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Automation Technologies 5/2016

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Automation Technologies 5/2016

Secure communication for

Secure communication for Industrie 4.0 systems INDUSTRIAL COMMUNICATION Anja Moldehn Manufacturing companies are facing the challenge of optimally planning and implementing complex manufacturing processes. Production is to proceed without interruption or rejects. When combined with high flexibility, this ensures the competitiveness of the manufactured products. Intelligent and secure communications structures are necessary to meet these challenges. The forward-looking Industrie 4.0 government initiative points to solutions for fulfilling the increasing demands on flexibility, individualization, and efficiency in manufacturing companies. These allow manufacturing to remain competitive in the long term through the use of digital, networked system solutions. Phoenix Contact, too, is picking up on the advantages of Industrie 4.0, some of which are abstract, and applying them to practical requirements of future-oriented production. The company has defined a total of six fields of action that focus on high flexibility, performance, quality, and economy. Among them are consistent digitization, secure communication, autonomous adjustment to changed framework conditions, simple installation and operation, as well as efficient use of resources. Author: Dipl.-Ing. Anja Moldehn, Marketing Specialist Industrie 4.0, Phoenix Contact Electronics GmbH, Bad Pyrmont, Germany Protection against electrical interference and unauthorized access The two fields of action mentioned first form the foundation of the initiative. Only when all relevant information is available in digital format and all participants of the value chain are networked can the Industrie 4.0 approach be systematically implemented. Digital data is taken to maximize added value at any given time. The connection of people, objects, and systems leads to dynamic, self-organizing added-value networks. These can then be improved according to various criteria, such as cost, availability, or resource consumption. Intelligent mechatronic systems exchange their data across locations and companies through public or private network infrastructures. This communication on the basis of Ethernet and the Internet ensures high production availability. At the same time, it forms the foundation of flexible, self-optimizing manufacturing processes. That is why it is imperative that data transmission be reliably protected from electrical interference and unauthorized outside access. Efficient operation based on material flow and retooling times Phoenix Contact is calling on its extensive experience based on the deep integration of its components, systems, and solutions with the objective of implementing the fields of action of the Industrie 4.0 initiative to the greatest degree possible at the present. In addition, the company’s far-reaching in-house mechanical engineering expertise and its automation specialists’ know-how accumulated over many years are incorporated into Industrie 4.0-capable machines and systems. This has led, among other things, to a new production line at the Bad Pyrmont location that manufactures six-millimeter-wide isolation amplifiers for interference-free signal transmission. AUTOMATION TECHNOLOGIES 5/2016

This plant’s manufacturing process has been improved in terms of how the product, worker, and machine communicate with each other. A continuous material flow in the process chain and short production retooling times for all of the 98 product variants contribute to efficient methods of operation. When ordering isolation amplifiers, customers can use an internet-based configurator to select the input or output signal type, for instance. This gives rise to more than 1,000 different module versions. In order to allow such a wide variety of products to be manufactured in small lots of 5 to 480 at mass-production costs, personnel and machines must work quickly and economically. Flexible processing on the basis of a circulation system It is a long way from the bare PCB to a complete, packaged product. After soldering paste has been applied and SMDs have been mounted, sets of four PCBs are checked for the correct arrangement of the individual components. Up to 154 small components, such as resistors, capacitors, and diodes, can be installed on a single PCB. After soldering, a stamping machine cuts out the PCB. Then it is placed on a workpiece carrier and fed into the Industrie 4.0 system cycle. Around 20 workpiece carriers circulate around the production line at the same time, allowing employees to work at capacity and the system to function economically. First, the workpiece carrier is conveyed through a short cycle. After a laser has completed labeling and the recesses have been milled, the housing is completed. In the next step, the PCB is inserted and coupled with the housing. Next comes the long cycle. In the so-called soldering portal, the housing is soldered to the PCB. Now the module is completely functional. During downstream programming of the respective firmware, a cylinder lifts the workpiece carrier to the test head. This is followed by high-voltage and final electrical testing. Communication between products and facility control system When an order is loaded to the production line, first the work plan is generated. As soon as the product is in the workpiece carrier, an RFID tag creates a connection to the information that the higherlevel system provides. That includes the indication of which tests are to be performed on the article and whether and what firmware must be implemented. The workstation machine operator comes into contact with each module three times. Each contact involves a different task. One is to read out the RFID chip to compare the finished article’s image area with the specifications displayed on the screen. Another is to insert the PCB and package the finished module. The processing status of the individual products is communicated to the higher-level system via the RFID tag. That is why the screen only shows the information or options that personnel need to perform the current task. The communication between the article and the facility control system thus makes the high About Phoenix Contact The family owned company is based in Blomberg, Germany and generated a turnover of 1,91 billion euros in 2015. The company has its own production sites in 10 countries, a global network of 50 sales subsidiaries and 30 local agencies, employing more than 14,500 people worldwide. It is amongst the top global players and innovators in the field of electrical engineering and automation. 01 Whether firmware is being programmed or electrical tests are being performed, retooling the programming or test head only requires a few steps 02 A router with an intelligent firewall facilitates remote maintenance complexity resulting from the wide range of variants manageable for personnel. They receive assistance, allowing them to complete work quickly and without errors. Comprehensive digitization is a further key requirement As the example at Phoenix Contact shows, systems are already flexible. So if people and machines, too, interact optimally, even small lots can be produced economically. But what is required for implementing a perfectly networked plant and the associated productivity gains? In order to gain all the advantages of tomorrow’s industrial manufacturing, it is imperative that the actual article communicate with the processes that are based on digital data. To this end, the products involved must be just as thoroughly digitized as the individual workstations through which they pass during manufacturing. This allows the human actor to operate the production system economically because of support from assisting systems. In addition, both data exchange and the design of the communicated content must be adequate for the production systems. If operators want to ensure that their production locations will continue to be successful, they must organize standards and guidelines sufficiently open so that they cover changing conditions and business models. Photographs: Phoenix Contact AUTOMATION TECHNOLOGIES 5/2016


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