According to Dr. Christopher Ganz, Group Service R&D Manager, ABB has been equipping devices and systems with software and (digital) interfaces for over 40 years and already generates 55% of its sales with corresponding products. In total, ABB can look back on over

• 70 million connected devices,
• 70,000 digital control systems and
• 6000 enterprise-class software solutions

Against this backdrop, Ganz sees his own company as a digital 'hidden champion', although it still needs to position itself more strongly externally when it comes to Industry 4.0. The company is now bundling its range of digital solutions and services across all industries under the slogan 'ABB Ability', with the aim of further enhancing existing technologies with new services and technologies and thus further increasing productivity through less downtime, greater efficiency and better returns.

What Christopher Ganz feels is important to emphasize in the discussions surrounding IoT, Industry 4.0 & Co: "Digitalization is more than just connecting an intelligent device to the cloud. Rather, there are many analytics functions in between, which need to be used in a targeted manner where it makes the most sense. And this can also be directly on the machine - keyword analytics at the edge."

When it comes to the cloud in general, Ganz believes that "the time has passed for anyone to believe that they can master this area as an individual." Instead, all the major market players now have their own solutions and customers will opt for different solutions depending on their requirements and preferences. This poses the challenge of how data can be exchanged between the different clouds in a simple or standardized way. "Once we have reached the same level as we have today, for example with IEC 61840 switchgear, we will have achieved a great deal," says the digitalization expert.

Speaking of switchgear: ABB will be presenting the concept of a digital switchgear at the Hannover Messe. In future, analog signals via copper cables will be replaced by digital communication via fiber optic cables. Furthermore, digital substations will also contain intelligent electronic devices with integrated information and communication technology. Their status data will be collected in real time and around the clock via the Internet of Things. This data can then be filtered and analyzed using cloud-based software.

Milestone in level measurement

In addition to power distribution, ABB will also be presenting various innovations in the field of classic automation technology in Hanover. With the LLT100 laser level transmitter, for example, the company is launching a "milestone in continuous non-contact level measurement". The devices are able to detect the fill level in silos or tanks of both bulk materials and liquids. They do this regardless of the physical properties of the measured medium.

The LLT100 is suitable for level measurement of bulk solids with a bulk height of 100 meters and liquid columns of up to 30 meters. The devices can be adapted to a wide range of applications using accessories or special mounting brackets.

© ABB

By using a pulse laser for time-of-flight measurement, the LLT100 enables very precise distance measurement. Power is supplied via the 4 to 20 mA signal line. The transmitter can be equipped with an aluminum or stainless steel housing and a variety of process connections. It therefore meets the requirements for use in hazardous areas and for applications with high pressures or temperatures. Special hygienic versions are available for use in pharmaceutical or food applications.

Another trade fair innovation concerns the topic of drive technology: In recognition of the fact that preventing harmonics is a better strategy than treating the symptoms, ABB has developed a complete series of so-called 'Ultra Low Harmonic Drives'. Their basic concept is to pack a corresponding filter, an active mains inverter and a motor inverter into a single frequency inverter unit.

Harmonic content reduced by up to 97

According to the responsible product manager Fred Donabauer, a key advantage of this approach is that there is no need for additional devices for harmonic damping or power compensation.

According to Donabauer, the integrated harmonic damping actually reduces the harmonic content by up to 97% compared to conventional frequency inverters. In other words, the harmonic content of the current in the new devices is typically less than 3 %, and the harmonic content of the voltage is even significantly less than 1 %.

Compared to alternative solutions for damping or eliminating harmonics, the Ultra Low Harmonic Drives have a number of advantages. Donabauer explains: "A multi-pulse solution requires a special multi-winding transformer and is associated with higher cabling and installation costs as well as a high weight.

Other decisive advantages of ultra-low harmonic drives are the power factor 1, even in the partial load range, as well as lower transformer losses, which increase the overall efficiency of the drive train." With the multi-pulse solution, on the other hand, you have to accept compromises, as the power factor is lower and the higher harmonic content in the mains current puts a strain on the transformer, which makes oversizing necessary. Furthermore, the effect of harmonic reduction in the multi-pulse solution depends on the voltage symmetry and the quality of the secondary windings. The advantages are similar when compared with passive harmonic filters.

The latter require an additional filter and cause current harmonics of typically 5 to 10 %. Further characteristics of this solution are a power factor well below 1 at partial load, there is a risk of resonances in the network and, last but not least, there is a load-dependent voltage drop across the filter, which requires the motor to be oversized.

In the future, ABB will offer ULHD variants for industrial drives as well as devices for HVAC and water/wastewater applications in the power range from 4 kW to 3.2 MW (380 V to 690 V).