u-remote - Remote IO System Modernization with Weidmüller
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- เผยแพร่เมื่อ 12 มิ.ย. 2024
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⌚Timestamps:
00:00 - Intro
00:50 - Challenge
02:43 - Solution
05:38 - u-remote
08:36 - Wrap Up
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In this case study, we will look at the value of modernizing remote I/O systems based on the experience of a leading industrial company specializing in the storage and distribution of bulk liquid products.
To respect this company’s privacy, we will not use their name but we can tell you that this company operates 114 facilities in over nine countries around the world.
At their Amsterdam facility, this company was running a bulk liquid terminal using an aging DCS.
This Distributed Control System was built up from two controllers with 17 I/O racks on a Profibus network. These I/O racks interfaced with over 700 I/O points on different devices including pumps, tanks, and motor-operated valves.
Although this system was working, the company faced several challenges which were becoming worse with each passing year. The main challenges associated with the original remote I/O system were:
1) Spare Part Availability: Although the Distributed Control System was still supported by the manufacturer; it was becoming increasingly difficult for the company to find spare parts in stock.
2) Limited Functionality: Operational technology has taken major leaps forward in recent years. Automation manufacturers are constantly innovating and introducing new features into their products.
3) Network Limitations: Like many others, the company wanted to collect more data from their field devices to analyze and optimize their system’s performance.
The company understood that it was time to upgrade its remote I/O system to a modern system that leveraged state-of-the-art technology.
As a starting point, the company made a list of what its ideal solution would look like. The features that were mentioned on the company’s wish list included: Ease of Use, Small Footprint, Maintenance Friendly, and Cost-Effective.
1) Ease of Use: The new remote I/O system had to be easier to use and have more functionality than the old system.
2) Small Footprint: The company wanted to collect more data from field devices, which meant increasing the number of I/O points per I/O rack.
3) Maintenance Friendly: The remote I/O system had to be built with reliable hardware that would function without failure for a long time.
4) Cost-Effective: The remote I/O system should be cost-effective. The company knew that they wanted a lot of features but felt that a modern remote I/O system should be affordable and its cost should reflect the amount of value that the remote I/O system offered.
At Hannover Messe, they came across Weidmüller’s remote I/O system, u-remote.
This system seemed to meet all of the company’s needs and after several consultations with Weidmüller’s applications engineering team, the company decided to upgrade its facility using Weidmüller’s u-remote system.
Since Weidmüller’s u-remote I/O system is compatible with most industrial networks including Profinet, EtherCAT, Ethernet/IP, and Modbus/TCP, Weidmüller’s application engineering team was able to work with the company to determine what industrial network was best suited to their needs.
Ultimately, the company settled on an Ethernet-based network that used the Modbus/TCP communication protocol.
After switching to a Modbus/TCP network, the company could focus on upgrading the density of each remote I/O rack. u-remote I/O modules are incredibly thin at 11.5 mm per module and each u-remote I/O station supports up to 64 modules with a single power supply.
Since they could fit more I/O modules per rack, the company was able to reduce the number of remote I/O racks in the Distributed Control System from 17 racks to 11. The end result was a system with fewer points of failure and spare parts requirements.
@WeidmuellerGlobal
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Learn more about u -remote:
www.weidmueller.com/int/produ...
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#RealPars #weidmüller #plc
It's my favorite Remote IO system. Weidmuller you rock.
This is refreshing to see. It seems a lot of organisations equate not interfering with obsolete hardware running critical systems as safe.
Hopefully, Siemens will adopt these new features & functionalities in future.
Thank you Realpars very helpful
Glad to hear that, Wilberth!
I've worked with this I/O module. Awesome video!
Thank you very much! Glad to hear that
Thank you for making such a video.🙏😊
Our pleasure!
Love to know about this
Thank you sir
You're very welcome!
Very good and informative video. Can we except a course on Weidmuller remote I/O ?
Very good!
Glad you think so!
Thanks for the video.
But I have a question. When I check the price of weidmüller IO modules, they seem pretty much. (Same with s7 1200 plc & modules or higher)
Of course, I don't know the details in this situation but if I design something like that, I prefer a plc that communicates over profinet with controller plc instead of I/O module .
All specifications I/O modules have existed in plcs too.
Why do we prefer weidmüller or other I/O modules instead of a plc?
There are many reasons to choose an I/O subsystem such as Weidemuller. One is the cost of hardware and installation. The other is the physical space requirements for installation. For compact I/O such as this, it is easy to install a small rack with 10-12 I/O in a very small space, where S7-1200 I/O would require a much larger footprint. In many machine control applications, I may need 1 or 2 I/O of different types, and the smaller footprint of the I/O cards makes the overall installation more compact.
Thanks
You're very welcome!
great product from weidmuller
Web servers usually available in CPUs. IOs can be forced from there also in my Brands. What does it mean by forcing IOs of a remote station? Can the IOs be forced directly without having access to CPU and it’s program?
Every PLC is different, and some do no allow forcing at all. But for those which do allow it, you are typically able to force outputs from the programming station for any output regardless of where the DO card is located (local rack or remote rack). When you force and output, you are overriding the output image table in the CPU, and the CPU communicates that change to the I/O rack. The presence of a force is indicated at the CPU, not at the remote I/O rack. The remote I/O rack simply places the output states to what is sent to it by the CPU.
I would like to see a video of this Remote IO being linked to Allen Bradley PLCs please.
Thanks for your topic suggestion, Darthen! I will happily go ahead and pass this on to our course developers.
Happy learning!
nice
Thank you!
How to work RF transmitter and receiver plz make a vidios plz..
Thanks for your feedback and suggestion, Saikumar! I will definitely go ahead and pass this on to our course developers.
Good video. I have two questions:
1) What is the importance of web server?
2) Can Modbus carry more data than profibus?
Thanks.
A web server is firmware that is embedded into a device, such as a PLC, that allows the device's data to be accessed using a web browser. With an embedded web server, it can be possible to configure and monitor the device using an ethernet connection to the device without application software other than a web browser. When comparing communication protocols, speed and bandwidth are important. Profibus can be configured to operate at many different speeds; Modbus comes in many "flavors", including RTU and TCP. Modbus TCP runs at the same speed as ethernet (10Mbps or 100Mbps). ProfibusDP can operate at 1.2Mbps, so theoretically, Modbus TCP is faster. By the same token, even the slowest Profibus DP baud rate is faster than the fastest Modbus RTU rate. But do differences in speed really matter for communication with an I/O rack or VFD that likely has, at most, 256k of data available for reading/writing? Probably not. Both ProfibusDP and Modbus TCP are fast and can handle any control application.
Will Weidmuller still suport them 40 years later, like the other big names do? Didnt even know they did automation stuff, only know them from their pliers and acient looking terminal blocks
I'm going with no.
U think siemens support 40 year old systems. When they brake your have to upgrade. Dont get fooled by 'big companies support'.
How to creat different different RF weves in remote plz make a vidios
Hi Saikumar,
Thanks for your feedback and suggestion! I will definitely go ahead and pass this on to our course developers.
Happy learning!
IM-151HF....👍
Interesting, I have to compare this with the WAGO PFC200 series, especially against 750-8212/025-001.
It's difficult to believe that adding several remotes of the old system is disruptive and changing the remotes isn't. There must be many hundreds of IO in this example for them to be so concerned with prices of the remotes. Most mechanical pieces of equipment cost the same as several remotes combined. Price of automation equipment is peanuts in terms of CAPEX
But it is a very important question when you are in the OPEX side. Commissioning and troubleshooting time is gold.
Sounds like they found something that checks all the boxes. Hope that something doesn't turn out to be a big pile of crap.
Its been on the market over 5 years with thousands of global installations. C1D2, SIL2 safety ratings robust and rugged.
@@Al-yc4cn Thanks for the info. 👍