IO-Link- and EtherCAT-enabled power supplies: How can they help you optimise your system performance?
We see a global shift towards a data-driven economy developing at unprecedented speed which heavily affects the future role of data in the manufacturing industry. Therefore smart manufacturing is becoming increasingly important, data-driven insights are crucial for optimising system performance and ensuring operational efficiency. The power supply is placed at a central nodal point in every system and records a significant amount of real-time information that is of particular interest to the operating company as well as the system manufacturer.
A growing line-up of PULS power supplies give you access to this information via IO-Link or EtherCAT. In this blog article you will learn how you can profit from those solutions now and in the future.
What is the condition of the power supply? Do you still have enough power left to supply further modules inside the cabinet? What is the quality of the mains voltage like? And how does the temperature develop inside and outside of the power supply?
Many PULS power supplies are able to answer these questions with real application data. This information can help to tackle the big questions within the application: Is your system running at its optimum and as expected? If not, which adjustments need to be made?
Knowing the answers can help increase system availability and reduce maintenance and operating costs. And last but not least, reliable data is the key to success in smart manufacturing. This means the power supply has the potential – in parallel with its function as a converter – to also act as a sensor and therefore makes a significant contribution to your approaches for predictive maintenance and automation of industrial processes, which leads to a higher output, better performance and lower costs.
Power supplies with a communication interface strengthen availability of the overall system
Power supplies perform a rather more passive role in terms of communication output. Following installation, they need to work reliably in the background and remain as maintenance-free as possible – ideally for many years.
So the question which communication protocols a power supply manufacturer like PULS should support in the long-term is essential and must be well considered. Based on many meetings with various customers and market analysis we decided to go for IO-Link and EtherCAT. The reasons for this decision are explained in this article.
Therefore we are extending our portfolio with IO-Link and EtherCAT versions of our most popular products.
For example the reliable and efficient 1-phase 480 W DIN rail power supply CP20 is available as an EtherCAT (CP20.241-ETC, CP20.481-ETC), IO-Link (CP20.242-IOL) version as well as a hybrid version with IO-Link and an integrated power supply condition display (CP20.248-IOL). For the higher power demand, the well-established 3-phase 960 W DIN rail power supply QT40 comes with IO-Link. These devices are ready for a simple integration into existing communication networks. Our robust IP54, IP65 and IP67 Field Power Supplies (FIEPOS) for decentralised applications feature IO-Link as well and another variant supporting EtherCAT is under development.
With all these new tools at hand customers profit from a future-proof solution that alongside a highly efficient and reliable energy supply embedded in a compact housing, also provides completely new insights into the performance requirements and physical processes of their systems or machines. This valuable information can be used to to better understand what is really going on in the application to optimise the availability and capacity utilisation of the system. In addition, the data helps to reduce energy costs, permits needs-oriented, preventative maintenance and provides valuable information for sustainability reports.
Remote diagnostics and automated parameterisation
The connection via IO-Link or EtherCAT also facilitates remote diagnostics and parameterisation via the user software being applied in the automation system. The system engineer can set the output voltage via the configuration software and the devices can be switched on and off remotely assuming remote access is enabled in the user software.
The settings made by the user, as well as critical process values, are saved on the automation system with full resistance to voltage failures and simultaneously on the built-in non-volatile memory in the power supply. If a device exchange becomes necessary, rapid, automated parameterisation of the new device is carried out during ongoing operation – in accordance with the parameters stored on the automation system. Downtime due to maintenance work is therefore avoided in the long term.
The data sent by the power supply also provide information on the cause of the fault and simplify problem-solving. This data is categorised in cyclical data, acyclical data and events.
The output current is included in the process data, for example, and is communicated to the master in a cyclical data telegram. The acyclical signals include device information such as input and output parameters that can be queried at all times.
Special events are also reported by the power supply. These events could be warnings or error messages, such as too low or too high input voltages, an overload or too high temperatures. If an abnormal condition arises, the power supply sends a message to the IO-Link or EtherCAT master and displays to the user the need for action, even before a failure actually occurs. Maintenance is therefore preventative and needs-oriented. This means that rigid cycles of regular servicing work are no longer required. In turn, this saves costs on new purchases and maintenance.
Additionally, events or warnings can trigger application reactions. In the simplest case, this can establish a safe state of the system. Furthermore, it is even possible to completely avoid system downtime based on the communicated events and therefore prevent insufficient product quality.
Now let’s dive deeper into the advantages of IO-Link and EtherCAT.
Advantages of the IO-Link communication protocol
IO-Link is based on serial, bidirectional point-to-point communication. The system is very robust overall and also has a high level of security – two factors that PULS pays particular attention to in the development of its industrial power supplies. The devices are often exposed to the harsh environments of the lower automation level and at the same time need to be protected against sabotage from outside. Data transmission via IO-Link is tried and tested for this usage.
The component costs for an IO-Link port in the power supply is relatively low in comparison to more complex communication protocols. Due to the low number of additional components, the MTBF value (Mean Time Between Failures) is almost as high as for the products without IO-Link. E.g. the MTBF for the QT40.241 (without IO-Link) is 375,000 h and for the QT40.241-IOL (with IO-Link) 350,000 h. This means that there are no compromises in terms of the reliability of the devices.
The same also applies to the long lifetime of 62,000 hours – at 3AC 480V, continuous full load and +40°C ambient temperature. This makes the IO-Link-compatible power supplies particularly well suited to failure-critical applications, such as in the automotive industry, factory automation and process industries.
In addition, IO-Link has been designed from the ground up as a user-friendly plug and play solution. Installation and operation are simple and can be realised cost-effectively. Standard shielded IO cables are all that are required for the cabling. Integration capability in all standard field bus and automation systems is ensured, offering flexible usage options.
Additional advantages of the EtherCAT communication protocol
The integration of the available PULS power supplies with EtherCAT interface into existing EtherCAT networks is very easy and works without additional gateways, which is a big plus for users who already rely on this field bus solution.
The biggest benefit of EtherCAT is its real-time capabilities, high-speed data transmission and easy integration, which outperforms any other industrial communication. This allows the power supply data to be used within real-time control loops. Based on the data, drives and other high-energy users can be optimally controlled to maintain overall dynamic power needs at their optimum level.
The data enables improved system efficiency as power supplies can be used at the optimal operating point. This leads to increased system throughput, improved product quality, and reduced waste, ultimately benefiting end-users by delivering better results due to the consistent performance and minimal disruptions.
Power supplies with EtherCAT interface are ideal for maintenance, logging and remote control in large-scale systems.
Have you ever heard of ADELBus?
The newest member of the PULS Group, Adelsystem, has developed its own communication network for its DC-UPS solutions, called ADELBus. This network allows the connection of all components in a system using a single communication protocol based on MODbus-RTU or CANbus technology, depending on the application field.
ADELBus enables the remote monitoring and control of all system parameters. It is designed to be simple yet powerful, providing robust and versatile communication capabilities for various industrial applications.
AI decisions in the factory based on digital load profiles
The data recorded by power supplies with IO-Link or EtherCAT forms the basis for the technical innovations of the coming years. Above all, PULS is thinking here of the importance of machine learning in combination with the ongoing progress in terms of artificial intelligence (AI). The power supply is already supplying precise measurements of the output current, in other words, the load current. On the basis of these very carefully measured values, it is possible to detect and describe digital load profiles.
Based on information on the output current, for example, it is possible to determine whether or not a load changes across an extended period. This change can be an indication of signs of wear in the machine or plant. As an example, in the case of knocked out profiles, a sinus curve would be detectable in the load profile. As part of computer-aided data analysis based on artificial neural networks, this anomaly would be detected and reported.
Data is also provided by many other system components in parallel. Certain patterns can be recognised in these data sets and linked to operating states. The next step would then be a similarly automated decision-making process on the subsequent procedure using AI. This approach means that the power supply and other components as data sources open up entirely new options in the use of AI in the factory environment.
The use of current as a standardised data source in the production process plays an important role here. As a physical value, current supplies precise, interpretable and reliable data. This means that common big data problems in established company structures, such as incompatibility and inconsistency of data, or difficulties in networking and scaling, can be avoided.
Summary: Let power supply data work for you
In conclusion, leveraging your power supply unit as a data source offers significant advantages for both operating companies and system manufacturers. By integrating PULS power supplies with IO-Link or EtherCAT, you gain access to valuable real-time information such as output current, voltage levels, temperature development, and load on the power supply. This data enhances system availability and reduces maintenance costs while supporting predictive maintenance and automation of industrial processes.
With the addition of communication interfaces, power supplies play a more active role in system diagnostics and parameterisation. The integration of IO-Link and EtherCAT into PULS power supplies ensures compatibility with existing networks and provides robust, real-time data transmission. This enables remote diagnostics, automated parameterisation, and efficient maintenance, ultimately leading to improved system efficiency, reduced energy costs, and enhanced overall performance.
Moreover, these systems are ready for an AI-shaped future. The data recorded by power supplies with IO-Link or EtherCAT forms the basis for technical innovations, including machine learning and artificial intelligence applications. This opens up new possibilities for optimising system performance and predictive maintenance.
Explore the benefits of these advanced power supply solutions and discover how they contribute to the success of your smart manufacturing initiatives.
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