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3301 Invensys Triconex system
3301 Invensys Triconex system
Module Clips Drive controller servo motor
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Definition of IO Link Protocol and Its Interface
IO Link is a peer-to-peer, serial digital communication protocol designed for periodic data exchange between sensors/actuators and controllers (PLCs). The IO Link protocol was first proposed by Siemens and has now become an international standard IEC 61131-9. With the advancement of Industry 4.0, the use of IO Link is becoming increasingly widespread. Today”s article will introduce the definition of the IO Link protocol and its interfaces.
Factory automation can be divided into execution layer, on-site layer, on-site control layer, workshop control layer, and management layer according to functional division. As shown in the following figure:
The execution layer includes various execution mechanisms (valves, pumps, motors, etc.) and sensors, which are the muscles and peripheral nerves of factory automation. They receive commands from the upper layer and complete specified actions.
The on-3301 Invensys Triconex system site layer includes various distributed IO3301 Invensys Triconex system systems, which are the central nervous system of factory automation. It conveys control instructions from the upper layer to the execution layer; And feedback the signals from the execution layer to the control layer, serving as the information center;
The on-site control layer includes various PLC systems, which are the brains of factory automation. It issues corresponding instructions and commands the execution layer to complete corresponding actions based on internal program requirements and signal feedback from the execution layer;
The workshop control layer (MES) and management layer communicate with various PLC systems at the management level to complete management tasks at the workshop and factory levels.
The IO Link protocol to be introduced in this article is a protocol that transfers data between the execution layer and the field layer. An IO Link system consists of the following components:
1) IO Link Master;
2) IO Link Device;
3) Non shielded 3-5 core standard cable;
4) Tools for configuring IO Link parameters;
The IO Link Master transfers data between the IO Link device and the PLC. It is usually a distributed IO module with IO Link connection channels on the module. The IO Link Device is connected to the channel of the IO Link Master through a cable, and the IO Link Master exchanges data with the PLC through a bus. As shown in the following figure:
Every IO Link device needs to be connected to a channel of the IO Link supervisor, so IO Link is a peer-to-peer communication protocol, not a bus protocol.
IO Link devices are divided into two types: sensors and actuators: sensors are usually the four pin interface of M12, and actuators are usually the five pin interface of M12.
According to IEC 60974-5-2, the definition of IO Link Device pins follows the following regulations:
1) Pin 1 (PIN1): 24V power supply positive pole;
2) Pin 3 (PIN3): 0V
3) Pin 4 (PIN4): IO Link communication or standard IO output;
The pin definition of the IO Link device is shown in the following figure:
Which types of equipment should PLC module manufacturers develop first?
We know that PLC, also known as programmable logic controller, collects variable data through various IOs to achieve the purpose of automated control. Therefore, developing PLC is largely about developing IO. However, with so many types of IO, which PLC module manufacturers should develop first? Let me share my opinion:
1. Digital input IO, including PNP and NPN digital input IO, counter input IO, etc.
2. Digital output IO, including PNP and NPN digital output IO, PWM pulse output IO, relay output IO, and so on.
3. Analog input IO, including current acquisition input IO, voltage acquisition input IO, temperature acquisition input IO, and so on. The current input IO can collect currents ranging from 0 to 20 milliamperes, while the voltage input IO can collect voltages ranging from negative 10V to positive 10V. Temperature acquisition IO includes thermocouples and thermal resistors.
4. The style of analog output IO is similar to that of analog input IO, but does not include temperature analog, mainly voltage and current type.
What are the advantages of Ethernet remote IO modules that can be cascaded?
Advantages and specific application scenarios of Ethernet remote IO modules that can be cascaded
For scenarios where data collection control points are linearly distributed, such as streetlights, bridges, streetlights, digital factories, parking lot parking monitoring, smart parking lots, smart parking racks, and building automation control systems in smart parks, using cascading dual Ethernet remote IO modules saves more costs than using single Ethernet remote IO modules.
The Ethernet remote IO module that can be cascaded is a new type of Ethernet remote IO module that supports MAC layer data exchange and can achieve hand in hand connection. This not only saves switch interfaces, but also reduces a large amount of Ethernet cable costs, wiring space, and wiring costs.
Its advantages are as follows:3301 Invensys Triconex system
1. No need for a large number of Ethernet switches or occupying Ethernet switch ports;
2. It can save a lot of Ethernet cables, cable space, and labor costs for installing cables;
3. The overall cost has significantly decreased;
4. Supports both Modbus RTU protocol, Modbus TCP protocol, and the Internet of Things protocol MQTT protocol;
5. Support TCP Server and TCP Client services;3301 Invensys Triconex system
6. Can be connected to SCADA systems, PLC systems, or cloud platforms;
7. The series uses a MAC layer for data exchange, ensuring that network connectivity does not cause communication issues with subsequent devices due to device failures in the middle.
The comparison between cascaded Ethernet remote IO modules and traditional IO modules used in building automation systems is shown in the following figure:
1. Adopting a cascaded dual Ethernet remote IO module, data acquisition and control wiring for floors with a height of 70 meters only requires a 70 meter Ethernet cable;
2. Using a traditional single Ethernet remote IO module, the data acquisition and control system wiring for a 70 meter high floor requires a 280 meter Ethernet cable.
It can be seen that using cascaded dual Ethernet remote IO modules can save a lot of wiring costs compared to traditional single Ethernet remote IO modules.
Application of Ethernet Remote IO Module in Building Automation System
For building automation systems, each data acquisition control point is linearly distributed in each floor. Therefore, it is very suitable to use Ethernet remote IO modules that can be cascaded to achieve data acquisition and control.
The Ethernet remote IO module that can be cascaded supports MAC layer data exchange and can achieve a hand in hand connection method. This can not only save switch interfaces, but also reduce a large amount of Ethernet cable costs, wiring space, and wiring costs.
Its advantages are as follows:
1. No need for a large number of Ethernet switches or occupying Ethernet switch ports;
2. It can save a lot of Ethernet cables, cable space, and labor costs for installing cables;
3. The overall cost has significantly decreased;
4. The M160E supports both Modbus RTU protocol, Modbus TCP protocol, and the Internet of Things protocol MQTT protocol. In addition, it also supports TCP Server and TCP Client services; Can be connected to SCADA systems, PLC systems, or cloud platforms;
4. The M160E series uses a MAC layer for data exchange, ensuring that network connectivity does not cause communication issues with subsequent devices due to device failures in the middle.
Comparison between cascaded Ethernet remote IO modules and traditional IO modules for building automation systems:
1. Adopting a cascaded dual Ethernet remote IO module, data acquisition and control wiring for floors with a height of 70 meters only requires a 70 meter Ethernet cable;
2. Using a traditional single Ethernet remote IO module, the data acquisition and control system wiring for a 70 meter high floor requires a 280 meter Ethernet cable.
Therefore, we can conclude that for scenarios where data collection control points are linearly distributed, such as streetlights, bridges, streetlights, digital factories, parking lot parking monitoring, smart parking lots, smart parking racks, and building automation systems in smart parks, using cascading dual Ethernet remote IO modules saves more costs than using single Ethernet remote IO modules.
Application of IO Link in Industrial Automation
This article mainly introduces the overall solution of ST IO Link communication master station used in industrial systems, including the following 5 aspects:
Firstly, the application of IO Link in industrial automation; The second is the introduction of ST IO Link main station transceiver; The third is the introduction of our ST”s IO Link main site evaluation board; The fourth is an introduction to the reference design scheme of the IO Link main station; The fifth is a demonstration of the IO Link master station reference design.
The industrial automation system can be said to be composed of many levels. The top level is usually industrial Ethernet to transmit data to the upper control center or monitoring center of the factory, while the middle layer is usually some PLC system for specialized process processing, such as controlling a specialized assembly line or production line. At the bottom, there are usually many industrial sensors, such as temperature sensors, pressure sensors, flow sensors, or proximity sensors, as well as some actuators, such as valves, moving lights, relays, or contactors, which are used for collecting and controlling physical quantities.
Between these levels, there will also be some modules or gateways for conversion and processing work. Therefore, in traditional industrial systems, there are many different level standards and communication protocols on site, resulting in poor modularity and versatility. Because there are both analog signals on site, such as a 4 to 20 mA current loop and analog voltage signals, as well as digital signals. In such an environment, analog signals are particularly susceptible to interference from harsh on-site environments. At the same time, sensors or actuators for analog transmission cannot perform on-site remote configuration or calibration 3301 Invensys Triconex system diagnosis work. In order to solve the transmission of the last segment of data to sensors and actuators in industrial field environments, as described earlier, we have introduced a specialized digital interface IO Link to achieve fully digital transmission between the interface modules of sensors and industrial field buses. The bidirectional data transmission makes it possible to parameterize the interaction of on-site data, diagnose and transmit information. By using this technology, remote condition monitoring and predictable maintenance of terminal equipment can be achieved, thereby effectively alleviating the problem of production line downtime.
Its advantages include:3301 Invensys Triconex system
Firstly, whether it is a pure digital sensor, an analog sensor after digital quantization, or different types of actuators, unified access can be achieved, thus achieving a simplified and standardized system architecture. Secondly, the transmission of digital signals will have stronger anti-interference ability than the transmission of analog signals, so the reliability of the system will also be stronger. Thirdly, through the bidirectional transmission of digital signals, more intelligent and advanced actuators or sensors can be used, making it easier to achieve status monitoring and system diagnostic protection functions. In this way, any issues and status of the production line can be monitored and maintained in real-time, ensuring the reliability, maintainability, and upgradability of the entire production line, thereby ensuring the minimum downtime.
The following is the specific content about IO Link technology
Firstly, the definition of the IO LINK standard enables data transmission, processing, configuration, and diagnostic information exchange between sensors or actuators and control systems. Secondly, this is a simple peer-to-peer communication architecture, where a master port is connected to a device port. Then, it can achieve compatibility with existing communication architectures, such as reusing cables and interfaces. At the same time, the IO Link system also has backward compatibility upgrade capability, as the master end of the system uses digital binary serial communication to interact with devices, and vice versa.
It can be said that IO link makes the system simpler:
Firstly, this is a universal standard communication method that complies with IEC61131-9. Secondly, IO Link is an intelligent communication system that solves the digital information exchange and transmission of the last distance from the control host to the terminal device. Thirdly, IO Link is simple to use and can be said to be plug and play, compatible with some existing system devices.
Some related products and solutions provided by ST in IO Link communication solutions
Firstly, in this communication system, the IO Link Master, which connects to the upper computer controller, is one of the main key solutions that will be mentioned later. Secondly, ST can provide some communication chips on the IO Link Master project, such as L6360. On the other side of the sensor or actuator end, namely the IO Link Slave end, ST can provide communication chips L6362A and L6364 on this IO Link Slave slave project. According to standards, this three-wire point-to-point communication method is easily compatible with some existing sensor actuators” standard ports, such as M12 standard industrial connectors and M12 standard connector wires. In addition, its advantages include the ability to achieve point-to-point bidirectional signal transmission within a single cable, as well as the general power supply requirements of the master end to the sensor actuator. According to the general requirements of the current industry, the maximum length of this cable is 20 meters, and the three wires inside are 24V, 0V, and data cables. The L+of this chip can support up to 500 milliamperes. If greater current is needed, there are also other L+drivers, including Load Switch IPS and other products, which can provide greater current or can be applied externally. The IO Link communication speed can generally reach a baud rate of 230.4K per COM3, and it also has functions such as status indication and detection.
For some specific application characteristics of IO Link, the communication transceiver system composed of L6360 and L6362A can support three standard data types of IO Link, namely COM1 (4.8k), COM2 (38.4K), and COM3 (230.4K) modes. This communication system can meet the requirements of all modern standards, industrial sensors, and actuators: firstly, it can quickly and very easily configure or reconfigure sensors or actuators. Secondly, it can be widely applied to various standardized sensors or systems that execute information. Thirdly, as a digital communication system, compared to traditional analog signal transmission systems, it can reduce power consumption and improve system efficiency. Fourthly, it has complete diagnostic and protection functions, which can improve the reliability of related systems. Therefore, it can be widely used to drive various digital sensors and actuators, as well as input and output modules of PLC, in order to achieve and meet various requirements of Industry 4.0.
How to Determine the Interference Problem of PROFINET IO Communication
Preliminary Diagnosis of PROFINET Interference Problems
1. Overview
When debugging PROFINET IO communication, it is common to encounter communication failures. One of the reasons for communication failures is interference. PROFINET IO communication equipment often operates in complex industrial electromagnetic environments, and incorrect shielding grounding or non-standard installation may lead to communication interference problems. Since optical signals are not affected by electromagnetic interference, this article only introduces interference problems with electrical signals.
2. How to determine interference issues
If PROFINET IO communication is affected by electromagnetic interference, a simple judgment can generally be made through the following aspects:
2.1. Judging the communication status through PROFINET IO
If the following communication phenomena are found during PROFINET IO communication debugging or operation, it may be affected by electromagnetic interference:
① Occasionally, communication is interrupted and restored.
② When certain on-site devices or specific operations are turned on, communication is interrupted, and on the contrary, communication returns to normal.
2.2. By using STEP7 online diagnostic information to determine and view the diagnostic buffer information of the IO controller, how to detect the presence of frequent communication failures and recovery information between the IO controller and IO devices in the diagnostic buffer, as shown in the following figure, may be affected by electromagnetic interference:
14 STEP7 Device Diagnostic Buffer Information
3. How to troubleshoot and solve interference problems
If a suspected electromagnetic interference causing PROFINET IO communication failure is found, how should we troubleshoot and solve it? The following will be introduced from the following aspects:
3.1 Increase PROFINET IO communication watchdog time
Due to PROFINET IO communication failure occurring during watchdog time, the IO controller did not provide input or output data (IO data) to the IO device, and watchdog time=the number of update cycles allowed for IO data loss × The refresh time is usually automatically calculated and allocated by the IO controller. This time value is generally small. If electromagnetic interference is encountered, the probability of communication failure occurring within the automatically calculated watchdog time will increase. At this time, we can appropriately increase the PROFINET IO communication refresh time or the number of update cycles allowed for IO data loss to increase the watchdog time. However, this method may not solve serious electromagnetic interference problems, and it is recommended to eliminate and solve them through subsequent methods.
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