Cyber-physical systems link real objects with virtual objects, i.e. machines with information processing systems. Cross-system communication allows energy and process control as well as predictive maintenance to be realized - if the devices have the appropriate interfaces.

Schmalz develops vacuum components specifically for networking in vacuum automation that not only record energy and performance-relevant data and send it to the cloud, but also monitor and analyze it. Thanks to IO-Link or Industrial Ethernet interfaces, the smart field devices are able to communicate seamlessly from the sensor and actuator level to the higher-level controller (PLC) and on to the control level. Communication works in both directions: In addition to transmitting data on the status or energy consumption, parameters can be changed via the controller and transferred to the smart field device.

In addition to the IO-Link and Industrial Ethernet interface, Schmalz integrates an NFC (Near Field Communication) interface into the intelligent vacuum components. In order to exchange information wirelessly over short distances, a point-to-point connection is established between the smart field device and the user's NFC-enabled mobile end device. No separate energy source is required in the component for transmission. Instead, a coil is installed that is energized via the smartphone. The coil induces a voltage in a processor, which then transmits its information via an antenna. Users can therefore read process data as well as maintenance and service information directly on their smartphone. The device speaks to the user in plain language: if there is a standstill, it provides clear information about the source of the error instead of cryptic error codes. The component can also be parameterized via smartphone. The 'ControlRoom' app is available for this purpose: parameter changes made via NFC can be transferred directly to the device or copied from one device to another.

Another advantage of NFC is the direct assignment of product to smartphone. Two devices are only connected over a very short distance of a maximum of 2 cm. This means that the user can be sure that no neighbouring devices are parameterized unintentionally.

From the airflow to the data stream

The vacuum components are quickly integrated into the application environment via interfaces such as IO-Link, Ethernet or NFC. They enable seamless process monitoring, early fault detection and timely, predictable maintenance.

© Lard

The benefits of digitalization at component level for vacuum applications can be seen in the compact terminal 'SCTMi'. This bundles up to 16 individual vacuum generators into one unit, which only has one electrical and one compressed air connection. This allows different parts to be handled simultaneously and independently with just one system. The vacuum is generated by a Venturi nozzle and detected by a sensor. Users can read out the exact vacuum value via the IO-Link process data or on the display of the generator.

The ejectors are also controlled via the cyclical process data and current information is reported back by the ''SCTMi''. Users can also access setting values, parameters and measurement and analysis data via the IO-Link connection. In addition, the diagnostic and forecasting functions of the vacuum components derive information about the status of the system and identify trends in quality and performance. The data is transmitted to an internal or external cloud, where it is processed and analyzed: If the system detects values running out of tolerance or creeping changes, these can be displayed to the user quickly and clearly. For example, the system checks the leakage and dynamic pressure for predictive maintenance evaluations.

Condition monitoring events are triggered, for example, if the dynamic pressure values deviate, the evacuation times of the ejectors exceed their limit values or sensor voltages are outside the operating range. The energy monitoring function keeps an eye on the energy consumption of the connected vacuum systems. This monitoring is based on the measured air consumption, which is calculated taking into account the system pressure and nozzle size. Users can specify an externally recorded pressure value via the IO-Link process data. If this value is available, the ejector can measure the absolute air consumption in addition to the percentage.

Quickly integrated

IO-Link also simplifies the integration of the compact terminal into the system environment: Schmalz provides a comprehensive IO-Link configuration file IODD (IO Device Description), which contains information on identification, device parameters, process and diagnostic data and communication properties, among other things. The replacement of devices is also simplified, as the IO-Link protocol contains an automatic data transfer mechanism. When replacing a device with a new one of the same type, the setting parameters of the old device are automatically saved by the master in the new device.

Author:
Andreas Dölker is Head of Corporate Communications at Schmalz in Glatten.