What is IO-Link?

Most sensors and actuators today are already equipped with microprocessors, which can be used for parameterization, storing configuration data, and controlling indication. The obvious next step is to overcome the bottleneck of the binary standard interface and make additional functions centrally accessible for the automation system.

For this reason a lot of well-known manufacturers from the field of automation have come together and developed a fieldbus independent communication interface for sensors and actuators: IO-Link. Compatibility with existing technologies was the primary objective during development in order to guarantee investment protection.

Technology

IO-Link is based on a point-to-point connection between the sensor/actuator and an interface module. Up to now, the binary connection was only designed for transferring switching information, but IO-Link now allows two bytes to be transferred normally in a 2 ms cycle via a combined switching status and data channel. Other information can be exchanged in addition to the process values, such as parameters or diagnostics messages. This enables communication with sensors and actuators down to the �last meter� to be established for universal communication.

What is Pick-to-Light?

Turck Pick-to-Light solutions provide operators with a visual indication of the required part in an assembly sequence. Actions (correct or false) are indicated by means of lights and optional audible signals. Completed operations can either be automatically or manually acknowledged.

All components in Turck Pick-to-Light systems are perfectly matched ensuring quick and reliable installation and maintenance.

What is PROFINET?

The Profinet protocol is based on Industrial Ethernet and is a communication standard for factory automation. It describes the entire data exchange between so-called slaves such as Turck's multiprotocol I/O modules and a controller, the Profinet master. In this function Profinet is considered the successor to the Profibus fieldbus protocol.

Profinet was optimized in the area of cyclical data exchange and offers several new functions and extensions compared to conventional fieldbuses, particularly in relation to parameterization and diagnostics. Profinet offers users flexibility in the design of their network structures and enables them to transfer both process data in real-time (RT) as well as additional IT data via a single cable.

The system overview provides an initial impression of the network architecture and the different I/O and network components. Connections can be implemented via linear, star and tree structures, or also via a redundant ring topology (MRP).

What is Multiprotocol?

Turck offers a complete line of industrial Ethernet products, including on-machine, in-cabinet, block, and modular I/O. The multiprotocol technology by Turck is an innovative new approach to Ethernet distributed I/O; multiprotocol I/O devices automatically self-configure to the active fieldbus protocol on each power-up. Supported protocols include Modbus TCP, EtherNet/IP and PROFINET.

What are the benefits of Industrial Ethernet?

Industrial Ethernet benefits users by utilizing tools and techniques familiar to traditional office communication systems, and extending them to industrial applications. This facilitates data transfer across the entire plant floor - as well as plant-to-plant and globally - via secure network connections.

With Industrial Ethernet remote maintenance can be established easily. Like this on-site service can be reduces to a minimum, what is good for you and your customer.

Multiprotocol: The Easy Way to Industrial Ethernet

Multiprotocol products are simple and intuitive, allowing easy transition between multiple common industrial Ethernet protocols without the need to physically switch parts. An advanced webserver integrated in all Turck multiprotocol devices facilitates simple device configuration and troubleshooting via web-browser. Furthermore, an impressive array of advanced features for each supported protocol has been incorporated into the devices to meet many unique application requirements.

Turck�s multiprotocol technology makes moving from one industrial Ethernet protocol to another plug-in simple. Turck�s multiprotocol products offer a seamless transition to industrial Ethernet, whichever industrial Ethernet protocol that may be.

What is Industry 4.0?

The term "Industry 4.0" describes the fourth industrial revolution. In practice it is more of an evolution than a revolution. Business and value creation processes are becoming ever more closely linked and increasingly automated. Industry 4.0 resolves the dichotomy between customized products and mass production. For this to happen, commercial, logistics, and production processes have to be closely interlinked.

Although Industry 4.0 is often portrayed as a blueprint for factories of the future, intelligent applications which allow for customizable, highly flexible production have long since been a reality.

Turck will support you on the path to Industry 4.0 with innovative solutions to acquire, condition and transfer relevant production data.

Key Technology

Whether RFID, IO-link, OPC-UA or Ethernet � as a specialist in the key technologies of industry 4.0 Turck paves the way to the intelligent future factory for you.

RFID

With the RFID system BL ident Turck has implemented solutions for flexible control of production processes, but also for the spare parts/service business, piracy protection or serialization. Together with the IP67 I/O PLC modules from Turck you have available robust solutions with distributed intelligence for data processing or for control tasks.

IO-Link

Turck offers one of the most comprehensive portfolios of IO-Link solutions - ranging from numerous sensors and connection technology to fieldbus and Ethernet I/O systems with IO-Link masters in the protection classes IP20 and I67. How to benefit from intelligent data acquisition and communication solutions from a single source.

Ethernet

Ethernet is the standard for communication, not only in the IT world, but also in the industrial environment. Turck offers especially user-friendly solutions such as the multiprotocol technology that supports the automatic use of I/O systems in the Ethernet protocols PROFINET, Modbus TCP or EtherNet/IP.

OPC-UA

OPC-UA is the world's next standard for integrative communication across all levels of the automation pyramid. In close cooperation with science and industry, Turck participated in the development of the standard and has already implemented it in the first products

Let us be so bold to predict the death of PLCs as we know them

Demonstrating our commitment to flexible, custom solutions, Turck has developed the next big thing for control: the field logic controller (FLC). Turck's FLC solutions are made possible by ARGEE (A Really Great Engineering Environment), a revolutionary web-based programming environment that allows users to set conditions and actions directly at the field level. By utilizing HTML5, Turck provides a complete engineering environment for users to write, run, simulate, debug, and monitor code, all without requiring the use of a PLC.

Using FLCs, Turck's multiprotocol block I/O products can act as simple I/O devices or as standalone logic controllers. While ARGEE programming is not designed to replace a PLC outright, it can be used to change the way we think about control, allowing FLC devices to:

• Be used without a PLC in standalone applications
• Perform arithmetic functions, use timers, counters, and even toggle bits
• Share data with a PLC via assigned I/O variables

Technology

Using a simple "Condition" and "Action" principle that is integrated into a flow chart user interface, ARGEE allows users with little or no programming experience to easily configure and program their Turck FLC devices.

ARGEE challenges what an I/O device can do by creating a hybrid between simple block I/O and higher level PLCs. The result - Turck's FLC.

Open system

Unlike the programming environments of major control manufacturers, the software is independent of the more than 400 hardware manufacturers that use the automation platform. Openness and interoperability of devices and systems from different manufacturers are therefore a fundamental feature of the program. More and more users worldwide appreciate this approach and are reinforcing the system as a whole with their solutions.

IEC 61131-3 ensures interoperability

The software follows the international standard for PLC programming IEC 61131-3, which in turn guarantees interoperability of Codesys programs with other standardized devices. Programming in Codesys is based on programming languages such as AWL, ST, FUP and others, which ensures smooth communication with other devices and systems.

Limitless

Codesys allows the use of different fieldbuses/Ethernet protocols in an automation system. When users create applications in combination with Profinet and EtherNet/IP or EtherCAT, they benefit in turn from the openness of the software.

Condition Monitoring of Machines and Systems

The term condition monitoring refers to the process of monitoring a parameter of conditions in machines and systems. Nowadays, "listening" to motors, electronic devices or areas of a system to check for faults goes far beyond on-site inspections by workers.

Thanks to state-of-the-art sensor technology, intelligent field devices and wireless transmission, condition monitoring can be carried out not just continuously but from absolutely anywhere. On the basis of the collected data, systems can indicate an imminent failure at an early stage. Reliable condition monitoring is therefore essential for predictive maintenance.

Simplify condition monitoring of your plant using products from Turck � from sturdy sensors to system solutions with flexible cloud monitoring. Whether the system is in a new build or you want to retrofit the solutions you have in an existing environment � all devices can be easily integrated into your existing automation system. Alternatively, decentralized standalone systems can monitor key condition data without affecting the main control unit.

Ethernet in the Process Industry

Industrial Ethernet has been a vital networking and communication solution in factory automation for decades. Today, it is quite widespread. The process automation industry presents special challenges due to potentially explosive atmospheres, which have so far not allowed the use of Ethernet. These requirements include intrinsic safety, configuration in run, redundancies for maximum availability and a long cable length, which is limited to 100 meters for industrial Ethernet. When using Ethernet solutions in the process industry, it is important to distinguish applications where they will be used by their respective Zones.

Ethernet for Ex Zone 2

Turck offers its excom I/O system with Ethernet for installation in Zone 2. The system can pick up signals from Zone 1 or 0. To plug and unplug the Ethernet connectors at the gateway in run, users must ensure that the gateways are de-energized or work with a hot work permit. All other components such as power supply units, gateways or I/O modules can be exchanged during operation without a hot work permit

Ethernet for Ex Zone 1

Using Ethernet in Ex Zone 1 is technically more difficult. With interlinked devices, it must be ensured that power levels do not add up. Today, a consortium of companies is working to overcome these hurdles and develop a standard for a two-wire Intrinsically Safe (IS) Ethernet. Communication and power supply take place over the same line. The future standard is usually referred to as Advanced Physical Layer (APL). However, these developments are not yet suitable for broad industrial use in Zone 1 (status 03/2020). One day, APL should enable Ethernet connections up to the field devices. However, classic 4 to 20 mA technology and I/O systems will continue to exist in parallel for cost reasons alone, even after APL has been established.

Cloud Solutions for Industrial Applications

Cloud solutions provide flexible access to storage, computing power or software. Data is not stored on the local IT hardware, but on servers. This allows users to access information or initiate actions from different web-enabled devices, regardless of location and time.

Unlike business or private clouds, industrial clouds are highly specialized. They need to address vertical integration within specific industries, support standardized communication protocols with bidirectional information flow and meet high security requirements.

Data preprocessing in edge controllers

In order to process data from machines and sensors specifically in the cloud, filtering in the edge, i.e. at the "outer edge" of a local network, is an important process. In edge controllers, users can define which information should be transferred to the cloud and which should remain in the OT environment instead. This reduces the data density on the servers.

Via cable, WLAN or mobile communication

Communication from field level to the cloud can take different paths. In addition to the option of connecting applications via mobile radio, existing Internet access points at the location can be used either wired or via WLAN. Future-proof standard protocols are OPC UA and MQTT, allowing components alongside Turck Cloud Solutions to be integrated into various clouds such as MS Azure, Alibaba or Amazon Web Services.

Functional Safety for Machines and Processes

As part of Machinery Directive 2006/42/EC, all manufacturers must assess the risk posed by their products so that people who come into contact with the machine are protected. However, the Machinery Directive does not apply solely in the EU. It is also used in other countries in the European Single Market. Local standards often make reference to European safety standards, which are listed in the Machinery Directive as harmonized standards.

The risk posed by the machine must be reduced to a reasonable residual level. To this end, the manufacturer carries out a three-stage risk assessment. The risk must be reduced through design measures, by applying technical safeguards and by providing user information such as manuals.

Classifying risks into performance levels

In order to assess which technical safeguards are appropriate to the risk in question, manufacturers are guided by parameters that indicate the probability that safety-related components will fail. These parameters are called performance levels (PL). First, the manufacturer determines the required performance level (PLr) of a safety function. After designing a safety control to implement this function, the manufacturer determines the actual performance level. At the end of the process, PL and PLr must be the same. Broadly speaking, there are three types of safety controls.

Why Building Machines Modular?

The core idea of modularity in mechanical engineering is to divide complex machines into modules so that they can be individually assembled with an increasing number of identical parts. The combination of these modules covers the variance of machine types. Thanks to the economies of scale that this achieves, modular machines can be manufactured faster and more cost-effectively. In addition, they can be put into operation more quickly and expanded with greater flexibility.

Standardized interfaces are required to ensure the units can be combined easily and quickly. These include mechanical interfaces, but also those needed for power transmission, communication and, if necessary, compressed air. Modularity is not a characteristic that can be defined with a categorical yes or no. Instead, it ranges from low to absolute modularity.

Decentralized automation promotes modularization

Consistent modularization is not possible with point-to-point wiring in the central control cabinet. These central structures make it difficult to replace a module or expand a machine. Machine modules require autonomous structures. These can be implemented in small on-site control boxes on the module with IP20 components.

However, wiring and installation are usually more complex than for components with IP67 protection class, which can be mounted directly on the machine without any additional safeguards. However, if certain components are not IP67-rated or if special requirements apply in relation to hygienic design, food conformity or chemical resistance, IP20 solutions in the protective housing are often essential.

IP67 automation components facilitate the interconnectivity of modules. Decentralized I/O components for mounting directly in the field allow signals to be collected directly at the point of generation on the module and coupled from module to module via an Ethernet connection � and all without a control cabinet. This reduces installation costs and shortens commissioning times at the end customer's premises.

RFID Solutions for Production and Logistics

End-to-end tracking of incoming and outgoing goods, confirming automatically that the intended materials and tools are being used in production, or providing access points with increased security. For such industrial tasks, RFID has proven itself as a powerful Auto-ID technology for Industry 4.0, with contactless transmission of large amounts of information, even over long distances, and easy connection to higher-level systems from PLC to ERP.

Choosing the right frequency band

HF technology (13.56 MHz) is an important driver of digital production processes, it is based on magnetic near-field communication. However, if higher ranges or bulk readings of 200 data carriers and more are required, users should opt for UHF technology (865...928 MHz). Turck's modular RFID system BL ident enables the parallel operation of read/write heads in the HF and UHF range � and thanks to protection class IP67, this can also be done directly on site at the machine or plant. This allows consistently decentralized signal processing in the field.

Data transfer to higher-level systems

Communication in logistics and production plants today is divided into hierarchically structured levels. RFID readers with an Ethernet interface establish a direct exchange of information with higher-level systems, such as PLC, SCADA, MES and ERP or the cloud. Thus, goods movements are visible in real time, detected goods are matched with the database or, perhaps, automatic invoices are already created in the accounting software.

IIoT applications via OPC UA

The platform-independent communication standard OPC UA simplifies the integration of RFID solutions into PLC, MES, ERP or cloud systems. With the AutoID Companion Specification, it is also possible to exchange devices between Auto-Ident systems from different manufacturers. Turck played a significant role in the development of the standard and has an own RFID interface with OPC UA server in its portfolio. For secure communication, the interface offers mixed operation of HF and UHF read/write heads.