Industrial revolution 4.0 has already set in, and industrial automation is a profound part of it. One of the crucial aspects of implementing a successful automation ecosystem in any industry is seamless communication between devices. For a long time, the traditional field buses like PROFIBUS, HART, FF, Modbus and a few others have been the been the standard communication solution for field layer connectivity.
However, with the ubiquity of Ethernet in the layers above sensors/PLCs and to take advantage of the IT tools and technologies in the OT layer, Ethernet is increasingly being looked as a communication bus in the field layer also. this has led to the idea of the Ethernet Advanced Physical layer (APL).
Ethernet-APL is a subset of the widely used Ethernet standard and it is describes the physical layer of the Ethernet communication specially designed for industrial engineering services. With high communication speeds over long distances and a single, twisted-pair cable for power and communication signal supply, this layer proves to be a robust solution for a better bandwidth communications link between field-level devices and control systems in process automation applications. In simple terms, Ethernet-APL is the upgraded link between Ethernet communication and instrumentation.
Ever since BASF, a German chemical company and the largest chemical producer in the world successfully tested Ethernet APL for the first time in 2019, many companies have successfully implemented the same in various IIoT networks. In February 2020, ABB’s trials proved that Ethernet APL effectively eliminates gateways and protocol conversions at various industrial network levels.
Ethernet-APL makes infrastructure deployment a seamless process as the devices connected over it share the same advanced physical layer. This also indicates that it enables devices in the industrial network to be connected at any time, irrespective of where they are placed in the factory or processing plant.
There are numerous reasons why industries willing to integrate IIoT must consider Ethernet-APL. We have discussed them in the next sections.
Ethernet-APL enables seamless integration of various processes and creates effective communication between the control and plant field devices for long distances process variables, secondary parameters, and asset health feedback and seamlessly communicating them over long distances.
Some of the major benefits of incorporating Ethernet APL in industrial automation applications are:
Improved Plant Availability
In addition to pure process values, modern field devices provide valuable additional data. With Ethernet-APL, plant operators can make the most of the devices in real-time, centrally monitor their components’ status, and identify maintenance requirements early on. This avoids unplanned downtime and increases plant availability significantly.
Cost-Effective Plant Optimization
Ethernet-APL supports the trunk-and-spur technology established in the process industry and is applicable to any industrial Ethernet protocol such as EtherNet/IP,HART-IP, and PROFINET. This simplifies integration for planners, plant designers, and plant operators since existing installations and infrastructures can still be used and investments are protected.
Adds Flexibility to the Plant
IEEE and IEC standards layout communication protocol, testing, and certification of products to implement Ethernet-APL into any plant automated systems in any part of the world. This way, in an industrial environment, devices from different manufacturers, irrespective of their state of origin, can have interoperable communication within the working ecosystem.
Coherent Communication at all levels
Ethernet-APL allows a common communication infrastructure for all levels of process management. This is because field devices can be easily connected to the higher-level system. The high transfer speed of 10Mbit/s and the full-duplex infrastructure make it suitable for data transmission over a length of approximately 1000 m.
APL – For IIoT Applications
The Industrial Internet of Things is undoubtedly an integral part of the industrial automation workspace. Therefore, the high-speed, industrial Ethernet-based Ethernet-APL is touted as the future of industrial communication systems. Many of the leading communication protocol associations like the OPCFoundation, ODVA, PROFIBUS, and PROFINET International are in the process of supporting APL, which makes it compatible with any existing processing system.
It supports 2-WISE (2-wire intrinsically safe Ethernet) and therefore eliminates the need for numerous calculations, which makes it simpler to verify the intrinsic safety of devices within the Ethernet-APL automation network.
Ethernet-APL comes as a blessing for the manufacturing and process industry in particular, as they lacked a standard network capable of high-speed transfer of data within field devices irrespective of their implementation level in the Industry 4.0 architecture.
How APL is Serving the Special Requirements of Process Industries
Ethernet-APL is specially crafted for process industries. Since these industries involve works at hazardous and explosive areas, deployment of industrial Ethernet seemed like a far thought for quite long. However, with the introduction of an advanced physical layer into the Ethernet, 2-WISE became a reality.
The 2-WISE infrastructure makes it safe to be deployed in such hazardous areas. This improved the overall plant availability and brought remote access to many devices in the process industry 4.0.
Conclusion
Advanced Physical Layer or APL has brought in a new ray of hope for effective adoption and implementation of IIoT in the industries. Utthunga’s innovation-driven team is ready to support you in your APL plans. Get in touch with us and get the best industrial engineering services that elevate the efficiency of your plant and plant assets for increased ROI.
The term “simulator” means “imitator of a situation or a process”. In the digital sense, we can say that a protocol simulator or a network simulator is a computer-generated simulation of a protocol before bringing the product to the market.
There is a paradigm shift in industries like industrial OEMs, discrete, power, and process utilities to move towards automation. This implies more interconnected devices over the internet with interlinked communication between the devices. In order to carry out a reliable and seamless automated working ecosystem in IIoT, many foundations like OPC, ETG, PI and others have laid down certain industrial protocols that a product must follow.
Protocol testing is a crucial element that product engineering companies like Utthunga take care of. It is imperative as it checks the alignment of the hardware or software product with the industrial protocol standards. This helps to address an issue, be it a design glitch, or points out the challenges in implementing it. Protocol simulation is a part of product testing and it helps to check if a hardware or software is working as per the communication protocol standard and purpose.
Protocol simulation is mainly carried out for checking the accuracy and latency of the communications over the wire. It is done by creating scenarios that are similar to the real-time use cases. These mimic the exact situations that are similar to the real-time use cases and help you evaluate the possible risks and challenges associated with the product. Knowing these before its release helps you create a product that stands apart in quality among your competitors.
How Simulation Can Save Your Product Development Time And Cost?
Simulation can be carried out in various ways, it all depends on your ultimate goal. If a reduced product development time and cost is on your checklist, then you can use the simulation approaches that we have listed down:
Protocol simulation to test for design reliability
In industries, especially in the current automated ecosystem, the device which you manufacture must be in compliance with the industry standards. When you create a device prototype and simulate it to test the design capabilities, you get to interact with the unknown design features and may discover some loopholes as well. This saves you product development time, as you optimize your product before it reaches the market. This way you can fix the glitches and then move on mass production.
Finite element analysis
Industrial devices are subjected to a lot of unpredictable scenarios and stresses that requires your product to be robust enough to handle such unforeseen situations. The finite element analysis helps you to validate your product in this context. It ensures your product can endure unpredictable stresses (in the connectivity/communications context) up to a certain limit. You can carry out FEA even in the design stage, to get a real idea as to what to expect from your product and the areas which need improvements.
It helps to improve the reliability of the product before an untested product reaches your customers and ruins your brand image. It also makes manual testing a lot easier.
APIs in protocol simulation allow easy integration of your product to various software frameworks. This means test engineers can leverage better test automation solutions to carry out protocol simulations with high precision. Utthunga’s protocol simulators are configurable as a server-side application in your industrial devices. So, it enables remote control of the devices through various programming languages like Python, Java, C++, and others.
Industries have complex systems. Protocol simulators like master simulators and slave simulators when used in the product development cycle, help them to create a reliable product.
Since such a simulator is capable of providing practical feedback at the designing stages itself, it comes across as a time and cost saver. It also empowers design engineers to understand the possible glitches in the design and create an optimum layout for the same.
These allow simulation of the required prototype at the luxury of the lab, or during R&D or engineering. The control systems can be built to test the devices in various load and real-time scenarios. These can run on a desktop and be integrated with the control systems and another master systems that communicates with these field devices. Therefore the overall infrastructure, cost to procure, deploy and maintain the devices can be considerably reduced.
In research and development, these protocol simulators act like a perfect aid to train the operational personnel and get an in-depth knowledge of the functionalities of the product. It also helps the R&D department to come with innovative ideas for creating a better product that matches the growing demands of the users.
Conclusion
A protocol simulator helps create a virtual representation of the product even in its design stage. It helps design and product engineers understand the dynamics of the device’s operation at each phase of the production cycle.Choosing the protocol simulator, therefore, should be a well-thought decision, if you are keen on creating error-free, top-quality devices. Utthunga’s protocol simulator is carefully created by our panel of experts who have gained years of experience in this field. Get in touch with our team, to know more about our exceptional services tailored to get you Industrie 4.0 ready. Utthunga has deep capabilities in industrial protocols, and our protocol simulators are an extension of Utthunga’s rich and deep protocol expertise. All our protocol simulators are built on top of our uSimulate framework – tried and tested in the field for years. We support several protocols like Modbus, EtherCAT, IEC-104, GE-GSM and others. Adding a new protocol (legacy or proprietary) to the simulator family is fairly easy as well.
Open Process AutomationTM Standard (O-PASTM Standard) or “Standard of Standards” as it’s popularly known is an initiative to create a new age automation system with a different architecture than the existing process automation systems that uses Distributed Control Systems (DCS) and Programmable Logic Controllers (PLCs). As automation applications require ultra-high availability and real-time performance, process automation systems have always been highly proprietary. The reason behind developing this standard is to transform from a closed, proprietary, distributed control systems towards a standards-based open, secure and interoperable process automation architecture.
In 2016, The Open Group launched the Open Process AutomationTM Forum (OPAF) to create an open, secure and interoperable process control architecture to:
Facilitate access to leading-edge capacity
Safeguard asset owner’s application software
Easy integration of high-grade components
Use an adaptive intrinsic security model
Facilitate innovation value creation
This blog aims to show why and how OPC UA can be applied to realize the Open Process AutomationTM Standard. Before that, let us be familiar with the Open Process AutomationTM Forum. In simple terms, The Open Group Open Process Automation™ Forum is an international forum that comprises users, system integrators, suppliers, academia, and organizations.
These stakeholders work together to develop a standards-based, open, secure, and interoperable process control architecture called Open Process AutomationTM Standard or O-PASTM. In version 1 of O-PASTM, published in 2019, the critical quality attribute of interoperability was addressed. In version 2, published in January 2020, the O-PASTM Standard addressed configuration portability, and version 3.0 will be addressing application portability.
Version 1.0 of the O-PASTM Standard unlocks the potential of emerging data communications technology. Version 1.0 was created with significant information from three existing standards:
The seven parts that makeup the latest preliminary 2.1 version of O-PASTM Standard are:
Part 1 – Technical Architecture Overview
Part 2 – Security (informative)
Part 3 – Profiles
Part 4 – Connectivity Framework (OCF)
Part 5 – System Management
Part 6 – Information Models based on OPC UA (Multipart specification ranging from 6.1 to 6.6)
Part 7 – Physical Platform
Part 1 – Technical Architecture Overview
This informative part demonstrates an OPAS-conformant system through a set of interfaces to the components.
Part 2 – Security
This part addresses the cybersecurity functionality of components that should be conformant to O-PASTM. This part of the standard also explains the security principles and guidelines incorporated into the interfaces.
Part 3 – Profiles
This part of the version defines the hardware and software interfaces for which OPAF needs to develop conformance tests and ensure the interoperability of the products. A profile describes the set of discrete functionalities or technologies available for each DCN. They may be composed of other profiles, facets, as well as individual conformance requirements.
Part 4 – O-PASTM Connectivity Framework (OCF)
This part forms the interoperable core of the system, and OCF is more than a network. OCF is the underlying structure that enables disparate elements to interoperate as a system. This is based on the OPC UA connectivity framework.
Part 5 – System Management
This part covers the basic functionality and interface standards that allow the management and monitoring of functions using a standard interface. The system management addresses the hardware, operating systems, and platform software, applications, and networks.
Part 6 – Information and Exchange Models
This part defines the common services and the common information exchange structure that enable the portability of applications such as function blocks, alarm applications, IEC 61131-3 programs, and IEC 61499-1 applications among others.
Part 7 – Physical Platform
This part defines the Distributed Control Platform (DCP) and the associated I/O subsystem required to support O-PASTM conformant components. It defines the physical equipment used to embody control and I/O functionality.
The O-PASTM Standard supports communication interactions within a service-oriented architecture. In automation systems, it outlines the specific interfaces of the hardware and software components used to architect, build, and start-up automation systems for end-users. The vision for the O-PASTM Standard V2.0 addressed configuration portability and can be used in an unlimited number of architectures. Meaning, every process automation system needs to be “fit for a reason” to meet specific objectives.
Why OPC UA is important for Open Process AutomationTM Forum
The lower L1, L2 layers of the automation pyramid is heavily proprietary with a tight vendor control over the devices where the PLC’s, DCS, sensors, actuators and IO devices operate. This is where the vendors have strong hold over the end-users. As a revenue generating path, they are reluctant to lose this advantage. Additionally, this poses interoperability, security and connectivity issues causing significant lifecycle and capital costs for the stakeholders.
This inherent lack of standardization in the lower OT layers is a constant pressure point for the automation industry. O-PASTM Standard solves this standardization & connectivity issue and uses OPC UA as one of the foundation for developing this standard. This de-facto standard is used for open process automation integrating controls, data, enterprise systems and serves as a fundamental enabler for manufacturers.
Building the basic components of this standard (like DCN, gateways, OCI interfaces, OCF) using OPC UA helps them achieve secure data integration and interoperability at all levels of the IT/OT integration. This involves leveraging the OPC UA connectivity (Part 4 of O-PASTM and information modeling capabilities (Part 6 of O-PASTM) which play a key role in the O-PAS™ reference architecture.
How O-PASTM leverages OPC UA
From the below architecture diagram it’s evident that a Distributed Control Node (DCN) is the heart of the OPAF architecture. Here a single DCN is similar to a small machine capable of control, running applications, and other functions for seamless data exchange with the higher Advanced Computing Platform (ACP) layers. This component interfaces with the O-PASTM Connectivity Framework (OCF) layer that is based on the OPC UA connectivity framework.
The connectivity framework allows interoperability for process-related data between instances of DCNs. It also defines the mechanisms for handling the information flow between the DCN instances. The framework defines the run-time environments used to communicate data.
Basically each DCN has a profile which describes a set of full-featured definition of functionalities or technologies. For example:
The DCNs (i.e. O-PAS conformant components) are built conforming to anyone of the primary profiles specified in the O-PASTM:
OBC
O-PAS Basic Configuration
OCF
O-PAS Connectivity Framework (OPC UA Client/server, OPC UA PubSub profiles)
OSM
O-PAS System Management
NET
Network Stack
CMI
Configuration Management Interface
SEC
Security
DCP
Distributed Control Platform (Physical hardware)
The OPC UA information model capability is used to define and build these DCN profiles. Part 6 of the O-PASTM and its subparts defines related set of information and exchange models, such as basic configuration, alarm models, or function block models. This provides a standard format used for the exchange of import/export information across management applications. It also provides standard services used for the download/upload of information to O-PASTM conformant components.
According to the report OPC UA Momentum Continues to Build published by the ARC Advisory Group and endorsed by the OPC Foundation, it provides timely insights into what makes OPC UA the global standard of choice for industrial data communications in process and discrete manufacturing industries. From an IIoT and Industry 4.0 perspective, the report examines how the OPC UA technology is the standard that solves the interoperability challenges.
Key take-away from the report that help maximize OPC UA adoption include:
OPC UA standard is open and vendor agnostic, and the standard and Companion Specifications are freely available to everyone.
OPC UA is an enabler for next-generation automation standards that will, potentially change the industry structure of process automation e.g. Ethernet Advanced Physical Layer (Ethernet APL), NAMUR Open Architecture, and the Open Process Automation Forum (OPAF)
OPC UA is arguably the most extensive ecosystem for secured industrial interoperability
OPC UA is independent of underlying transport layers. As such, it uses the most suitable transports for the right applications (ex. TCP, UDP, MQTT, and 5G)
OPC UA is highly extensible via its Information Modeling (IM) capabilities. This makes OPC UA an excellent fit for use by automation vendors and other standards organizations wishing to express and share semantic data seamlessly across all verticals.
The OPC Foundation Field Level Communications (FLC) Initiative is defining a new OPC UA Field eXchange (OPC UA FX) standard that is supported by virtually all leading process automation suppliers.
OPC UA FX will extend OPC UA to the field level to enable open, unified, and standards-based communications between sensors, actuators, controllers, and the cloud.
Forward-looking companies should make OPC UA a crucial part of their long-term strategies today because the changes this technology brings will become a necessity faster than most people anticipate
OPAF is making outstanding records in creating a comprehensive, open process automation standard. Since it is partially built on other established industry standards like OPC UA, the O-PASTM Standard can improve interoperability in industrial automation systems and components.
OPAF fulfills its mission to deliver effective process automation solutions with the collaborative efforts of the OPC Foundation. Utthunga’s expertise in OPC UA standard and by adopting our OPC related products and solutions, businesses can benefit from low implementation and support costs for end-users and enable vendors to experiment around an open standard.
Get in touch with our OPAF experts to experience a new-age open, secure by design and interoperable process automation ecosystem.
The current wave of the industrial revolution, also known as the Industrie 4.0, has proven to improve the production process in various aspects. To realize the promised benefits, a strong communication protocol that allows semantic interoperability among interconnected devices is needed. In manufacturing industries where processes are greatly dependent on the industrial sensors and actuators, there are a few challenges that hinder seamless plant floor communication.
Take for example, the use of 4-20mA analog signals for communication between proximity switches and sensors. Although this produced satisfactory results, it did not provide any scope for diagnostics. So, the issues in the process go unnoticed until the whole system comes to a standstill. The combination of digital and analog devices also requires multiple cable and hence a tedious installation and maintenance process.
To overcome such challenges, the IO-Link Consortium Community, an organization in which key user companies from various industries and leading automation suppliers join forces to support, promote and advance the IO-Link technology. With over 120 members and strong support in Europe, Asia and the Americas, IO-Link has become the leading sensor and actuator interface in the world. The common goal of these companies is to develop and promote a unified and bi-directional communication architecture that involved an easy implementation process and the ability to diagnose the errors at the right time. The IO-Link protocol thus came as a knight in shining armor for the industries to help them gain the best of the Industrie 4.0.
IO-Link is a robust; point-to-point communication protocol specifically designed for devices like actuators and sensors. The IO-Link client is independent of the control network and communicates with an IO-Link master port. This port is placed on a gateway and transfers the data and or signals to the control system for further operations.
IO-Link proves to be beneficial for the factory automation processes especially in the digital era ofIndustrial Automation. With embedded software systems now becoming an inevitable part of industries, more IO-Links help them to leverage the power of Industrial automation and IIoT.
To get a gist of the benefits you can expect through the proper implementation of IO-Links, read the entire blog.
IO-Link Wired setup enhances factory automation communication for Industry 4.0 applications
Incorporating automation processes into an existing manual based manufacturing end processes are a primary challenge that IR4.0 possesses. To overcome this, many factory communication protocols have been introduced by various institutions.
For the device level, the communication IO-Link protocol is the most viable options to choose from. The reason being many, that we shall discuss in the next section. On the factory floor, IO-Link has long been seen as a wired communication network.
A basic IO-Link communication cycle involves:
A request from the master device
Waiting Time- for the request to reach the client device
Processing time of the request from the client device
Answer from the device to the master.
Waiting Time- for the answer to reaching the master.
In general, factory automation units have wired IO-Links that offer high flexibility and enhances the communication systems between the controllers and the system actuators and sensors. However, with the advent of reliable wireless networks, industries are now adopting wireless IO-Link set up these days.
The popularity of the IO-Link for the communication between sensors, actuators, and the control level is steadily increasing with each passing year. In a wireless setup, an approximate 5ms maximum cycle is achievable with high probability. In addition to this, it also provides the required flexibility in automation solutions and opens door to the possibility of using battery-powered or energy-harvesting sensors as well.
How IO-Link Benefits OEMs and End Users
As already mentioned, IO-Link be it wired or wireless creates ripples of benefits for OEMs and ends users.As already mentioned, IO-Link be it wired or wireless creates ripples of benefits for OEMs and ends users. One of the advantages of IO-Link is that by incorporating the smart sensors with IO-Link, you can optimize your smart factory with powerful data and diagnostics and prepare them for the future – to increase your uptime and productivity. Along with faster time to market and lower total cost of ownership, OEMs and end usersalso benefit from improved asset utilization and risk management.
Typically a smart sensor functions as a regular sensor unless it’s connected to an IO-Link master. When connected, you can leverage all the advanced configuration data capabilities that IO-Link has to offer.
Let us have a look into some of the key advantages of implementing IO-Link for OEMs and end users.
Enables better maintenance
One of the main reason behind the popularity of the IO-Link is its diagnostic capabilities. It means the servers are informed well in advance about any forthcoming issues. This makes them ready for need-oriented maintenance and a better factory automation system.
Efficient operation
As IO-Link sensors are independent of the control network and their accessibility no longer plays a role in automation, you can place them directly at the point of operation. This means the machining process can be optimized to operate at maximum efficiency in the minimum time frame.
Consistent Network
The IO-Link being a standard communication protocol between IO sensors/actuators and the control network brings consistency in your automation network. So you get to integrate more devices into your IO-Link protocol network and introduce flexibility to your network.
Makes your system versatile and future proof
IO-Link sensors and actuators do more than just process and transmitting data to and from the control network. IO-Link protocol integration facilitates reliable and efficient communication between devices. Having IO-Link devices means your system has access to integrated diagnostics and parameterization which also reduces the commissioning time to a great extent. Overall it imbibes versatility to your system and makes it ready for the future of IIoT.
Enables processing of three types of data
With the IO-Link, you can access and process three types of data namely process data, service data, and event data.
Process data includes data such as temperature, the pressure that is transmitted by the sensors or actuators upon request from the IO-Link master request.
Service data refers to the one related to the product and not process and includes manufacturer name, product model number, and the like.
Event data usually comes from sensors when any event notification has to be raised like an increase in pressure.
Provides IODD for each IO device
IO-Link protocol integration assigns each IO device with an IODD or IO Device Description such that the master manufacturers display the same IODD for each of their devices. This way, the operability of all the IO-Links is uniform irrespective of the manufacturer.
Reduces or eliminates wired networks
Since IO-Link protocol integration allows uniformity among the sensors, actuators, and control system, there is no need for separate wires. This way the number of wires can be reduced to a great extent. As wireless networks reign the IIoT arena, the concept of wireless IO-Link protocol integration is also gaining popularity.
Increases machine availability
With IO-Link protocol porting, you can enjoy an errorless and fast data exchange between sensors, actuators, and the control system. This increases the operation speed and reduces the downtime and improves the commissioning processes. Overall the machine errors are reduced thereby giving you more out of the machines.
Conclusion
The 21st century has paved the way to better industrial processes through the advent of industrial automation or the IR4.0. IO-Link protocol porting and IO-Link protocol integration has greatly helped OEMs and end-users alike, in making their production process in compliance with the IIoT set up. If you are looking for a reliable and flexible IO protocol integration for your plant, we at Utthunga have the state of the art technologies.
IO-Link – an integral part in the Industrial Automation
As more devices are interconnected at the factory level, the automation process greatly depends on seamless communications between devices from the shop floor such as sensors and actuators to the control systems like PLCs, and others. To ensure this, IO-Link is one of the first standardized input-output data communication protocol that connect devices bi-directionally. It means the devices are paired in a point-to-point communication that they can transmit information to and fro.
IO-Link enables point-to-point communication over short distances. Such an effective, seamless communication protocol is undoubtedly one of the crucial elements of the factory automation process that comes in as a part of Industry 4.0. Implementing the effective IO-Link strategies plays an important role in the overall network efficiency. Not only this, it facilitates ease of configuration as it reduces the number of wires and connections for OEMs and the end-users alike. IO-Link handles data types like process data, parameter data, and event data. All of these make it somewhat similar to a universal connector, which reduces downtime and improves visibility into the plant floor.
Why is an IO-Link required?
One of the most critical challenges in implementing an automated factory setup is setting up effective communication between devices at the ground level. For the manufacturing industry, IO-Link is required for more reasons than one.
First, it fills in the communication gap present even at the lowest automation hierarchy level. It also acts as a liaison in identifying error codes and help the service professionals troubleshoot the issue without shutting down the production or manufacturing process. It also makes remote access possible wherein the users are connected to a master/network to verify and configure the required sensor-level information.
Holistically put, we can say industries require IO-Link if they are looking for a cost-effective way to improve their efficiency and machine availability, which are crucial elements in implementing a successful automated factory. To understand this further, we have jotted down the top eight advantages of the IO-Link in this article’s next section.
Embedding IO-Link in your field-level devices like sensors and actuators facilitates better data transfer between them and the controllers via an IO-Link master. It in turn, enables you to connect the sensors and controllers like PLC, HMI, SCADA, etc. without worrying about loss of data.
Enhanced Diagnostic Capability
One of the crucial issues that cause hindrance in implementing a seamless automation experience is that errors in data processing or handling go unnoticed or are discovered quite late. It may lead your manufacturing or production unit to go to a standstill. With the IO-Link, since the communication is bidirectional and more visible, errors can be detected and examined for severity at the right time. It helps in troubleshooting the issues without stalling the production processes.
Better Data Storage and Data Availability
IO-Link offers improved data storage options. IO-Link offers parameterization of data that can be stored within the IO-Link master. This makes the automatic configuration of the IO-Link possible. Also, the types of data available vary from process data, service data, and event data. Process data is the information that a machine sends or measures; the service data refers to the report that spells the technical and manufacturing details of the device. The event data is the information such as notifications or upgrades that are critical and time-specific.
Remote Access to Device Configuration and Monitoring
IO-Link enables users to connect via IO-Link master or a network for remote access to sensors, actuators, controllers from virtually any location. It allows users to examine and modify the device parameters when required from anywhere. It improves overall productivity and plant efficiency.
Auto Device Replacement
Not only does the IO-Link allow remote access to device settings, but the data storage capacity also facilitates automated parameter reassignment. It makes device replacement a lot easier and hassle-free. Users can easily import all the required data to the replaced device and continue their factory automation process.
Simplified Wiring
Since the IO-Link is free of any complicated wiring, it reduces the hassles related to the same. As it supports many communication protocols, the IO-Link devices can be configured with existing wiring, reducing the overall implementation costs to a minimum. It also does not require any analog sensors and actuators, which in turn negates the need for additional connection wires.
Device Validation
IO-Link offers users to carry out device validation before leveraging them for the production process. It also empowers users to make an informed decision like pairing the IO devices with the correct IO master link.
Saves Time and Money During Device Setup
As the IO-Link does not require an additional setup for configuration and is compatible with many communication devices, the device setup becomes easy and does not require much time. With automation, you can reduce the time required for device setup, all within your budget constraint.
To stride ahead in the digital world, you need to be clear about your goals and objectives regarding adopting new technologies. Utthunga’s IO-Link Master Stack and configurator are appreciated throughout the industrial space for the quality we serve. Our team of experts guide you through the implementation and maintenance process for your manufacturing or production, so you leverage the ultimate benefits of deploying an IO-Link system into your network.
If reduced operational costs and improved plant efficiency are what you need, then contact us, and we will make sure our IO-Link products do the magic for you.
Embedded systems are a ubiquitous and crucial part of the industrial automation. Whether it’s a small controller, an HVAC, or a complicated system, embedded systems are everywhere in the manufacturing space. You need embedded systems to help in improving the performance, operational and power efficiency and to even control processes in the complex industrial realms. Building and maintaining an embedded system, the software that goes into these systems, is anything but a trivial task. It requires specialized tools like build tools, cross compiler, unit test tools, and documentation generators among others. The process of setting up such an embedded environment in your system could therefore be quite overwhelming. Docker helps in making the whole process a lot easier and manageable. Docker is similar to virtual machines but is a light-weight version of the same. This creates containers that share common components with the Docker installation.
Dockers are one of the preferred containers used by software developers these days. Embedded system developers are also now leveraging the benefits containers bring into their software through Dockers. Installing Docker is relatively easy and it supports different OS platforms. Once installed, you need to define a run time environment with a Docker file and create a Docker image. Once this is done, all you are left is to execute the image with the run command and share the files between the host and container. To share, you need to create a bind mount which is created every time you run an image with the “mount” option. Since embedded systems have a fairly slow rate of system update changes, you can use the lightweight Docker on a minimum build then start layering on top of it. However, running Docker on an embedded system comes with its own set of challenges. For example, Docker uses the latest LINUX kernel, which may not match the embedded system’s kernel features. Another important hurdle that developers often face is that Docker image architecture should match the run time environment.
Containerization of software applications is fast gaining popularity and is speculated to disrupt the “industrial automation” as we know today, for good. For developers, the array of container images means the collaborative creation of software deliverables is possible without overlooking the requirements for running an application within a machine environment. With the introduction of containers, industrial automation may also witness an end to the vertically integrated business model, which hasn’t changed much since the times of PLCs and DCSs. This is because the acceptance of containerization has paved the way for an efficient embedded system and easier implementation of the same into the current Industry 4.0 scenarios. It also makes automation accessible and easy to deploy in various machines.
Containers and Maintenance (Sustenance Engineering) of Embedded Systems
The industrial OT world traditionally consists of proprietary embedded systems that focus on reliability, longevity and safety.With technology advancements, maintenance of these older systemshas become a burden. The wide popularity of containerization has made containerization an important maintenance strategy for the embedded systems. Product sustenance or re-engineering is basically fine tuning your released products to add new services and enhance their existing features. It virtually extends your end of the lifecycle or older products with periodic fixes, updates and enhancements that assures reduced maintenance costs, help maximize profits as well as retain your customers. Some of the ways in which containerization adds value to your sustenance engineering are:
Ready to implement container images reduce the development time needed for application updates, defect fixes or new features enhancements
Resource utilization and sharing is optimized with better maintenance plans
Container frameworks and prebuilt tool chains enable the development and maintenance of applications on multiple embedded hardware platforms like STM32, Kinetis, ARM series etc.
Software containerization and isolation of other processes and applications protects your application from hacks and attacks. This security aspect limits the effect of a vulnerability to that particular container and thus not compromise the entire system.
Key Benefits of Docker Containers on Embedded Systems
There are multiple motivations to leverage Docker containers benefits in an embedded environment. Easy to use, they provide a lightweight and minimal way to solve legacy architecture problems etc.
Docker supports Windows, iOS, and Linux
Developers can use the tools available in their local development environment. It means they need not install tools to run a Docker on the embedded system
Developers can check the code against toolchains without worrying about tools co-existing.
Your development team can use the same tools and build environment without having to install them
Containers enable edge computing and convergence of services at the edge or gateway level
The pre-integrated container platform allows developers to create applications that scale up to their business requirements and deliver qualitytime-to-market solutions in an accelerated manner
Containers allows isolation of storage, network, and memory resources among others enabling developers to have an isolated and logical view of the OS
Portability of containers allows it to run anywhere allowing greater flexibility in the development and deployment of applications on any OS or development environment.
Conclusion
Even with its set of challenges, Docker seems to be the game-changer in the Industry4.0 era. With embedded systems playing a pivotal role in many industries, your developers can use Docker to deploy automated machines. If you want smart solutions for a decentralized plant floor, you need to get professional development assistance from Utthunga. We help you create embedded systems that truly bring out the best degree of productivity for your company. Leverage Utthunga’s embedded system consultations services and products which have transformed industries across various verticals includingdiscrete, process, oil and gas, and power industries. Contact us to know more.
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