Industry 4.0 is the integration of automation in production lines with the Internet of Things (IoT), transforming existing factories into Smart Factories capable of communicating with stakeholders for real-time management and control through a network system. The use of single-wire automatic AS-interface systems plays a crucial role in achieving excellent operational efficiency, and to highlight this, SCMA will explain why single-wire automation AS-interface is beneficial.
Benefits of Single-Wire Automation AS-Interface
The single-wire automation AS-interface system offers numerous benefits to ensure optimal performance of the system.
Main Benefits of Single-Wire Automation AS-Interface
- A tangled bundle of wires is replaced by a single cable (two wires) that carries both power and data throughout the system.
- High-speed data transmission, taking less than 10ms for systems with up to 248 inputs and 186 outputs.
- Easy and quick installation, requiring only a push of the cable through a finger hole, and designed to prevent reverse polarity connections.
- AS-interface wiring is not limited in form, offering true freedom in design.
- The cost per point for the AS-interface system is the lowest compared to other wiring methods.
- The AS-interface system was developed through collaboration among sensor manufacturers, ensuring seamless interoperability of devices within the system.
- Flexibility in design and installation makes the AS-interface a true Plug & Play network system.
Comparison of Parallel Wiring and AS-Interface
Parallel Wiring
- Requires a large number of wires according to the I/O count of the control system, making maintenance and system updates difficult.
- When one of the I/O device wires shorts out, users not only have to trace all the wires and terminals to locate the fault but a short circuit may also severely damage the PLC system.
- If an I/O device wire breaks, it can cause control system operation errors and may lead to other issues that need fixing.
- Water, chemicals, heat, electromagnetic fields, impact or vibration; all of these have the potential to disrupt communication between PLC and I/O devices in the field.
- When a PLC's I/O card fails, it is necessary to stop the operation of the PLC or the entire production process.
- Replacing a PLC's I/O card may require setting up all new addresses, which requires specific computers and software and takes considerable time to manage.
- Old-style parallel wiring requires experienced maintenance technicians who have worked for many years to handle repairs, improvements, and troubleshooting of problematic systems. However, this process is costly in terms of both time and expenses.
SINGLE-WIRE INSTALLATION IN AUTOMATION SYSTEMS WITH AS-INTERFACE
- There is a display showing all system operations (including in case of cable break or short circuit) in an easy-to-understand and clearly visible language.
- PLC, software, and PLC programming remain the same. Only AS-i Gateway replaces all PLC I/O cards.
- AS-i modules installed in the Field take over the role of Junction boxes, Terminal blocks, and Cable glands that can be freely distributed to various locations as needed.
- The yellow flat cable transmits both signals and 24VDC power. If the flat cable breaks, the Gateway will detect the break location or if there is a short circuit, the damage prevention system will activate.
- I/O modules and I/O devices in production processes. If an Analog I/O device connection breaks, the Gateway can identify the broken position. Or if a Digital I/O device connection shorts out, the damage prevention system activates. Other I/O modules continue to function normally, with the Gateway able to detect short circuit positions. Additionally, I/O modules can be removed, replaced, or added while PLC and Gateway are still operational.
- The cable (flat cable) structure and design completely prevent polarity reversal at 100%, including easy installation by simply pressing without the need to cut or strip wires.
- AS-Interface single-wire installation makes system troubleshooting easy when problems occur, with warning messages displayed on the screen indicating where the problem is. No need for highly experienced technicians; after a few hours of training in AS-Interface systems, quick and effective problem-solving can be achieved.
FORMS OF I/O MODULES
Examples of AS-interface I/O wiring include four options to choose from
- BRANCH LINE
- TREE
- LINE
- STAR
So, if asked what the benefits of a single-wire configuration in an AS-interface automation system are, it must be said that this is a system designed to elevate factories towards Industry 4.0 efficiently, with easy and convenient use, as well as durability and difficulty in modification. SCMA offers reliable IFM brand products from Germany along with efficient automation systems to help every factory truly step into Industry 4.0.
