“To enable lean production-enabled data processing optimization in Industry 4.0 and Industrial Internet of Things (IIoT) systems, it can be done through condition monitoring, predictive maintenance, overall equipment effectiveness (OEE) analysis and tracking, diagnostics, and troubleshooting. A common problem is that legacy equipment is either not designed to connect, or may use one of several communication protocols, making it expensive to replace all of the equipment. To ensure maximum efficiency and obtain actionable machine data, in many cases it will be simpler and more affordable to implement an overlay network that can connect existing automation islands and legacy equipment.
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Author: Jeff Shepard
To enable lean production-enabled data processing optimization in Industry 4.0 and Industrial Internet of Things (IIoT) systems, it can be done through condition monitoring, predictive maintenance, overall equipment effectiveness (OEE) analysis and tracking, diagnostics, and troubleshooting. A common problem is that legacy equipment is either not designed to connect, or may use one of several communication protocols, making it expensive to replace all of the equipment. To ensure maximum efficiency and obtain actionable machine data, in many cases it will be simpler and more affordable to implement an overlay network that can connect existing automation islands and legacy equipment.
Designing such overlay networks is extremely challenging. The design requires a controller that can receive signals from sensors and other devices using various communication protocols, combine these signals into a unified stream of usable data, and output this data to an edge computing resource or the cloud . Such systems require adapters that can directly connect sensors, indicators, and other devices. Adapters are required to connect previously incompatible device types, including legacy devices.
Additionally, to ensure reliable operation, filters are required to protect data communications from electrical noise and transients. All of these components should meet IP65, IP67 and IP68 environmental standards for operation in industrial environments, and the solution needs to be easy to implement and affordable.
This article briefly discusses the problems associated with connecting legacy devices to the IIoT. It then describes the architecture of Banner Engineering’s Snap Signal family of hardware and software tools and how they can be used to address these challenges. This article uses the Snap Signal device as an example, including the DXMR90 controller, associated converters, adapters, and filters, as well as application considerations when implementing wired and wireless edge computing or cloud connectivity.
Connect legacy devices with the IIoT
Many factories predate the IIoT and Industry 4.0, and it is often impossible to interconnect all equipment and machines into a single network, resulting in islands of automation. Even without being isolated on “islands,” legacy equipment is difficult to interconnect because of flexibility issues created by the use of proprietary communication protocols, non-standard connectors and cables, and other factors.
The Snap Signal IIoT overlay network provides a fast, flexible, and cost-effective way to capture a wide range of incompatible data communication protocols, convert them to standards that can be easily distributed, and send them to edge or cloud computing resources for analysis and operation to connect legacy equipment, automation islands (Figure 1).
Figure 1: The Snap Signal overlay network provides a modular architecture to connect legacy devices, automation islands, and edge or cloud computing resources. (Image courtesy of Banner Engineering)
Deploying a flexible and reliable IIoT overlay network requires several key components:
• Adapter – A standard format used for rewiring and connecting various device wiring schemes for sensors, indicators, and other devices to overlay networks.
• Data Converters – for converting incompatible formats such as discrete, analog and various digital formats on legacy equipment or automation islands to standard protocols such as IO-Link or Modbus for centralized performance monitoring.
• Filters – used to protect data from damage in electrically noisy industrial environments, thereby improving signal integrity and reliability and reducing troubleshooting requirements.
• Programmable controllers – for integrating data from multiple data sources and for local data processing, as well as providing connectivity to integrate legacy equipment and automation islands into the IIoT.
・Wired or wireless connectivity – for distributing collected data to edge computing resources and/or the cloud, such as Banner’s Cloud Data Service (CDS), etc., which provides data visualization, judges machine performance, and sends email or text Alerts to support real-time operation, maintenance and repair of machines (Figure 2).
Figure 2: The consolidated data can be sent to an edge computing resource or cloud, such as Banner’s CDS (screenshot above), via a wired or wireless connection. (Image courtesy of Banner Engineering)
Controller for consolidating multiple data streams
Programmable controllers and data converters are key devices for designing overlay networks. Banner’s DXMR90 industrial controller acts as a communications backbone, combining signals from multiple Modbus ports into a unified data stream that is forwarded using the Industrial Ethernet protocol. For example, the Model DXMR90-X1 device includes four Modbus masters that support parallel communication with up to four serial networks (Figure 3).
Figure 3: The ports above the DXMR90 device include a configurable Modbus port 0 (left), Modbus master ports (1 to 4, below), configurable Modbus port 0/PW for RS-485 and input power (upper right) side), and a D-coded Ethernet port (lower right). (Image courtesy of Banner Engineering)
The DXMR90 is a highly integrated communications controller with the following features:
• Ability to work with a range of Modbus devices, converting Modbus RTU to Modbus TCP/IP, Ethernet I/P or Profinet.
• Four independent Modbus master ports that can connect slave devices without manually assigning addresses to devices.
・ Local control and connectivity to:
Modbus/TCP, Modbus RTU, Ethernet/IP and Profinet, automation protocols
Internet protocols, including RESTful APIs and MQTT, and web services from AWS, etc.
Email direct notification
• Internal logic controller with predefined operating rules, which can also be programmed using MicroPython or ScriptBasic.
• IP65, IP67 and IP68 rated enclosures simplify deployment in industrial environments.
・ Fast status indication is achieved through user programmable LED lights.
• A wired Ethernet cable or a cell phone-enabled DXM controller can be used to connect to a database, such as Banner’s CDS.
Connecting devices in an IIoT network with converters
High-efficiency data conversion capabilities are required to integrate legacy equipment and automation islands into overlay networks. To do this, designers can use Banner’s small plug-in S15C series of in-line converters to convert condition monitoring and process sensor data in various formats into digital IO-Link data (Figure 4). For example, the S15C-MGN-KQ is a Modbus master to IO-Link device converter that can be configured by the user to read up to 60 registers, write up to 15 registers, and the predefined Modbus registers are automatically passed through the IO- Link to send.
Figure 4: The S15C series of in-line data converters can convert various types of signals, including discrete, analog, and other signals, to industrial protocols such as Modbus, IO-Link, PWM, and PFM. (Image courtesy of Banner Engineering)
The S15C converter is 15 mm in diameter, has an IP68-rated overmolded housing and M12 connections, using the same power supply as the connected device. The 20 m communication limitation of IO-Link can be eliminated by using the S15C converter, as these converters can be installed at the end of the Modbus link, close to the IO-Link master.
The S15C series converters include the following eight models:
• Six Modbus to IO-Link converters for use with Banner’s range of Modbus sensors including Ultrasonic, Measuring Light Curtains, Temperature/Humidity, Vibration/Temperature and GPS. In addition, there is a universal converter that can be configured so that most Modbus devices can be deployed as IO-Link devices.
・ Two analog sensor versions for converting 0 – 10 VDC or 4 – 20 mA signals into corresponding digital values and forwarding as IO-Link data.
Connect the adapter and filter to complete the network connection
In addition to controllers and data converters, designers also need to connect adapters and noise filters to quickly deploy flexible and cost-effective overlay networks. Push-in wiring adapters, such as Banner’s S15A-F14325-M14325-Q, allow direct connection of sensors, indicators, or other devices, changing wiring and isolating signals as needed to meet specific application needs (Figure 5). These wiring adapters are available in standard and custom configurations.
Figure 5: S15A adapters such as the S15A-F14325-M14325-Q use M12 connections for ease of installation and can be rewired as needed to meet specific application requirements. (Image courtesy of Banner Engineering)
S15F in-line filters such as the S15F-L-4000-Q are also important components in the overlay network (Figure 6). This filter easily eliminates electrical noise and transient voltage issues that can adversely affect network performance. Like the S15A adapter and S15C converter, this filter is packaged in an overmolded configuration with M12 connections and IP65, IP67 and IP68 standards. Installing an S15F in-line filter can improve signal integrity and reduce the need for network troubleshooting.
Figure 6: An S15F in-line filter such as the S15F-L-4000-Q can be used immediately to protect equipment from electrical noise and transients, and its M12 connection makes it easy to install in a network any desired location. (Image courtesy of Banner Engineering)
Design and Deployment of the Snap Signal Network
The design and deployment of the Snap Signal overlay network begins with identifying the data sources that need to be monitored. Then, you need to decide whether to add new sensors or indicators to complement existing equipment. The design steps for the Snap Signal network include:
• Use the Banner System Diagram method to identify and select Snap Signal components required for a specific installation.
• Plan the optimal wiring path, including placing T-connectors and filters between the device to be monitored and the DXMR90 controller.
・ Determine if the unit needs to use a wired Ethernet connection for local data consumption, or an edge gateway device to wirelessly connect to the cloud platform.
Snap Signal is a true overlay network that does not require replacing any existing hardware. The modular plug-and-play Snap Signal architecture makes installation simple:
· Install new sensors or other equipment and add breakout cables to each device that needs to be monitored to maintain existing connections to machine controls while also providing a second path for overlay networks.
・ Install the appropriate in-line signal converter.
・Add T-connectors, filters, and other network wiring as needed to complete the network and DXMR90 controller connections.
• Program the DXMR90 to create custom inspection and control sequences using ScriptBasic or MicroPython programming and/or embedded motion rules.
・Connect the DXMR90 to edge computing resources using an Ethernet connection, or connect to a cellular-enabled DXM controller for cloud connectivity.
Epilogue
Overlaying IIoT networks addresses the need for designers to connect legacy equipment and automation islands to industrial networks to collect actionable data to support existing factories to increase productivity. The design and implementation of such overlay networks is complex, but can be greatly simplified using Banner Engineering’s topology and Snap Signal lines as shown. The line includes the DXMR90 industrial controller, data converters, wiring adapters, filters, and other components needed to implement and distribute the IIoT overlay network to edge computing resources or the cloud. The modular, programmable, and flexible design of the Snap Signal network architecture supports the addition of new equipment and secures future installations.
The Links: 2DI75D-100 MCC56-14IO1B