How to add IoT capability to existing systems: Part 1
08 January 2018
Image courtesy of DesignSpark/YouTube
Do you want to know how to bring existing legacy products into the IoT environment? DesignSpark demonstrates, in Part 1 of this article, how using remote I/O modules from Brainbox will add Ethernet connectivity to installed systems, allowing the release of data from old and existing machines.
Using remote I/O modules from Brainbox is a great solution for a simple upgrade of installed systems as it means there’s no need to invest in expensive upgrades to get the best out of your current system.
The devices used in the following demonstration are:
• An Ethernet to Digital I/O with RS232 Serial unit ED-204 (789-8141)
• An Ethernet to 16 Digital Out unit ED-527 (789-8122)
• An Ethernet switch SW-504 (847-4752)
SW-504 Ethernet switch
This switch is an unmanaged switch and requires no software, it simply provides more Ethernet ports to connect everything together.
SW504 switch (Credit: DesignSpark)
So, on the demo board (see image/video), the PLC, HMI, ED-204 and ED-257 are connected to the SW-504 Ethernet switch, allowing all the equipment to become a connected network. Once this is done, you are free from the physical proximity of wiring constraints and you can monitor and control from a central location and even keep tabs on the production line on the move.
Remote I/O demo board
Remote I/O or Distributed I/O are I/O units located away from the PLC and this is what we have with the ED-204 and ED-527. Ethernet based Remote I/O is a great way to expand control and monitoring capabilities across a wide area.
Watch this handy video for more information on setting up remote I/O: https://www.youtube.com/watch?v=W4VTHcrVrDg
Setup overview
To make it easier, all the devices have a fixed IP address. Once you have everything plugged into the network you can go into the Schneider Electric M221 PLC or the Magelis HMI to locate the devices you want to talk to.
Remote IO board (Credit: DesignSpark)
The ED-204 and ED-527 devices come with Modbus TCP so can talk to the Schneider devices as soon as you tell them to use this language. Once this is done, you can set the PLC and HMI to talk also using Modbus TCP. This protocol is a selected option within Schneider Electric software.
Going back to the demo board, we can now control the fan from either the HIM or by using the stop/start buttons. This can be used in numerous industrial applications, for example a machine shutdown if a safety door is open.
The Ethernet to Digital I/O can monitor inputs such as sensors and switches, as well as control remote outputs like fans, buzzers and displays as shown through the ED-527 Ethernet to 16 output devices.
With these products you can:
• Know how many events have occurred
• Know immediately if there is a breakdown
• Know that your machine is making money in real time
• Knowing how long your machine is up and running for helps you calculate your machine’s Overall Equipment Effectiveness
• This data can then be used as hard evidence to review future capital investment decisions
Via the HMI, you can see what the sensors and outputs are doing in real-time and gather that information for review to work out system performance.
Both the PLC and HMI are programmed using Vijeo (HMI design) and SoMachine (PLC Ladder Logic) software tools from Schneider.
Watch the video to see the demonstration in action.
Stay tuned for Part 2 which looks at bridging the gap between legacy systems and the IoT
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