AS-Interface for drive and conveyor technology

Bihl+Wiedemann

Thomas Rönitzsch | Inka Krischke, 11.04.2023, 09:01

AS-Interface for drive and conveyor technology

ASi-3 for collecting individual binary signals, ASi-5 for complex tasks where high transmission speeds and large data bandwidths as well as efficient addressing of participants are important - a 'dream team' especially for intralogistics systems.

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In spring 2022, Bihl+Wiedemann presented a Zero Pressure Accumulation (ZPA) solution for zero pressure accumulation conveying in buffer and accumulation sections of stationary material flow systems. This enables autonomous and controller-independent integration of motorized rollers, DC motors and frequency inverters of various makes and different performance classes, while at the same time opening up detailed and fieldbus-independent diagnostic options. Modules for drives from Rockwell Automation, ebm-papst and Bonfiglioli now complement the modules previously available for manufacturers of motorized rollers such as Interroll, Itoh Denki and Rulmeca as well as for suppliers of DC motors and frequency inverters such as Lenze, SEW-Eurodrive and Nord Drivesystems. This means that Bihl+Wiedemann's solutions for ASi-3 and ASi-5 are compatible with drive infrastructures that are standard in many modern material handling systems. New developments such as the 24 V brake chopper for limiting voltage feedback to the supply line and ASi-5 cable duct modules round off the portfolio.

Regenerative energy recovery

Bihl+Wiedemann offers a wide range of options for using AS-Interface for drive technology.

When operating 24 V roller drives, the 'BWU4915' brake chopper with IP67 protection limits the overvoltage that occurs on the AUX line during braking operations of the drive due to feedback. This prevents unintentional mains shutdowns or error messages due to overload. Each brake chopper is able to compensate for the overvoltage of at least two rollers at the same time, and in many cases even more. For this purpose, the module can be connected to the black AUX profile cable using piercing technology - whereby the flat housing of the module is particularly suitable for installation in cable ducts and other types of cable guides. Two integrated LEDs on the module enable quick on-site diagnostics by signaling whether a voltage is correctly applied and whether actively fed back energy is being compensated.

Integrate up to four motorized pulleys

The 24 V brake chopper 'BWU4915' can be used to compensate for the overvoltage of at least two motorized rollers at the same time.

The new ASi-5 cable duct motor modules 'BWU4893' and 'BWU4894' for 24 V and 48 V motorized rollers respectively simplify the connection of several roller drives in one application: The design and dimensions of the housing as well as the integrated cables for sensors and motors have been optimized for space-saving installation in the cable duct along the material flow path. Up to four motorized rollers and up to eight sensors can be connected and supplied to each module. Each of the four motorized rollers can be controlled individually and therefore flexibly - under a single ASi-5 subscriber number (ASi address). Various status LEDs provide support during commissioning and enable simple diagnostics of the inputs during operation or in the event of a motor fault. Protection class IP54 takes into account the conditions of cable duct installation - the temperature range specified at -30 to +70 °C enables the motor modules to be used in refrigerated and deep-freeze environments as well as in conveyor systems with correspondingly higher ambient temperatures.

ASi-5 cable duct modules from Bihl+Wiedemann can control up to four ZPA zones independently of each other.

One interesting feature of these modules for conveyor applications is the ability to continuously write speed as well as start and stop ramps with cycle times of up to 1.27 ms. Secondly, each of these ASi-5 cable duct modules offers the option of implementing up to four ZPA zones autonomously - without a higher-level controller and the associated programming effort and independently of the drive solution used in the system, with the help of Bihl+Wiedemann's PC software. In combination with ASi-5 cable duct modules for two motors, the number of unused motor connections can be minimized in applications, reducing connection costs.

Standardized and safe

The ZPA solution from Bihl+Wiedemann works independently of the control and drive solutions used in the system.

Thanks to the broad portfolio of motor modules and gateways, drive solutions with AS-Interface from Bihl+Wiedemann are independent of the controllers or drives used. This means that once ASi installations have been created, they can be ported as a whole, for example to a different automation environment. In addition, thanks to standardized drive profiles, drive technology with ASi always feels the same, regardless of which drive is used. This user experience also applies to the parameterization of frequency inverters and DC drives from different manufacturers. This is ensured by a transparent parameter channel in the Bihl+Wiedemann PC software. The freely available parameters and values are initially stored in the motor module based on the manufacturer's documentation and transferred to the drive during commissioning. This means that the drives can be parameterized and commissioned directly via ASi - without additional software or a direct connection to the drive. If a large number of drives need to be parameterized, this can be done via copy-and-paste in the PC software. This considerably reduces the time required. The additional backup in the motor modules and in the ASi Master ensures availability during operation, as saving the parameters enables spare parts to be replaced smoothly and also prevents errors when replacing motors or motor modules.

Smart automation platform for the material flow

The author: Thomas Rönitzsch is responsible for corporate communications at Bihl+Wiedemann in Mannheim.

AS-Interface is well known as a simple and safe connection technology for automation components in the field - no other wiring technology makes it possible to integrate both individual components and devices in large quantities cost-effectively and efficiently into conveyor systems. The gateways and modules from Bihl+Wiedemann turn ASi-3 and ASi-5 into a smart automation platform at the lower field level - with variable connectivity to higher-level fieldbus systems and control levels, such as those found in warehouse and material flow technology, in conveyor and sorting systems or in order picking systems.

Wiring technology for drive solutions
The classic features of AS-Interface, such as the reduced wiring effort with the help of the ASi cable, the connection of devices via fail-safe penetration technology exactly where they are needed, the free choice between line, ring or star topology in the system layout, the transmission of standard and safety signals on the same cable as well as the extensive portfolio of products and their simple integration with the help of Bihl+Wiedemann's PC software with hardware catalog for drag-and-drop system configuration, parameter cloning for faster commissioning of identical drives, ZPA parameterization and commissioning wizard have all contributed to AS-Interface becoming established as an internationally standardized wiring system in drive technology. While the above arguments apply to all ASi generations - including ASi-3, which is particularly suitable for simple applications such as collecting binary signals - ASi-5 offers further advantages. These include in particular a larger data bandwidth, higher transmission speeds, more efficient addressing of subscribers (only one IP node for over 100 subscribers) the option of integrating intelligent IO-Link devices, and extended channel-specific diagnostic options, more comprehensive and detailed error messages and suggested solutions. The important information from the ASi network - process data and diagnostics - is also available for typical Industry 4.0 applications thanks to the OPC UA server integrated in the gateway. In addition, important parameters such as the power supply and the current motor current can be transmitted cyclically. In practice, motor modules are often used in pure ASi-3 or ASi-5 applications, but in many cases mixed installations make perfect sense - for example, when a simple signal light is controlled with ASi-3, but the inverter is controlled with ASi-5.

Wiring technology for drive solutions

The classic features of AS-Interface, such as the reduced wiring effort with the help of the ASi cable, the connection of devices via fail-safe penetration technology exactly where they are needed, the free choice between line, ring or star topology in the system layout, the transmission of standard and safety signals on the same cable as well as the extensive portfolio of products and their simple integration with the help of Bihl+Wiedemann's PC software with hardware catalog for drag-and-drop system configuration, parameter cloning for faster commissioning of identical drives, ZPA parameterization and commissioning wizard have all contributed to AS-Interface becoming established as an internationally standardized wiring system in drive technology. While the above arguments apply to all ASi generations - including ASi-3, which is particularly suitable for simple applications such as collecting binary signals - ASi-5 offers further advantages.

These include in particular

a larger data bandwidth,
higher transmission speeds,
more efficient addressing of subscribers (only one IP node for over 100 subscribers)
the option of integrating intelligent IO-Link devices, and
extended channel-specific diagnostic options, more comprehensive and detailed error messages and suggested solutions.

The important information from the ASi network - process data and diagnostics - is also available for typical Industry 4.0 applications thanks to the OPC UA server integrated in the gateway. In addition, important parameters such as the power supply and the current motor current can be transmitted cyclically. In practice, motor modules are often used in pure ASi-3 or ASi-5 applications, but in many cases mixed installations make perfect sense - for example, when a simple signal light is controlled with ASi-3, but the inverter is controlled with ASi-5.

Visit Bihl+Wiedemann at the trade fairs!

Hannover Messe: Hall 9, Stand H01
Logimat: Hall 1, Stand 1A14

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