78%

100%6

Weidmüller Information & News | No. 16

14

18

Safe interaction between man and machine u-remote integrates protection and diagnostics in an ultra-compact format

“Power is in the air” Contactless power transmission opens up new automation perspectives

WIN !More best connections inside Let’s connect.

Industry 4.0Industrial Connectivity goes into the network

»The rapid advancement toward Industry 4.0 requires the best connections – at a technological as well as at a personal level.«

Dear readers,

A s a partner in Industrial Connectivity, we are helping to promote the intelligent networking of the production process and to prepare our customers for the rapid advancement toward Industry 4.0.

This requires the best connections – at a technological as well as at a personal level. Therefore, we respond to the invocation of this year's motto of the Hannover Messe “Join the Network!” with our proven central idea: Let’s connect.

Industry 4.0 is presently coming of age. Yesterday they were still just ideas; today we are already active in the development of specific products and applications. The futuristic direction led us along real paths that will gradually make industrial production more flexible, more efficient, more safe and, not least, save more resources. Solutions such as our new current monitor station, which creates the necessary transparency for preventive condition monitoring and targeted optimisation with information on environmental conditions, process data and connected devices, are based on these endeavours. Further communication-enabled automation devices will follow this example – Industrial Connectivity goes into the network.

Open networking also characterises our co-operations with customers, our diverse association activities as well as our participation in joint technology projects related to Industry 4.0. Find out more in our lead article from page 6 – or contact us directly. For example, pay a visit

to the Hannover Messe where you can find us in Hall 11, Stand B60. That’s also where you can experience other topics covered in this magazine first-hand.

Our key topics this year include the safe interaction of man and machine that we also support with our remote I/O solution. Protection and diagnostics are integrated in u-remote in an ultra-compact format, which simplifies the design and implementation of safety concepts of any size. Another highlight is the contactless transmission of power over an air gap of up to five millimetres, which opens up new perspectives for more flexible automation.

I hope you find this issue stimulating and enjoy reading it.

Let’s connect.

Kind regards,

Volpert Briel Sales and Marketing Director

2 | Editorial

WIN! on the web and as a newsletterThe online version of our customer magazine WIN! keeps you regularly updated with news and stories from the world of Industrial Connectivity: ▶ www.weidmueller.com/win

You can also register there for the WIN! newsletter, which provides you with the latest articles four times a year.

78%

100%

In Brief 4 News and trends

The latest news on products, technologies and awards

In Focus 6 “Industry 4.0 must benefit the end user”

Industrial Connectivity goes into the network – at a technological and personal level

Industry 4.0 reaches the customers of tomorrow with smart servicesGuest article by Prof Dr Henning Kagermann, President of acatech

Imprint

Editor Weidmüller Interface GmbH & Co. KG,Global Market Communication, Klingenbergstraße 16,32758 Detmold, GermanyEditorial office Julia BusseLayout Media-Print Informationstechnologie GmbHContact win@weidmueller.dePictures Weidmüller Group, MS Oberflächentechnik AG (p. 16-17), Nordex SE (p. 21)

© 2015 by Weidmüller Interface GmbH & Co. KG.Reproduction and publication, in full or in part, onlyallowed with express permission by the Editor.

The next print edition of WIN! will be appearing in November 2015.

14

186

In Action 16 Don’t waste time with powder

applicationsu-remote ensures noticeable gains in efficiency in powder coating systems

20 “Thoroughly illuminating”FieldPower® Wind Energy impresses turbine manufacturer Nordex as a complete lighting and supply system

22 As clear as daylight! Photovoltaics make water treatment “greener”Combiner boxes support solar power on the roof of a water treatment plant

In Detail 11 Web-based services

Shape design-in processes in device development in a uniquely efficient way

12 Intelligent networking between production and building facilitiesInsights into Weidmüller’s transparent factory convey potential energy-saving actions

14 Safe interaction between man and machineFully designed with safety in mind, u-remote simplifies the design and implementation of safety concepts

18 “Power is in the air”Contactless power transmission opens up new automation perspectives

3Content |

Tips for secure crimp connectionsIn any machines and systems, secure connections are essential. If the contacting is faulty, it can lead to time-consuming and cost-intensive malfunctions. For durable connections, therefore, it is recommended to heed the following tips when crimping.

1.Challenge: Secure seating for spring-based connectionsConnections using “PUSH IN” technology save time during installation. But if the conductor with the crimping is not inserted into the contact point in the correct position, safe connection is not automatically guaranteed.

Professional tip: Crimping with square or hexagon profileTo provide sufficient contact area for secure contacting, square or hexagon crimping is recommended. Thanks to parallel opposite surfaces, the position of the conductor fed into the contact point does not matter. The square and hexagonal crimp shapes of the PZ 10 HEX and PZ 10 SQR mean that users also achieve secure connections using spring-based connection technologies – such as “PUSH IN” – every time.

2.Challenge: Clean crimpingThere is more to reliable contacts than just crimp shape and connection type. The quality of the crimp also plays a crucial role. Depending on the cross-section, the proviso is that 0 to 0.5 mm of the conductor should protrude from the ferrule tube. Individual wires should also not be pushed back or protrude from the collar. The ferrule sleeve must be completely filled by the conductor; otherwise the rated cross-section of the conductor may sometimes be impaired.

Professional tip: Crimping with spring effectAll these requirements are met by spring-loaded crimping tools. The great advantage of these tools is a self-adjusting crimping die which automatically adjusts to the respective cross-section. Tools such as PZ 10 HEX and PZ 10 SQR also allow for safe compensation of any size discrepancy between the conductor and wire end ferrule.

Configure and monitor with the latest FDT2 technologyFDT2 is one of the most important recent advancements in manufacturer-independent standards for the automation industry. Weidmüller is the first provider to support the enhanced specification with device drivers and a customised frame application.

Higher speeds plus generally improved performance are among the core advantages of FDT2. The enhanced

specification also increases IT security for installation and application, comprehensive PLC integration as well as the

support of all important networks in production and process automation.

As a member of the FDT Group, Weidmüller resolutely supports the new FDT2 specification – both with an own FDT2 frame, the “WI Manager” and as the first provider with the corresponding DTMs (device drivers). This offer from Weidmüller provides a complete parameterisation solution in compliance with the latest technology for its ACT20 signal converters that can be configured with PC – such as the ACT20C.

4 | In Brief

Uniquely simple and clearThanks to its integrated display, the ACT20P Pro DCDC II analogue signal converter provides highest measurement accuracy and extremely simple configuration.

The secure isolation and precise conversion of analogue current and voltage signals are counted among the most important conditions for smooth processes. The especially simple configuration and the integrated display are the main features that make our Pro DCDC II analogue signal converters from the ACT20P series stand out. Also, the high-performance module, which measures just 12.5 mm wide, has an all-purpose input range which boasts a high insulation effect and above-average measurement accuracy. Reliable connections are guaranteed thanks to individually configurable protection against mismating and the release lever for the female plug.

These properties not only make the ACT20P Pro DCDC II a universal solution. Above all else, the product

cuts an impressive figure as one of the most process-reliable and accurate signal converters available on the market.

Convince yourself about the signal converter in this video: ▶ www.weidmueller.com/video_act20pprodcdcII

As an add-on for the DIP switches, the integrated display makes configuration an especially intuitive process and requires no other external devices

Ideal working environment for engineers honoured once again

Weidmüller has received yet another accolade for outstanding employer qualities by the Top Employers Institute for the seventh time in a row.

The “Top” certificate is awarded to companies with a high level of employee orientation and above-average employer benefits. In this regard, Weidmüller cut a convincing figure this year, offering a wide range of creative initiatives, fringe benefits and a talent management system that is coordinated with the corporate culture.

“Even for us as a medium-sized company, it is important to have a strong employer brand,” explains Chief Human Resources Officer Dr Jürgen Ober. “We are competing with a whole host of larger companies and hidden champions not only in the region of East Westphalia-Lippe, but also worldwide. We are doing everything we can to win potential talent. The only way we can do this is by offering a personalised total package. Since we are a family-owned company operating in the international arena we have the advantage of flat hierarchies as well as short decision-making channels. Employees also benefit from the attractive career development opportunities we offer.”

The in-house Weidmüller Academy, with main offices in Detmold and Shanghai, means Weidmüller can score especially in the aspects of developing opportunities

3.Challenge: Areas that are difficult to accessIn many installations, there is only limited space available in the cabinet. The crimping here requires a great deal of patience and dexterity.

Professional tip: Crimping with a rotating dieCrimping tools with a rotating crimp insert ensure there is a significantly reduced workload in areas that are difficult to access. Consequently, users can insert the tool as easily as the available space allows: Cables and wire-end ferrules can be fed in from the front or side as required.

You can see how this works in the video showing the example of the PZ 6 Roto L ▶ www.weidmueller.com/video_pz6rotol

5In Brief |

78%

100%

6 | In Focus

78%

100%

With own developments and involvement in working groups and standardisation committees, Weidmüller is playing a decisive role in driving the topic of Industry 4.0 forward. Dr Jan Stefan Michels, Head of Standard and Technology Development, explains how Weidmüller is currently pushing intelligent networking of production – both at a technological and a personal level.

WIN! Industry 4.0 is considered the key to making manufacturing companies more efficient and flexible in future. Which of the current solutions is Weidmüller using to support the conversion to the factory of the future? Michels: The classic automation pyramid with central control will no longer exist in Industry 4.0. With the goal of extremely versatile production facilities, it is being replaced by

networks of intelligent automation components interacting with each other. For the Smart Factory of tomorrow, therefore, we create Industrial Connectivity solutions on the basis of the latest information and communication technologies. Such as our network-capable ACT20C signal converters, for example, which convert analogue machine data into digital values and make them available in the network, thus acting as flexible providers of information in the context of production processes. Also based on this is one of our latest developments – the first communication-enabled current monitor station.

WIN! What is this further development? And which further steps will follow?

Michels: Our current monitor station, consisting of communication-enabled signal converters and current transformers, allows precise current measurements and provides comprehensive status information ➜

Interview

“Industry 4.0 must benefit the end user” Industrial Connectivity goes into the network

Dr Jan Stefan Michels is Weidmüller’s Head of Standard and Technology Development and so at the heart of the move towards the Smart Factory. His many tasks include representing Weidmüller in the Systems Aspects Working Group and in ZVEl’s senior management of Industry 4.0 (ZVEl = Zentralverband Elektrotechnik- und Elektronikindustrie e.V.= German Electrical and Electronic Manufacturers’ Association) as well as on the Industry 4.0 Platform

7In Focus |

Michels: Our industrial security router with VPN technology, for example, creates secure communication paths. It ensures that different communication networks harmonise smoothly and under the strictest security standards. We support the interpretation of the data transmitted with the aid of

OPC UA. Not only is the industrial M2M (Machine-to-Machine) communication protocol used for the transport of values, but makes machine readable information out of the process data. One example is the transmission of measured temperature values. Whereas previous systems only transfer the data “30”, specifications such as OPC UA

give a meaning to it. The additional information that this is a temperature value in a specific unit and format enables the “30” to be interpreted directly and intelligently processed.

WIN! Which customers are currently working with Weidmüller

in adopting new approaches towards Industry 4.0?

Michels: Basically, customers of any size and industry who already rely on early condition monitoring today. This can be within a production

cell, but also within network structures. Especially the industrial zones related to power, smart grids and process industry, but also specific production areas, such as the automotive sector, are already highly advanced in this regard. Wind power installations, for instance, are a typical application field for our new current monitor station. ➜

»Our developments are continually developed on the basis of specific customer requirements.«

The infrastructure box from Weidmüller and Belden/Hirschmann enables flexible production for the smallest of batch sizes –

without greater workloads or throughput times

®

over Ethernet. This enables preventive maintenance strategies on the basis of early error detection and detailed fault analyses. In the next step, there are also suitable maintenance software solutions that enable the measurement and control of power consumption, efficiency or process quality. We are also introducing further automation devices in network structures in order to further expand the possibilities of condition monitoring and diagnostics to this end. At this year’s Hannover Messe we are showing our visitors a fully networked machine in a live application.

WIN! The networking of interacting components goes hand-in-hand with data exchange and autonomous control. How does Weidmüller guarantee secure and reliable connections for this?

How the intelligent factory of tomorrow can appear in practice is demonstrated by SmartFactoryKL together with leading industrial partners. As part of an infrastructure solution, Weidmüller is helping to turn the plug-and-produce principle into reality.

As a leading centre of excellence and manufacturer-independent demonstration and research platform, SmartFactoryKL has set itself the task of paving the way towards the intelligent factory of tomorrow. The technological initiative of the Technische Universität Kaiserslautern is developing innovative factory systems in which the vision of Industry 4.0 is already reality.

Today, more than 30 partners are collaborating to take the SmartFactoryKL project forward – with new concepts, standards and solutions which form the basis of a highly flexible automation technology. Under the motto “Progress in the network”, SmartFactoryKL is presenting the first worldwide manufacturer-independent Industry 4.0 system in an industrial version at the Hannover Messe 2015 with 16 leading industrial partners.

In co-operation with Belden/Hirschmann, Weidmüller has devoted itself to the task of fast data transmission, sustainable power supply as well as

flexible and secure integration using an infrastructure box. Thanks to the plug-and-play capability, the accuracy of fit for a wide variety of system topologies and the integral power measurement by means of Weidmüller components, the infrastructure solution is highly flexible and transparent.

Progress in the SmartFactoryKL network

8 | In Focus

Guest article

Industry 4.0 reaches the customers of tomorrow with Smart Services

Prof Dr Henning Kagermann, President of the National Academy of Science and Engineering – acatech – explains how the Industry 4.0 Smart Factory is becoming the new economic paradigm and calls for cooperation across industrial sector boundaries – for a brave entry into the world of Smart Services.

Industry 4.0 is now on the German federal government’s digital agenda and is one of the main topics, if not the main topic, in industrial trade fairs. Innovative individual technologies and complete model factories are now in op-eration. But are we fast enough in Germany? Every object, every device and every machine can become an Internet node and commu-nicate with others. Today, there are already 15 billion of them. Industry 4.0 encompasses the impact of these networks on industrial production; however the economic change goes much deeper. Products will be replaced by individual packages of products, services and support services (Smart Services). The focus is on the user with his or her needs as a consumer, an employee, citizen, patient or tourist.

As early as 2012, the Industry 4.0 working group highlighted that the transfer of Industry 4.0 concepts to small and medium-sized

enterprises (SMEs) would be an essential condition for Germany’s success. Recent sur-veys show that only 40% of companies have taken note of the Industry 4.0 initiative. 50% of machine operators don’t even know the term. The early adopters are therefore all the more important. The innovation cluster “it’s OWL” shows how small and medium-sized en-terprises can actively shape and use Industry 4.0. Weidmüller is just one of the companies taking a lead and actively participating not only in the region of Eastern Westphalia-Lippe (Ostwestfalen-Lippe = OWL).

The Industry 4.0 smart factory is the starting point for a new economic paradigm. In the economy of the future, customers will not buy products and services off the shelf. Instead, they will purchase individual product service packages – Smart Services – over the Internet. This may sound visionary but it’s now part of our everyday life. We already access products and services online whether it’s a travel site, mobility app or media-streaming service.

In B2B, Smart Services are also becoming ever more important. Industrial plants will be leased and maintained as a service and tech-nological data traded on respective markets. The risk for established producers and service providers is that they lose their customer interfaces. A race for these interfaces and the corresponding data has already begun. It’s therefore all the more important that companies refine their value chain models digitally because whoever can generate tailored Smart Services from the data will define the business.

The winner of the race will emerge over the next two to three years. Can today’s market leaders systematically rework their business models digitally and become the lead suppli-ers of Smart Services? Or will intermediaries take over the leadership of key industrial sec-tors? With world-class machinery and plant engineering, cutting-edge products, a highly qualified skilled workforce and effective research, Germany currently finds itself in a

good position. Companies like Weidmüller, who work together in leading-edge clusters, have good prospects. We need pioneer-ing spirit and teamwork to succeed: every business and research institute must quickly develop secure software platforms and data analysis methods on which to base attractive Smart Services.

On a political level, a single European digital market with standardised data protection regulation should give innovators the oppor-tunity of scaling Smart Services quickly, just as is already possible in China and the US. In Germany’s particularly strict data protection culture, there’s also an opportunity because sovereignty over private and proprietary data is a prerequisite for confidence in Industry 4.0 and Smart Services. Security could become a hallmark for Smart Services made in Germany.

The working group Smart Service World, comprising some 140 experts from industry, science, trade unions and society at large, handed over its final report to the Federal Economics Minister at CeBIT. Our report is a wake-up call: if we shape digitalisation deci-sively we will create added value, jobs and prosperity. However, if we persist in market leadership niches, today’s market champions will become tomorrow’s dispensable delivery boys. Our technological sovereignty is at stake and we’ll secure it by opening up and cooperating across industrial sector borders in order to head out bravely into the Smart Service world: Isolating ourselves is not an option.

Prof Dr Henning Kagermann, PhD and habilitation in Theoretical Physics, has shaped the development of Germany’s IT landscape; until 2009, for example, in his position as Chief Executive Officer of SAP AG. Today as President of acatech, the National Academy of Science and Engineering, he leads, amongst other things, the “Innovation Dialogue” between the Federal Government, business and academia, so urging on with great authority, ideas and initiatives around the topic of Industry 4.0.

9In Focus |

The new ACT20C station with current measuring transducers brings more transparency into automation. Precision current measurements and comprehensive condition information via Ethernet are part of the performance spectrum of the communication-enabled solution.

During the distribution and evaluation of measured values by the control system, any active intervention is connected with safety risks. Communication-enabled automation components from Weidmüller therefore make it possible to draw information on the current condition of devices and functions directly from the field level via Ethernet.

Using the true RMS measurement procedure, ACT20C current transformers record correct

measured values up to 60 A, even for the distorted waveforms of AC and DC currents. The data transmitted allow you to

continuously monitor connected units in terms of whether levels are transgressing defined load points, as well as allowing you to maintain an overview of the units’ use and service life. Together with the ACT20C gateway, the new ACT20C current measuring transducers work within a station network. This also makes it possible to carry out configuration and diagnostics by means of remote access over an Ethernet network. Software configuration based on the FDT and FDT2 standards makes parameterisation, documentation and data backup easier.

The key to condition monitoring: The ACT20C station supports preventive maintenance strategies using automation-independent information about operating conditions and process data for connected devices

Here, it is vital that motor or brake overloads or anomalies are identified at an early stage and that operators respond to poor performance in cooling fans or rotor blade de-icing systems in a timely fashion.

WIN! Finding solutions for Industry 4.0 requires far-sightedness. How does Weidmüller manage to approach its customers’ future requirements today?

Michels: Our developments are continually developed on the basis of specific customer requirements, because at the end of the day Industry 4.0 must lead to a benefit for the end user. One particular advantage is that we ourselves are a manufacturing company which places demands on ever more flexible and efficient production. Thus, we also create high transparency regarding the power consumption in our own production,

and exploit the optimisation potential derived from this. Our underlying solution, consisting of measuring equipment and controlling software for the networking and processing of information, is based on many years of experience from which our customers can also benefit directly today. As part of our so-called “transparent factory”, we provide insights into the possibilities of predictive power monitoring and are open to co-operation.

WIN! The fact that Weidmüller opens its own factory to interested partners testifies to close networking at a personal level. In which other co-operations is Weidmüller actively involved for promoting Industry 4.0?

Michels: Our commitment in the context of Industry 4.0 is characterised by diverse association activities as well as participation in joint technology projects, such as within the framework

of the Industry 4.0 Platform, a recently founded initiative of the Federal Ministries of Economy and Energy as well as for Education and Research. A topical example is the implementation of an infrastructure box for the distribution of power, signals and data in future modular Industry 4.0 systems while taking the highest requirements of data security into account. We are implementing this project in the consortium of the SmartFactoryKL, a technological initiative of the Technische Universität Kaiserslautern. Weidmüller is building the box in cooperation with Belden/Hirschmann. The plug-and-play capability, the accuracy of fit for a wide variety of system topologies and the integral power measurement by means of our components makes the infrastructure solution flexible and transparent – so it exactly matches the core requirements to which Industry 4.0 responds.

Targeted monitoring and optimisation of systems and processes

10 | In Focus

1.Best connection solution for the required device function?Simply ask the AppGuide.

Weidmüller provides device developers with a unique selection tool that lets them find the right connection system for their application in just a few steps. The requirement here is: “Recommend instead of letting them search”. ▶ www.weidmueller.com/AppGuide

2.Professionally designed?No problem with extensive component libraries.

Simply download the required component data, decompress it, enter it into the EDA (Electronic Design Automation) system and install the required product on the printed circuit board – Design-In can be so fast and customised. ▶ www.weidmueller.com/EDA

4.Custom design requested?Quickly done with configurators.

From the allocation of possible counterparts for plug-in connectors up to the customised arrangement of housing elements: Online configurators open up a multitude of application-compatible design possibilities. ▶ http://galaxy.weidmueller.com

3.And now products you can actually touch?Personal Design-In prototype in 72 hours.

To test the components you found so fast, simply click in the online catalogue. Within 72 hours, developers receive the product as a free design-in sample – wherever they are in the world.▶ www.sample-service.com

EDA

Web-based services Shape design-in processes in a uniquely efficient way

With networked, web-based services, Weidmüller accompanies the path of the device developers – from application-oriented product recommendations up to customised configurations.

11In Detail |

Intelligent networking between production and building facilitiesInsights into a factory’s energy transparencyWeidmüller is in real-time dialogue over individual energy management challenges and issues. Interested partners go behind the scenes of Weidmüller’s production and experience first hand the potential of systematic energy-saving measures.

ConsultingTargeted consumption analysis and suggestions for measuring and visualising energy data

MeasurementEnergy Monitoring Box, as a plug-and-play solution with energy measuring devices, communication components and analogue signal converters

“Comprehensive, informative and impressive,” was how Jörg Blümle, Quality Management Team Leader from the plastics processor Reuter, summed up his impressions during an energy management tour of Weidmüller’s production facilities. “You can easily see how energy ➜

They know every nook and cranny of the transparent factory: Dr Christian von Toll, Project Leader Energy Management (left) and Gerhard Linke, Representative of Enviromental Management

12 | In Detail

»Comprehensive, informative, impressive!«Jörg Blümle, Quality Management Team Leader from the plastics processor Reuter,

sums up his impressions after a tour of Weidmüller’s transparent factory

efficiency is firmly anchored in Weidmüller’s overall approach and then put into practice. There’s a great deal of expertise here, which we would like to make the most of.”

Striving for energy efficient production is ubiquitous, as sustainable operations bring so many advantages: international competitiveness, conservation of both resources and environment together with cost savings. Anyone who does not have the expertise or personnel resources to implement their own comprehensive energy management system will find an experienced and straightforward partner in Weidmüller.

For production from production

“Weidmüller has been dealing responsibly with energy and resources for several decades now,” reports Dr Christian von Toll, Weidmüller’s Energy Management Project Manager. “Our new production hall is a prime example of the practical

implementation of accumulated expertise in order to achieve results. It was inaugurated in 2011 and certified according to ISO 50001. We therefore use it as a ’transparent factory’, where we can show interested customers a concrete example of energy management.”

The production hall at the company’s site in Detmold does not require its own heating system and needs 95% less energy than stipulated by the energy-saving regulations valid at the

time construction started in 2007. In addition, it heats the adjacent office building in the autumn and spring, thus cutting heating demand drastically.

“Weidmüller’s heating concept is very coherent and shows interesting results,” concludes André Gericke after the tour of the “transparent factory”. He is one of Reuter’s electricians engaged in the topic of energy management. “We can certainly pick up some tips here for our own production.”

A needs-based energy management solution

The innovative heat recovery system is only one example of many showing how Weidmüller reduces energy demand sustainably. An intelligent networked system for heating and cooling, compressed air optimisation in all phases, lighting control on demand, energy-efficient insulation and the systematic optimisation of the electrical system are further efficiency measures designed into the new production hall, which result in an annual energy saving of 1,665 tonnes of CO2.

As the basis for actually achieving savings potential, Weidmüller uses a holistic energy management system, which gathers and then displays visual information on energy flows. Weidmüller provides its customers with this integrated approach to finding a solution. It involves measuring equipment, monitoring software and consultation tailored to individual needs.

Energy-efficient production right from the start

Jörg Blümle and André Gericke from the plastic specialist Reuter are totally won over by the solution shown on the

1. Weidmüller’s Power Monitor even makes existing machinery transparent. 2. In the transparent factory, Project Leader Dr Christian von Toll demonstrates energy parameter investigation and analysis to the visitors from Reuter. 3. The guests were particularly impressed by the production hall’s innovative heating concept, which the Representative of Enviromental Management, Gerhard Linke, explains to them.

1

2

3

tour. “With Weidmüller as a partner and over the course of an open day, we really had our eyes opened,” recalls Jörg Blümle. “Contacts have intensified and we are already analysing potential opportunities together.” Working with Weidmüller, a measuring point concept for a new plant will be developed to provide energy-efficient production right from the start.

Are you interested in an individually tailored energy management solution? Contact us at:▶ energy@weidmueller.com

ControllingPower Manager Software as the key indicator cockpit for energy controlling

13In Detail |

Safe interaction between man and machine u-remote integrates protection and diagnostics in an ultra-compact formatProtected investments, staff safety and increased added value are Weidmüller’s objectives with u-remote. Fully designed with safety in mind, the remote I/O solution significantly simplifies the design and implementation of safety concepts of any size.

14| In Detail

»Safe operation combined with maximum performance levels.«

second, the tiniest disturbance to the rhythm could bring the whole production line to a halt,” explains Product Manager Andreas Hoffmann. “In the event of a fault or maintenance, we have made exact status analyses and a fast restarting process u-remote’s highest priority.”

Controlling complex systems safely and flexiblyUsing u-remote’s safe digital I/O modules for PROFIsafe and Fail Safe over EtherCAT gives plant operators a great deal of flexibility. Modern fieldbus technology allows decentralised safety equipment to be networked into an interconnected, coordinated safety system. As required, the selective disconnection of individual components depending on defined conditions can be programmed such that, in the case of a fault or maintenance, all production does not have to come to a halt.

u-remote also offers safe power-feed modules for safe disconnection when using

M an and machine shaking hands – this is the image accompanying the increasingly digital

networks in automation. However, in view of ever more complex technology and systems, it’s important to note that there are still serious issues in the context of interaction between man and machine.

“Safety has long been a global focus associated with steadily expanding and stricter standards. If nothing else, the introduction of Machinery Directive 2006/42/EC has added a new dynamic to the topic,” says Michael Matthesius, Head of Global Industry Management Machinery. “Weidmüller therefore attaches great importance to safety technology and creates future-oriented solutions which focus both on safety and economic viability – and in this context u-remote is an excellent example.”

As much safety as necessary, as little downtime as possibleSafe operation combined with maximum performance levels is one of the main objectives in machinery and factory automation. However, in striving for safety, downtime also has to be kept as low as possible. “An example that demonstrates this is multi-stage filling processes. Here, safety features such as emergency stops or light barriers on conveyor belts are essential. However, as automated operations are synchronised to the

The safe digital I/O modules contain many safety functions in a very slim unit making them ideal for distributed architectures where space is at a premium

standard-PLC and standard-I/O modules. With this fully integrated solution and in contrast to solutions with additional safety relays, the plant operator benefits from complete status information on inputs and outputs.

“Modern automation requires modern safety solutions,” summarises Mr Matthesius. “Thanks to its integrated protection, u-remote supports the safe man-machine interface and paves the way to ever more intelligent networked systems.”

15In Detail |

All of the furnaces and conveyors within the plant are controlled by means of a centralised Siemens S7-300 PLC. More than 1,000 programs – where settings can be saved and called up for various workpieces, including furnace programming – guarantee a high level of variability. The workpiece recognition element then automatically controls the pre-heating furnace, powder application and automatically regulated, gas catalytic, infrared powder furnace in a program-related manner.

At the end of 2014, the furnaces were redesigned for heating and curing applications as part of a further development process. The goal was

Q uickline – the name of the MDF powder coating system offered by Swiss company MS Oberflächentechnik –

says it all. The core benefits of the system include fast colour change and short throughput times. The key component of “MS Quickline” is an intelligent conveying system, which can be designed for both small-series and large-series coating and for single or double coating depending on the end customer’s requirements.

Don’t waste time with powder applicationsu-remote promotes efficient powder coating

When it was redesigning its furnaces, MS Oberflächentechnik AG wanted its new remote I/O system to be flexible to plan, quick to install and stable in operation. Today, u-remote is delivering noticeable efficiency advantages in all phases.

u-remote provides high performance connections between the central cabinet and the remote I/O units

to create a modular heating system which could be expanded by up to one line with seven furnaces as needed. To control the furnaces in a decentralised manner, MS Oberflächentechnik was looking for a flexible and easy-to-handle remote I/O solution – and that’s precisely what it found in Weidmüller’s u-remote system.

Particularly impressed by the modular concept

“When it was selecting an I/O solution, MS Oberflächentechnik had two requirements that were of prime importance. First, it wanted the system to be adaptable in terms of the inputs and outputs required and in terms of integration in the existing fieldbus environment. And second, it wanted the system to be simple and efficient to install and operate,” remembers Stefan Meier of Weidmüller, who was available on-site to help the customer as a direct contact person. Under these aspects, Urs Bösch, the Technology Manager at MS Oberflächentechnik, and his team assessed u-remote during Weidmüller’s presentation. “We were particularly impressed by the modular concept, which I believe provides the perfect support

16 | In Action

»We were particularly impressed by the modular concept, which provides the perfect support for our system’s variability.«Urs Bösch, Technology Manager at MS Oberflächentechnik

for our system’s variability,” explains Mr Bösch, mentioning one core benefit for his application. “In terms of installation, we gave the PUSH IN connection technology top marks. The intuitive, tool-free wiring meant that our assembly team could speed up their processes a great deal. The connections with their functional colour coding and the single-row modular design also prevent wiring mistakes.”

Identify mistakes without delay – or programming work

Mr Bösch believes that the extensive diagnostic functions are a decisive advantage for ongoing operation. A clear overview of the current system status is provided at all times using an integrated u-remote web server. This means that mistakes can be identified quickly and rectified purposefully in an emergency situation. Customised channel diagnostics are also a possibility since there are LEDs directly on the channel and status indicators on each module.

“Depending on the system type, between four and seven u-remote stations are being used along our modular heating system in a linear architecture. We can use the associated fieldbus coupler in accordance with the PROFINET IRT standard to conveniently connect the decentralised units and thus integrate them into

our PROFINET environment without a great deal of effort. My team and I are benefitting from enhanced efficiency, from the I/O system planning stage to the installation process and plant operation,” enthuses Mr Bösch, before smiling and adding, “That way, we don’t waste any unnecessary time on powder applications.”

1. The MS Quickline serves the powder coating of the wood product MDF. 2. The powder system enables various colour changes within six minutes. 3. Decentralised control boxes are used to control the linear arranged heating system. 4. Here, u-remote proves its advantages.

1

2

3 4

17In Action |

“Power is in the air” Contactless power transmission is opening up new automation prospectsTo transmit high levels of power as part of a maintenance-free solution, Weidmüller has optimised the proven inductive resonance coupling technology so that even powerful motors can be reliably supplied via an air gap.

T he development of intelligent power transmission solutions is just one of the key steps along the road to the smart factory. In conventional methods, the supply is connected manually by means of a

mechanical plug-in contact. But products such as these require a great deal of maintenance and need to be replaced often – causing frequent production downtimes. These weak points are alien to contactless power transmission, since it far exceeds the flexibility and lifecycle offered by conventional plug-in connections.

1. Product Manager Klaus Leuchs demonstrates FreeCon Contactless supplying power over an air gap of up to 5 millimetres. 2. When we use an electric toothbrush, the contactless induction charge helps to really get our creative juices flowing as we clean our teeth lost in thought. But in the industrial segment, Weidmüller’s optimised technology opens up countless opportunities for high-performance automation.

1

2

18 | In Detail

»FreeCon Contactless is the name of Weidmüller’s system, which supplies up to 240 Watts over an air gap.«

“Contactless power transmission is something we’re all familiar with. Take electric toothbrushes, for example. This transmission method means that the brushes are operated independent of a plug-in connection that’s subject to wear,” explains Product Manager Klaus Leuchs, providing a comparison. “Industrial applications benefit enormously from this level of flexibility. As a result, we have made the well-known inductive resonance coupling technology fit for tough industrial environments – and are opening up a wide range of applications for the first time ever by providing high power density with maximum efficiency.”

High power density with maximum efficiency

The FreeCon Contactless system from Weidmüller transmits up to 240 watts via an air gap – it’s a completely wear-free and especially efficient solution. The high power transmission means the range of industrial applications extends from robotics and rotating systems to driverless transport systems. Even high-vibration applications don’t pose any problem, since the system boasts a transmission distance of up to five millimetres, which is one-of-a-kind in its performance class.

The arbitrary approximation options also contribute to the flexible range of potential applications. The connection is established as soon as two modules are positioned opposite one another – and even remains stable in the event of rotational movements. This allows for completely new structures in industrial system construction and significantly helps to optimise production processes.

Last but not least, FreeCon Contactless scores top marks since all of these performance parameters could be implemented in the most compact design yet, which measures just 100 x 100 x 47 mm. The IP 65 system can thus be deployed in virtually any industrial environment in an especially space-saving manner.

But just how did Weidmüller manage to combine such a high level of power with such a compact format? “Our recipe for success is based on innovative thermal management, which enabled our developers to achieve an efficiency level of more than 90 per cent and thus to effectively reduce heat development,” reveals Mr Leuchs. “Under these conditions, we were able to implement the compact design we were aiming for.”

Intelligence for contact points in the field

FreeCon Contactless was developed in close collaboration with leading manufacturers from Germany’s automotive industry. One suggestion made in this partnership approach resulted in a fantastic feature: since the system is controlled by means of a PLC, the secondary side can be switched on or off using the primary side. The result is therefore a switchable device suitable for integration in a higher-level control programme.

Its plug and play capability means that FreeCon Contactless is just as easy to use as a plug-in connector and can therefore even be retrofitted for existing systems without any problems. Connections which, up until now, were made manually can be automatically established in a flash – opening up new prospects on the road to the smart factory.

FreeCon Contactless supports production automation by means of secure, contactless power transmission – which is tailored to industrial requirements and suitable for integration in a control programme.

FreeCon Contactless’ zero-maintenance feature goes hand-in-hand with an integrated diagnostic function and positioning control. The so-called “advanced pairing” aspect guarantees accurate coupling at all times – such as here, for example, with a robotic tool exchange

19In Detail |

FieldPower® Wind Energy offers everything required for the interior lighting and supply of wind power installations. As a customised solution, the system is an integral component of the current tower installations of leading turbine manufacturers – such as Nordex.

A job well done: the last of the 50 LED lights is installed! Twelve platforms and the wall areas are fitted with lights, and 200 metres of 2.5 mm² cable is connected up – ready to feed in 120 V DC

and distribute it along the 120 metre route to the nacelle.

When the power is switched on, it’s the moment everyone has been waiting for: will the lighting meet the expectations of Nordex, the turbine manufacturer? Just a short time ago, this was a busy construction site, but now the switch is flipped and the single and dual LEDs come on at full output. The project team nod their heads with satisfaction. For Hans Schlingmann of Weidmüller, the driving force behind the “FieldPower® Wind Energy” system solution, this is a wonderful moment every time.

System configuration that meets requirements in full

“Our goal is not just to provide individual components, but to develop solution concepts that simplify work processes

and enhance plant efficiency,” emphasises Mr Schlingmann, Business Development Manager Wind. “Successful pilot installations at customers such as Nordex demonstrate how that’s exactly what we do with our lighting and supply system for wind power installations.”

The core element of the solution is LED lights, which are notable for their low power consumption and low level of sensitivity to vibrations, shocks and extreme temperatures. These durable lights have proven themselves to be particularly robust during the installation process and are significantly less likely to fail. Together with a comprehensive system for an uninterruptible power supply as well as optional remote monitoring and outlets, they constitute a ready-to-fit solution for lighting, emergency lighting and power supply in the entire wind power installation. All parts have been tried-and-tested and are perfectly coordinated to one another. With comprehensive project support from Weidmüller, the system can be implemented with ease, whatever the application.

Knowing the benefits right from the outset

For the wind power installations that Nordex recently constructed near the district of Rostock, the project to install lighting in the towers began with the collection of project data. “The installation size and type, location, environmental conditions, country-specific standards and legislation – all these factors affect the customised planning process for a plant,” explains Olaf Prein, Global Segment Manager Wind at Weidmüller. “In a CAD simulation that is accurate in every detail, we show our customers how our system can be integrated in their wind power installations and outline the concrete benefits. Having ascertained all the components required, we then assist with the application-specific planning and implementation process for an individual supply and illumination concept.”

Weidmüller has lights to suit every requirement, which is a key advantage because Nordex plants are used all over the world, from Alaska to Australia. Anlagen von Nordex kommen von Alaska bis Australien zum Einsatz. Unlike conventional lights, the Weidmüller LED solution is fully geared towards universal use under harsh environmental conditions. A suitable light type that constantly meets the same high technical requirements can be selected for all system versions.

As a modular LED system solution, FieldPower® Wind Energy enables simple and quick pre-installation of the tower segments

“Thoroughly illuminating”LED system solution cuts an impressive figure in pilot installations

20 | In Action

“A thoroughly illuminating project” “When a wind power installation is constructed and commissioned, all consumers are supplied by a single electricity generator. In the past, I have often experienced the scenario where, during construction, some consumers of the wind turbine draw so much power that it caused voltage fluctuations in the lighting circuit. As a result, we were left

standing in the dark during the commissioning process and had to replace defective linear fluorescent luminaires again,” recalls Ralf Harder of Nordex. “It makes me all the more impressed by the LED system solution offered by Weidmüller. These impact-resistant lights proved their worth even when the wind power installation was being built. From the identification of requirements through to commissioning, the whole project has been thoroughly illuminating.”

Active planning supportCollection of project data and realistic simulation of the system configuration

Complete system solution Pioneering LED lighting, components suitable for pre-installation, practical remote monitoring and a complete power supply system

Support during installationAssembly of a test installation and intensive support with practical know-how

»Our goal is to develop solution concepts that simplify work processes and enhance plant efficiency.«

21In Action |

As clear as daylight! Photovoltaics make water treatment “greener”

modules and the inverter, they interconnect the electricity generated. This allows the power intensity of individual strings to be monitored for diagnostic purposes, so that low-output strings can be identified and serviced extremely rapidly.

“On the basis of recurring customer requirements, we have already developed numerous tried and tested configurations for photovoltaic systems. This is how we managed to fulfil the VACON® requirements directly with pre-wired combiner boxes,” reports Rudi Vanderstraeten, Industry Manager at Weidmüller, who advised VACON® during the project. “Thanks to the configuration of components for surge protection and string monitoring, our customer benefits from a holistic system solution that is particularly easy to implement in the existing SCADA topography. So not only is there clarity in water treatment, but energy generation on the roof is totally clear and sorted too.”

Covering an area the size of five football fields, the 3 MW system on the roof of the Aquiris water treatment plant is the largest of its kind in Belgium. Combiner boxes from Weidmüller help ensure that the 10,000 installed photovoltaic modules generate top-notch output exceeding 3.2 MW.

T he roughly 1.4 million inhabitants of the Brussels capital region produce around 275

million litres of wastewater every day. An annual total of 182 MWh is needed to treat this volume of water in the Aquiris treatment plant. To ensure that this energy is generated in the most environmentally friendly way possible, hydroelectric power and biogas production were recently supplemented by a photovoltaic system on the roof of the wastewater treatment plant. Together, these three technologies now cover a quarter of the overall electricity required for treating the wastewater.

Continuous performance transparencyThree 1 MW inverters from the Finnish manufacturer VACON®

provide a clean supply of energy into the national electricity grid. A crucial advantage here is the “Multimaster” concept with which VACON® ensures that the photovoltaic system always generates the maximum output in line with the sun’s intensity at any given time.

There is always high transparency in regard to the system status and electricity generation of the inverters. Thanks to remote monitoring and communication via Modbus TCP/RTU, the operator can track the output profile online and receives notifications of the latest developments via SMS text messages. Downtimes can therefore be minimised efficiently.

Monitoring of individual strings

Within the framework of this monitoring, the 60 combiner boxes that VACON® sourced from Weidmüller play a decisive role. Installed between the solar

60 combiner boxesFully configured connection, protection and monitoring system ready to connect

22 | In Action

Guests from the Land of the Rising SunA water treatment system that autonomously covers its electricity requirement in three different ways – this is definitely something special. In any case, it certainly impressed Weidmüller’s Japanese customers who visited the photovoltaics plant in Belgium.

“On a visit to our production facilities and in-house laboratory, we were able to give our guests from Japan a fairly good idea of the high quality standards we apply when we’re developing and producing our photovoltaics solutions. And the subsequent visit to Belgium served only to prove that our standards are continually upheld in application,” explains Klaus Holterhoff, Head of Weidmüller’s Application-Specific Solutions Division. “On the roof of the water treatment plant, the main focus was the installed combiner boxes, which we tailored especially to the plant’s specific requirements and its particular location.”

Clearly inspired by the photovoltaics solutions they examined, Weidmüller’s guests have already initiated some new projects of their own in Japan. Marubeni, for example, is relying on Weidmüller’s photovoltaics solutions, from the strings to the control

room, in what is presently an 82 MW plant. By and large, the so-called “Land of the Rising Sun” is one of the most important markets for solar energy. Indeed, the generation of solar power is a highly relevant national project for the fifth-largest consumer of energy in the world.

1. Japanese visitors get an insight into the installation of combiner boxes in Belgium. 2. In discussions with Weidmüller no questions are left open.

1

2

3.2 MW peak performancePhotovoltaic system on the roof of a water treatment plant

10,000 photovoltaic modulesThe aim: interconnection and monitoring of the current produced

23In Action |

Order number: 2009300000/03/2015/SMKW

Weidmüller Interface GmbH & Co. KGKlingenbergstraße 1632758 Detmold, GermanyT +49 5231 14-0F +49 5231 14-292083info@weidmueller.comwww.weidmueller.com

Weidmüller – Your partner in Industrial Connectivity

As experienced experts we support our customers and partners around the world with products, solutions and services in the industrial environment of power, signal and data. We are at home in their industries and markets and know the technological challenges of tomorrow. We are therefore continuously developing innovative, sustainable and useful solutions for their individual needs. Together we set standards in Industrial Connectivity.

Your local Weidmüller partner canbe found on our website:www.weidmueller.com/countries

Made in Germany