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An energy-efficient automation solution

Transferring energy data seamlessly and independently of buses
An energy-efficient automation solution

In the energy-intensive chemical industry, energy efficiency is of paramount importance. Before the energy processes in a plant can be optimised, however, all the plant’s energy data need to be collected and properly distributed. A combination of management modules for energy data capture and motor control together with an inline I/O system ensure a seamless data flow – from the point of energy consumption right through to the highest-level control and management systems.

The author: Carsten Henning IP 20 I/O Product Manager, Phoenix Contact Electronics

A whole series of crucial decisions are presently being made regarding the future use of energy sources and forms. The generation, processing and storage of many different energy forms are changing drastically. Experts agree that the frugal use of resources is the only feasible solution for securing the long-term availability of energy sources. Since this approach also has a positive effect on the global climate, conserving energy has become a huge trend. Many people buy energy-saving lamps, use washing machines with Class A++ energy efficiency, live in houses with an energy certificate or drive cars that consume less fuel. Such behaviour is motivated not only by environmental awareness but also by a desire to cut costs as energy becomes more expensive.
Technology integrated into lamps, washing machines, cars and houses reduces the power they consume by controlling energy and utilising it more efficiently. What is applicable for everyday objects should also be possible in machines and plants. This creates a need for energy-efficient automation technology – in factory automation as well as in process automation. To this end, all relevant information must be acquired as close to the process as possible and evaluated to obtain accurate data. In this scenario, the energy source itself provides the information. With its IT-powered automation concept, Phoenix Contact offers an automation solution that enables data to be acquired, transferred via a fieldbus system or an Ethernet network and processed both centrally and locally. This information is made available to higher-level control systems or office computers through connections to Ethernet based networks. The principle behind the concept is known as vertical integration.
EMM and EEM extend operating times
In the information chain, electronic motor management (EMM) and electronic energy management (EEM) modules from Phoenix Contact acquire the data and control the appropriate actuators. Using these devices, electrical quantities such as current, voltage and active power can be measured as well as direct energy consumption and operating hours. The electronic motor management modules can be parameterised so that when a specified value is either exceeded or not met, the motor automatically shuts down. This means that they continually monitor the state of the drives integrated in the machine or plant along with the associated mechanical system. In this way, wear and hazards are identified early on, allowing maintenance personnel to service the application depending on its particular condition – which in turn reduces downtimes. At the same time, energy peaks can be identified and processes configured to be more energy-efficient. It makes sense to deploy motor management modules wherever electric drives are used, for example on conveyor belts, pumps, fans, mills or mixers.
Capturing energy data
The energy management modules (EEM) only acquire energy data. They are extremely versatile. One new, but increasingly important, application is the acquisition of usage data in charging stations for electric cars. This involves small, distributed units equipped with a miniature control, such as the ILC 150 GSM/GPRS from Phoenix Contact, which are networked via the modem integrated in the PLC. Another use for energy management modules is monitoring energy data in ventilation and air conditioning systems. Thanks to these modules, energy demand can be better distributed, the risk of failure as a result of overload minimised and periods of peak energy demand shifted to times where cheaper rates apply. Intelligent energy management is also conceivable in applications such as refrigerated container monitoring on container ships, energy data monitoring in air filtration systems, energy management in industrial production facilities and energy consumption measurements of hot water for cleaning processes.
Integrated device bus
Up to 32 of these management modules can be lined up and automatically connected to a device bus – the Interface System Bus (IFS) – using the T-Bus mounting rail connector. The coupling to the control is realised independently of any specific fieldbus or network using Phoenix Contact’s Inline automation system. In addition to providing numerous functions, such as digital and analogue signals, the Interface System Bus can also be integrated into an Inline station with the help of the new IFS master terminal. The terminal is connected to the device bus via a shielded cable. The shield can be easily connected to the integrated Inline shield terminal. The connection from the Interface system bus and I/O system ensures that energy data is transferred transparently from where it is generated to the central control room.
User-friendly configuration
The modules support FDT/DTM technology for parameterising the management modules, so that data can be supplied to users easily and independently of controllers. With the Phoenix Contact solution, users have two options when configuring the lower-level device bus and allocating the appropriate parameters. The first alternative is part of the PC Worx control software. This is used with all control systems from Phoenix Contact, such as the 100-type Inline controllers. Secondly, the Inline IFS master can be accessed directly as a frame application via AutomationXplorer. To do this, the user simply connects a notebook to the interface of the Inline IFS master via a USB adapter. The modules can then be parameterised independently of the higher-level control system. In both cases, the data that has been set is saved on the pluggable memory of the Inline IFS master, and the system can be quickly re-commissioned again after a device has been replaced.
Hall 9, Booth F40

A modular automation system for (almost) any requirement

Facts & Figures

Automation technology is characterised by the wide variety of tasks it addresses. Different types of signals must be collected, transferred, processed, and output again. Using the Inline modular automation system from Phoenix Contact, machine and plant builders can adapt their solutions to the given requirements. The refined modular I/O system supports a wide array of functions. These include digital and analog input/output terminals, communication terminals such as RS 232 interfaces or the energy management modules’ master terminal, as well as special functions such as incremental encoder inputs.
Modules with different numbers of channels and bus headers for all of the usual fieldbus systems and networks enable the implementation of customised automation concepts. Automatic cross-wiring of terminals slashes the previous installation costs by up to 80 %. When maintenance is required, extensive diagnostic functions as well as withdrawable connectors prevent long downtimes. The Inline product range is rounded off by small 100-type controls for implementing complete automation solutions quickly and easily.
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