Data transparency - the key to optimised operation

As machines generally operate over decades, operating costs can quickly outweigh procurement costs: in fact, over a period of ten years they can sometimes be up five or even ten times higher than investment costs.

Downtime can be avoided through predictive maintenance and servicing, which means detailed information about the status of as many machine components as possible needs to be recorded. Intelligent analysis of this information can lead to machines being used at maximum capacity, without risking downtime. In order to make sound decisions and predictions regarding a machine’s status, a variety of data is required, such as information on machine statuses, temperatures, switching times and energy consumption.

Generally, today’s more complex equipment has its own electronics to record the data. However, in applications with large number of components, an intelligent wiring and communication system, like Eaton’s SmartWire-DT, offers a simple, quick and cost-effective solution to achieve the desired level of data transparency. In such systems, all devices are connected via an eight-pole line with simple plug connectors. The SmartWire-DT cable supplies power to the connected devices, while also supporting data communication.

Communication modules

The great advantage of such a system – in addition to its quick and simple installation – are its special communication modules. These are primarily ASICs equipped with interfaces for feeding in digital and analogue measurement signals, plus a processor for executing independent program algorithms; as well as a powerful communications interface. SmartWire-DT communication modules allow for the direct integration of connected devices into the central control system, or into the machine’s existing communication environment. This applies to push-buttons, contactors, simple switching devices and sensors. Additionally, units that provide a large amount of digital and analogue process data, such as manual motor starters with measurement electronics, soft starters and variable frequency drives.

Using this technology produces tangible added value throughout the machine’s life cycle. In engineering, for example, logical units can be planned more easily and effectively. This can help to reduce the project design workload by up to 70 per cent, while the wiring, testing and commissioning workload can be reduced by up to 85 per cent during commissioning. In total, an intelligent wiring system can provide a reduction of up to 30 per cent in the life cycle costs of an electrical installation, from project design to servicing and maintenance. Most importantly, however, thanks to the data transparency achieved, diagnostics and maintenance are improved along with machine availability and capacity use.

At device level, an intelligent wiring and communication system allows machine manufacturers and system integrators to easily record all data requested by the operator individually. This can then be displayed in a control station or display internal indicators.

Connection to the cloud is also possible. This is because SmartWire-DT can be connected to industry-standard fieldbuses via gateways, and therefore is poised to play a key role in Internet of Things (IoT) applications both now and in the future. Even if the machine manufacturer changes their control concept in the future, the field devices or the wiring system do not have to be redesigned, as replacing the gateway is usually sufficient. This means that new communication standards, such as OPC UA, are already supported. System integrators can also access machine and component data via the Internet and use it for diagnostics and servicing, for example.

However, SmartWire-DT communication modules not only enable high data transparency. They also enable each device to become a smart device due its integrated intelligence. These smart devices are capable of taking on tasks independently and in a decentralised manner, which is the basis for the transition to Industry 4.0.