Standardized Control Cabinet Solution From The Modular System

2023 Author: Hannah Pearcy | [email protected]. Last modified: 2023-05-24 11:12

Elaborate and expensive: Control cabinet solutions with automation technology for the control, diagnosis and monitoring of machines and systems are used in numerous industries to ensure an efficient and stable production process. Due to specific requirements, the control cabinets are usually individually designed and developed. This involves a considerable amount of time for planning and implementation as well as high costs.

Modular modular system for control cabinets

Against this background, Phoenix Contact has developed a standardized control cabinet solution that, due to the modular system on which it is based, meets the requirements of different applications by having a high degree of individualization. By using technologies such as the PLC Next Technology ecosystem or the controller-independent Safety Bridge Technology, the solution fulfills even high requirements such as that of Industry 4.0.

The control cabinet called the Smart Production Cabinet (SPC) is a modular, expandable control solution for the automation of machines and systems. The prefabricated system consists of coordinated hardware and software packages. A compact housing with degree of protection IP54 with a recessed 7-inch web panel forms the basic structure.

Hardware and software package

The preconfigured hardware includes:

• a Profinet-compatible controller from the PLC Next Technology ecosystem
• a standard I / O module with eight inputs and outputs
• two safety input modules
• a safety output module
• a power supply.

The devices are supplemented by a software package with libraries for diagnostic, basic, signaling and safety functions. In addition, there is a preset visualization that enables simple operation and can be easily expanded or customized.

Secure wired or radio-based communication

The PLC Next control integrated in the Smart Production Cabinet has a connection to the Proficloud from Phoenix Contact without requiring an additional gateway. In this way, users can access the information relevant to them at any time and from any location. In addition, the controller can be easily installed in existing Profinet systems, since it functions both as a Profinet controller and as a device.

In addition to wired data exchange via Profinet or OPC UA, the SPC control cabinet can be expanded to include a powerful WLAN module according to the latest IEEE standard 802.11n. In this way, mobile units - such as driverless transport systems (AGVs) - can also be controlled. Furthermore, communication connections can be initiated between several Smart Production Cabinets that are installed in independent networks.

Labelling

Mark components correctly in the control cabinet

The control cabinet solution also supports the user in complying with security standards. According to the international IEEE standard 62443, certain criteria must be met to protect the production area. That is why the SPC system can be supplemented with a security module for configuration. The security appliance of the FL M Guard product family shields the system with an intelligent firewall against unwanted access from outside the company. In addition, the device includes VPN access (Virtual Private Network), via which a secure connection to the remote maintenance of the machine or system by the manufacturer is possible.

Control and network-independent safety solution

With the Safety Bridge Technology (SBT) supported by the safe I / O modules, applications with functional safety requirements can also be operated - and this without safety control and regardless of the network used. It is even possible to wirelessly transmit all safety-related data signals via Bluetooth or WLAN. Applications such as two-hand start or emergency stop can therefore be easily implemented.

The SBT system consists of safe input and output modules and a logic module. The latter captures the safe signals and outputs them. In addition, the logic module generates and monitors the safety-related SBT transmission protocol and processes the logical links of the parameterized safety logic, thus taking on the task of safe control.

The Smart Production Cabinet can also be optionally expanded with a 4-in-1 motor starter from the Contactron series. The compact 22.5 mm narrow module combines starting, turning, protecting and the emergency stop up to SIL 3 or PL e in one housing. It is used wherever reversing and protecting three-phase asynchronous motors from 50 W to 3 kW are involved, such as conveyor belts, monorails and other logistic systems.

Function modules

Simplify installation in the control cabinet

The functions described for functional safety, wireless communication, security and motor control represent preconfigured components of the control cabinet solution and can therefore be used in the library with little or no programming adjustments. Of course, users are still free to make changes themselves or together with the specialists from Phoenix Contact.

Digital marketplace for software solutions

Since systems are never static, but always change in their physical and virtual structure, the software of the Smart Production Cabinet must be able to be constantly adapted to current needs. The PLC Next Technology ecosystem allows access to the PLC Next Store. It is a digital marketplace where pre-programmed software modules or complete solutions for industrial automation technology are available. These software applications (apps) can be loaded onto the controller quickly and easily. In this way, even users who do not have extensive programming knowledge can independently expand their application. The apps and function blocks can also be customized. In addition to classic programming in IEC 61131, modern high-level languages such as C ++ or C # are available.

The control cabinet solution can basically be used in all industries with production and conveyor systems in which a decentralized automation system is required for control, diagnosis and monitoring. Due to the open design, the Smart Production Cabinet is particularly suitable for:

• the automotive industry
• mechanical and plant engineering
• the logistics as well
• similar production processes.

Typical applications are punching, bending, welding or similar assembly and manufacturing machines. In addition, logistical units such as electric monorails, conveyor belts, roller conveyors and small warehouses can be operated with the control cabinet solution.

Individualized control cabinet solution

With the Smart Production Cabinet, Phoenix Contact has developed a system for many industries and markets that combines the advantages of a standardized with an individualized control cabinet solution. The user can buy a finished product from the e-shop and still have the option of individualizing it either with the support of the specialists from Phoenix Contact or by making their own adjustments. For this purpose, function blocks and apps are offered to him in the PLC Next Store so that he does not have to program himself.

Because the control used is based on the open ecosystem PLC Next Technology, the user can choose between classic and modern programming languages when programming. In addition, the controller offers a connection to the Proficloud to carry out extensive activities in the context of predictive maintenance or big data analyzes. The production area is well prepared for Industry 4.0 and the associated challenges.

* Andreas Stanislawski, Product Manager Factory Automation, Phoenix Contact Electronics GmbH, Bad Pyrmont