing networks to connect remote sensors and actuators. This architecture can facilitate developers in making full use of the concepts of Industrial 4.0 or the Industrial Internet of Things (IIoT), so that each sensor and its associated data points can be used to control and optimize the most complex industrial processes in real time.
To assist in the establishment of the IO-Link network platform, STMicroelectronics offers transceivers, protection ICs and STM8 (8-bit) and STM32 (32-bit) microcontrollers, which can realize the series connection of sensors and actuators supporting IO-Link in the smallest form factor. The L6364 is a dual channel transceiver for industrial sensor applications. It is designed to support the IO-Link standard and acts as a bridge between a microcontroller with sensor or actuator functions and a 24 V power supply and signaling cable.
Under normal operation, the L6364 is configured by the microcontroller through the SPI interface at startup. Generally, the L6364 operates as a single input/output IO-Link device to drive the output line as configured by the microcontroller. If the device is connected to the IO-Link master device, the master device may initiate communication and exchange data with the microcontroller, while the L6364 acts as the physical layer of communication.
A variety of IO-Link devices simplify the deployment process
Omron also offers solutions for the IO-Link standard for factory automation, including color mark detectors, photoelectric sensors, IO-Link master devices, and proximity sensors. By connecting the sensor and the controller through the IO-Link, all necessary information for stabilizing the operation of the sensor, such as the level of incident light, can be seen. By monitoring and false detection at the sensor level, downtime can be reduced, which is helpful for predictive maintenance and reduces commissioning time.
Omron's E3S-DC-IL is a color mark detector with high signal-to-noise ratio, which can communicate through IO-Link to provide real-time output monitoring and realize remote configuration changes. With a narrow beam and large lens, the E3S-DC-IL can be used to stably detect workpieces inclined at various angles. Efficient optical technology can provide high power, and even slight color differences can be detected stably. With a high luminance RGB LED light source, it can improve light intensity, handles glossy workpieces, and completely reduce noise. The high dynamic range covers all objects from black to mirror surfaces, is compatible with the Internet of Things, and also provides models supporting IO-Link. RGB information is sent to the host device through high-speed IO-Link communication, and the optimal threshold is set to reduce false detection.
The E3Z sensor supporting IO-Link enables users to easily configure and troubleshoot, while the E3Z-IL sensor enables users to set up instability detection of light or output. The IO-Link makes sensor-level information visible, reduces downtime, notifies faulty parts and changing conditions in the sensor in real time, and reduces the frequency of sudden failures. The incident light level monitor can avoid false detection to improve changeover efficiency, check individual sensor IDs in batches to greatly reduce commissioning time, and provide three types of induction methods and three types of connection methods.
The NX I/O system provides a variety of I/O devices. Its ultra-fast internal bus system is synchronized with the distributed clock of an EtherCAT network, resulting in deterministic I/O operations within the system, enabling machine manufacturers to improve machine productivity and output quality. The EtherNet/IP bus coupler can be used non-synchronous, for example with the CJ Series PLC.
The GX Series IO-Link master unit can make sensor-level communication visible, reduce machine downtime and minimize the recovery time when an abnormality is detected. Condition monitoring can be carried out for predictive maintenance. With a unique individual identification number, maintenance hours can be reduced. It is also a master unit with screw-less terminals, with an IP67 protection class suitable for watery and dusty environments. An IO-Link master unit may connect up to 8 photoelectric and proximity sensors.
E2E DC 3 - Wire Standard IO- Link Proximity Sensor
Omron introduces a standard E2E DC 3-wire proximity sensor with additional features of IO-Link, supporting real-time condition monitoring and remote sensor configuration, it can inform you that objects are too far or too close, improve changeover efficiency, and can be used to detect ferrous metals. In addition, the E2EQ-IL inductive proximity sensor has a slag-resistant coating, which can prevent the build of weld slag, thus avoiding output changes, and enables sensor level data in combination with IO-Link. The E2EQ-IL is a proximity sensor that can be used in welding spatter environments. It has similar functional characteristics to E2E DC, but has fluororesin coating and excellent spatter resistance.
Vibration sensors facilitate predictive maintenance
Driven by the increasing degree of automation, the demand for high-volume and small-size systems (such as machine spindles, conveyor belts, sorting tables, or machine tools) is increasing. These systems need better predictive maintenance, and reduced machine downtime is a critical consideration. In the past, accelerometers (vibration sensors) were mainly used for condition monitoring of heavy-duty high-end machinery (such as windmills, industrial pumps, compressors, and HVAC systems). However, driven by the transformation of the digital industry, the demand for high-volume and small-size machinery is increasing, so different accelerometer technologies can be used to monitor industrial conditions.
The piezoelectric vibration sensor introduced by TE includes a pressure transistor, which automatically generates a signal when the machine is subjected to external excitation (such as mechanical vibration) to generate stress. Most piezoelectric sensors are based on lead zirconate titanate (PZT) ceramics, which are polarized to align dipoles to produce crystals piezo-electric. PZT crystal is ideal for condition monitoring applications because of its wide temperature range, wide dynamic range, and wide bandwidth (which can be used for > 20kHz).
TE has also introduced a variable capacitance vibration sensor, which can obtain acceleration measurement values from capacitance change of vibration masses moving between two parallel capacitor plates. The change of capacitance is proportional to the applied acceleration. Variable capacitance accelerometers need to closely coupled to the IC to the sensing element to convert very small capacitance changes into voltage outputs. This conversion process usually leads to poor signal-to-noise ratio and limited dynamic range. Variable capacitance sensors are usually made of silicon wafers and made into miniature electromechanical system (MEMS) chips.
Conclusion
Devices that support the IO-Link standard can optimize complex industrial processes and simplify the deployment difficulty of factory automation systems. In addition, vibration sensors are used for predictive maintenance to reduce the downtime of machines, which is of vital importance to the development of factory automation. As long as technology can be used to solve the problems faced by factory automation, the promotion of Industry 4.0 will bring more substantial benefits.