We talk with John Naudziunas of Murrelektronik and John Roberts of B&R about the latest developments and persisting challenges of connectivity.

Define connectivity. What's considered leading edge today?

Roberts: Connectivity is the ability to connect to a machine from anywhere in the world and monitor every aspect of the control and motion system. The connection could be via a VPN tunnel over the Internet or Web browser, via a modem, remote view of the machine's visualization terminal, or locally within the factory network to perform the same functions.
Naudziunas: In the world of factory automation, connectivity is the ability to quickly install, change, or add electrical devices to a machine in minimal time.

For example, some flexible I/O systems add new dimensions to bus network connectivity with the expansion of single nodes to accommodate hundreds of inputs or output devices.

In what applications is connectivity most important?

Roberts: Any machine application involved is a critical process because one machine can bring an entire production line to a halt. For example, packaging machines are typically an essential part of most products; there is no point in cooking chicken wings if the packaging machine is not packing them.
Naudziunas: From packaging machinery to food processing to automotive manufacturing, designers rely heavily on connectivity to increase uptime. Connectors and cord sets let users quickly change any damaged device or cable in minutes, whereas before it could take up to several hours. For machinery manufacturers, connectivity facilitates electrical installation and reduces any chance for crossed wires.

What are limiting factors when trying to optimize connectivity?

Naudziunas: Cable flexibility is an issue because some manufacturers haven't yet realized the cost savings in using connectors on machinery. They look at material cost as an issue and don't consider the overall cost savings in installation and setup time. But more and more manufacturers are slowly changing to plug-n-play systems, seeing the full potential connectivity offers them.
Roberts: When a drive faults on a machine, an operator might see "Drive Fault" on the operator display without knowing what the real problem is. With digital drives connected to the control system via a fieldbus, there are more possibilities for getting extended error information. For example, with a power panel controlling the logic, motion, and display of the machine over an industry-standard fieldbus like Ethernet Powerlink, the ability to read extended diagnostic information on the local operator display or remotely via modem improves.

What should engineers know about component interactions and their effect on connectivity?

Roberts: Typically, the complexity increases as the number of different fieldbuses on a machine increases. This makes intercommunication between devices difficult or even impossible.
Naudziunas: Fortunately, sensor connections are designed to meet IEC standards. This helps eliminate any chance of one manufacturer's connectors not being compatible with others of similar manufacturing.

What can engineers do to improve connectivity in their design?

Roberts: Look for an integrated solution that incorporates all control aspects into a single package for motion, logic control, and visualization. This integration allows for control and diagnostic possibilities not available with discrete components.
Naudziunas: Consider the labor involved in wiring a panel or piece of machinery. Adding connectivity can reduce production time. When using any type of connectivity, it's best to find a company that provides a solution, not simply a product.

On display: PP15 Power Panel The PP15 offers an additional panel with integrated I/O points for control, positioning, and visualization tasks. FEATURES & BENEFITS Available with 16 digital inputs and outputs or with four analog inputs and outputs, in addition to the eight original inputs and outputs Access additional decentralized I/O points via a CAN interface IP65-protected display, 4x20 character resolution, 16 function keys, and 12 LEDs B&R INDUSTRIAL AUTOMATION CORP. Roswell, Ga. (770) 772-0400 www.br-automation.com

On display: Cube67 The Cube67 flexible I/O system allows drives with integrated power electronics to be triggered directly, which is especially useful in conveyor technology. FEATURES & BENEFITS Local triggering eliminates need for additional fieldbus interfaces for the motor Motor feedback sent without extra cables All connections within the system are plugged MURRELEKTRONIK INC. Duluth, Ga. (888) 230-6877 www.murrinc.com