Industrial Wireless Communication and Applications
The importance of automation in the industries has increased dramatically in recent years. Industrial communication is one of the keys to increasing efficiency, reducing total cost of ownership, and improving productivity. The huge potential, especially of wireless communication, opens up new perspectives here – from partial modernization of plants, right up to optimizing complex logistics or production processes.
Smart factories presently frequently represented by term “Industry 4.0” or the fourth industrial revolution, is a collective term embracing a number of contemporary automation, data exchange and manufacturing technologies. It had been defined as a collective term for technologies and concepts of value chain organization which draws together Cyber-Physical Systems, the Internet of Things and the Internet of Services.
Industry 4.0 facilitates the vision and execution of a “Smart Factory”. Within the modular structured Smart Factories of Industry 4.0, cyber-physical systems monitor physical processes, create a virtual copy of the physical world and make decentralized decisions. Over the Internet of Things, cyber-physical systems communicate and cooperate with each other and with humans in real time, and via the Internet of Services, both internal and cross-organizational services are offered and utilized by participants of the value chain.
When it comes to industrial networking today, many factories and process control facilities around the world are focused on upgrading to manage Ethernet networks. With the long, useful life of industrial devices, there is plenty of old equipment using legacy industrial protocols in active service. Indeed, much of our business involves helping companies upgrade to structured, reliable and easy-to-maintain industrial Ethernet infrastructure.
High-performance, reliable communication technology will exceed what is currently in use. This technology will make it possible to:
Transfer large amounts of data in real-time and with minimum delay
Connect a large number of individual devices in a very reliable manner and with the highest standards of data security
Utilize more and more wireless technologies, both within the plant and for remote connectivity
Operate in an energy-efficient manner.
Wireless Remote Networks
Continuous communication between widely separated plant sections in the area of water/wastewater, or high-speed remote maintenance access to machines and plants on the other side of the world – these are just two of the countless ways you can reap the benefits of Wireless Remote Communication. Thanks to integration in the SINAUT telecontrol system or an HMI/SCADA system, transferred process data is available at any time via mobile radio.
Industrial Wireless LAN
Wireless solutions are increasingly becoming a matter of course in machines and plants. In the case of high data communication requirements, Industrial Wireless LAN (IWLAN) backs innovations like deterministic radio and the Industrial Ethernet standard PROFINET. But IWLAN is also being widely used in industry-oriented applications. The high data transfer rates required there allow applications in association with video streaming as well as the transmission of visualization or language data. High deterministic or redundancy concept requirements can be covered by the IWLAN infrastructure.
Wireless HART is an open industry standard, developed for the particular requirements of wireless communication at the field level in the process industry. It meets all specific requirements for reliability, security, economy, and user-friendly operation system-wide. With more than 30 million installed devices worldwide, HART technology is the most frequently used communication protocol for intelligent process instrumentation at the field level. Wireless HART is backwards compatible with wired HART technology and thus offers maximum investment security.
IWLAN for Industrial and Industry-Related Areas
IWLAN is especially suitable for demanding industrial applications that require end-to-end, reliable and secure radio communication:
For implementation at industrial and automation customer sites
For outdoor environments with demanding climatic requirements
For low-cost integration in the control cabinet or in devices.
Thanks to the use of mobile devices linked via wireless data networks (e.g. wireless LAN), the efficiency of processes can be significantly improved. The primary benefit of wireless solutions is the simple and flexible availability of mobile or hard to access stations.
Mobile communication increases a company’s competitiveness, as it helps achieve greater flexibility through the use of wireless communication to automation devices and industrial terminal devices. As a result you can simplify maintenance work, reduce service costs and downtimes and deploy your personnel optimally.
Industrial Wireless LAN (IWLAN) is based on the WLAN standard IEEE 802.11 and provides extensions that are particularly suited to demanding industrial applications with real-time and redundancy requirements. Customers are thus provided with a single wireless network for both process-critical data and uncritical communication.
Manufacture of high-quality steel from scrap metal for the automotive, machine construction, and appliances Industries
Processing of approx. 600 000 tons of scrap metal per year
Use in extremely harsh environments
– Production of smoke and dust – Exceptionally high temperatures – Strong vibrations
Optimum positioning/locating of antennas since the entire building contains steel, e.g. cranes, racks, doors, assembly lines
Ensured reliability of motion sequences in the process
Assured production continuity and quality Demands placed on all electronic controls and components:
Maximum reliability even under difficult conditions; a failure could have devastating effects on productivity and safety.
Fast and secure data transfer:
The quality of the radio signals which reach the control system’s receiver despite the harsh ambient conditions is so high that further protection of the radio data can be omitted
The number of nutrunners used in vehicle final assembly should be reduced. The existing solution uses one nutrunner for each cycle and each barcode detection
Since the hard-wired solution with slip rings results in high maintenance costs, a reliable wireless communication solution is required to increase efficiency and reduce setup times
The products should be industrialized and available worldwide
Investment protection is also required by ensuring the long-term availability of the components used
Low investment costs owing to the reduced number of nutrunners
Reduction in maintenance costs and downtimes thanks to a reliable wireless and wear-free data transfer to mobile communication partners
Increased plant availability thanks to reliable, contactless transmission of power and data
Reduction of operator activity, for example scanning, cycle transfer, travel time allows higher throughput
Easy to change models, dependent only on material logistics
Possibility of integrating additional quality assurance applications
Complete nutrunner data can be loaded via the IWLAN line.
Safe and reliable transport system in harsh environment
Reduced maintenance outlay
Fast installation and startup
Simple connection to the control and MES levels
The solution should be reliable and high-performing and offer high availability.
High flexibility and plant availability
Fast installation and commissioning thanks to reliable Industrial Wireless LAN components
Simple connection to the control and MES levels.
Harbor plant / Container Logistics
A rugged radio system should be installed for outdoor use in a container handling system at the port of Hamburg. It should be possible to load and unload containers via IWLAN using automated guided vehicle systems (AGV). Both the driving area and the lanes between the storage blocks should be inspected reliably and economically, the system should be expandable and be insensitive to interference even as the number of vehicles rises
The system should be reliable and work together with other networks that are already in place, as the changeover to the new system can only take place step by step
Solid, expert support should be provided by the manufacturer during implementation and installation
Interference-free operation thanks to the excellent functioning of the radio network.
Savings in costs, as the existing infrastructure (masts and antennas) could be retained
Easy operation and configuration of all access points through the use of IWLAN controllers
Targeted on-site support during implementation and commissioning
Expandable radio network for further investments in the future.
Safety-related Operation of Robots
In the production of visually guided gantry robots, a scalable, expandable automation platform should be established for general tasks, such as palletizing and depalletizing heavy goods at high speed and with high precision
The aim is to significantly cut installation and commissioning costs, as large distances have to be covered in the plant
Commercially available components should be used to achieve the solution
A wireless, open and user-friendly safety system should be installed
Easier operation due to the use of a single network for all applications (image processing, safety, peripherals, motor control)
Wireless and safety components are contained in a single network, simplifying engineering and diagnostics
Cabling costs are cut by 30%, installation time is reduced and commissioning is facilitated
Equipment for the Public Transport System
Bidirectional transmission of data
Out of the train: Live streams of video monitoring (CCTV), passenger counting, ticketing, telemetry etc.
Into the train: Real-time IPTV, infotainment, WLAN hotspot
Control of up to 32 access points per tunnel, and additional redundancy if a controller fails
Extremely rugged IWLAN products, which are unaffected by shaking and jolting and can be used in a broad temperature range of to +
The radio network’s excellent functioning and IEEE 802.11b (11 Mbit/s) radio standard ensure interference-free operation