Adaptable Industrial PCs And Intelligent Networking Comprehensive security for the Transformation

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Pilz GmbH & Co. KG

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Wuxi InfiMotion Technology Co., Ltd.

Important foundations for the success of digital transformation are a clear strategy and the integration of modern technologies such as cloud computing, artificial intelligence, and IIoT. With regard to implementation, industrial transformation today focuses on application scenarios that combine automation and security solutions into an "all-in-one" package. This creates—in a very pragmatic way—greater continuity between safety and automation.

An easy-to-use solution for implementing Industry 4.0 concepts is industrial PCs, such as the IndustrialPI from Pilz. Designed as an open and modular industrial PC, it uses Linux as its operating system, a freely available open-source software. This industrial PC can be used either as a gateway in Industrial IoT (IIoT) environments or as a soft PLC in a wide range of applications.

Adaptable Industrial PCs Support

What can such adaptable industrial PCs achieve? Industrial PCs used as IIoT gateways provide intelligent diagnostic scenarios: always available in plain text and, above all, accessible regardless of location. This is because users should always keep an eye on their machines and systems to ensure that the production processes of decentralized systems run as smoothly as possible without major disruptions, or that commissioning can be carried out more quickly.

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The Pilz industrial PC can be easily integrated into existing system architectures. In the immediate vicinity of machines and systems, it collects process or operational data, for example, and transfers it directly, such as to a company cloud. And what do industrial PCs achieve as soft PLCs? When used as a soft PLC, the IndustrialPI also handles 'simple' automation tasks. One application: it controls machines and systems, such as gantry machines for sorting battery cells or case erectors in the packaging industry. There, it takes on tasks such as drive operations—whether pure control applications or synchronized axis movements in the drivetrain of machines. Such adaptable industrial PCs thus support users in implementing Industry 4.0 concepts individually—they adapt to the intended purpose.

Flexible connectivity as a critical factor

Another factor for the success of industrial transformation is connectivity, aiming for seamless communication in the field. The foundation for this is open and flexible IIoT architectures. Only dynamic solution approaches can ensure effective collaboration across numerous devices, installations, and applications. Here too, industrial PCs excel when they can be used as a gateway, data collector, and diagnostic unit, like the IndustrialPI. In the case of the Pilz industrial PC, this is possible in conjunction with the safe small control system PNOZmulti 2 and the automation system PSS 4000. This solution enables data exchange between the Internet of Things and cloud services.

In implementation, it is holistic automation solutions, including safety and security, that make modular and decentralized production plants flexibly extendable and quickly ready to operate. They also ensure that data communication is designed to be maximally flexible and reliable—with safety-oriented and standard communication.

The communication system IO-Link Safety and the standard FSoE (Failsafe over EtherCAT) already play a key role in a connected world today: IO-Link Safety technology is crucial for meeting important user requirements. It enables seamless safe communication with every sensor and actuator in the field. For example, Pilz IO-Link Safety sensors provide important status information. They also offer a wider range of features for intelligent diagnostics: the devices can self-identify and self-parameterize. This helps optimize processes, making components easier to replace and reducing downtime due to repairs. Moreover, this technology can monitor applications smartly. For instance, IO-Link Safety evaluates data from safety light curtains: information such as signal quality can be used for predictive maintenance. Thus, IO-Link Safety fulfills the demand for flexible automation through safe and standardized point-to-point communication. Furthermore, achieving the highest level of safety up to PL e per EN ISO 13849-1 (SIL 3 according to IEC 61508/62061) and being fieldbus-independent are additional advantages for the user. The result is greater availability of machines in today's and tomorrow's industries.

Secure Transmission Down to the Last Sensor

When discussing industrial communication today, secure data transmission to the "last" sensor should be the focus, especially for devices in the field. FSoE is also another standard for communication in this context. The main advantages of FSoE for industrial applications lie in the use of the so-called Black Channel principle. Through this, safety-critical data can be transmitted across various networks, including Ethernet and wireless connections. This supports the Industry 4.0 requirements for vertically integrated, real-time communication within the automation pyramid in smart factories. High reliability and safety in critical applications are ensured through standardization according to IEC 61784-3 and certification to Safety Integrity Level (SIL) 3. This "innovative" secure connectivity helps optimize manufacturing processes.

FSoE Also Stands for More Flexibility

FSoE can do even more: the FSoE communication protocol offers users greater flexibility, as it enables the simultaneous transmission of both safety-related and non-safety-related process data over a single EtherCAT network—hat is, also via a single-cable solution. This helps seamlessly integrate safety concepts into machine designs while also securely incorporating safety-relevant system structures.

When configurable small controllers use the safe FSoE protocol for communication, the efficiency and safety of production systems can be increased: by integrating safety functions into an existing EtherCAT network, separate or redundant safety wiring becomes unnecessary. This simplifies system architecture and reduces complexity for the user. In addition, these simplifications lower installation and maintenance costs.

Single-Cable Solution on Top

The safe small controller PNOZmulti 2, for example, supports EtherCAT in combination with the safe protocol Safety-over-EtherCAT FSoE (= Failsafe over EtherCAT). With it, users can transmit both control-related and safety-related information. Such a solution makes applications flexible and economical, as safety-relevant system structures can be integrated more easily. The PNOZmulti 2 single-cable solution also enables safety-relevant networking of infrastructures—for instance, with safe radar sensors like PSENradar and safe drive technology PMC, both from Pilz. When PNOZmulti 2 functions as an FSoE MainInstance, a comprehensive safe drive solution—"Safe Motion"—becomes possible. FSoE-capable actuators and sensors can then be easily integrated into the network.

Holistic automation solutions, including safety for a digitized industrial world, must enable flexible expansion and quick commissioning of modular and decentralized production plants, as well as reliable and flexibly designed communication in the field. These are important aspects of a successful transformation that ensures availability.

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