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In industrial manufacturing, the reliability of machines and equipment is paramount. Achieving high levels of machine flexibility, optimizing production processes, and ensuring remote serviceability are key performance parameters. However, accessing and interpreting data from sensors and actuators, which are essential for machine operation, can be challenging. This difficulty often leads to unexpected equipment failures and costly downtime, making the need for efficient and reliable power supplies a key focus for those in the industrial sector.

Efficiency, productivity, and reliability in manufacturing are gauged through various metrics. These include machine downtime and maintenance analytics, which are vital for operational efficiency and equipment effectiveness. Tracking and improving these metrics are essential for reducing machine downtime and maintaining a competitive edge.

Machine downtime refers to the timeframe during which a machine is not operational due to malfunctions, maintenance, or other issues. Reducing machine downtime is critical as it directly affects production capacity and efficiency. Similarly, machine maintenance and repair activities employ additional metrics to help monitor the status and effectiveness of the maintenance efforts. These metrics are critical for predictive and preventive maintenance strategies.

• Mean Time Between Failures (MTBF) represents the average time between equipment failures and is used to gauge reliability and predict performance. Higher MTBF indicates more reliable machinery.

• Mean Time to Repair (MTTR) measures the average time required to repair a machine or component after a failure. This is a critical metric for assessing the efficiency of the maintenance team. A lower MTTR value is indicative of faster recovery from breakdowns.

• Overall Equipment Effectiveness (OEE) combines availability, performance efficiency, and quality to provide an insight into the overall effectiveness of the equipment. OEE represents a comprehensive metric that reflects the percentage of manufacturing time that is truly productive.

By tracking and analyzing these metrics, manufacturers can obtain valuable insights into the operational aspects of their machinery and equipment, enabling proactive maintenance, informed decision-making, and continuous improvement in production processes. But achieving this is easier said than done; oftentimes, the siloed rigidity of manufacturing machines makes it practically impossible to adhere to the planned production schedule due to unscheduled downtime.

Well, that no longer must be the case, thanks to IO-Link.

IO-Link™ (IEC 61131-9) is a standardized global input/output technology that is part of the IEC 61131 family of standards. IO-Link is not a fieldbus nor a network protocol in the traditional sense; instead, IO-Link specifically focuses on single-drop digital communication interface (SDCI) for small sensors and actuators. IO-Link extends the traditional tried and tested three-wire digital input and digital output interface used by machine sensors and actuators into a low-level point-to-point communication link, allowing the transfer of parameters to sensors and actuators and the delivery of diagnostic information from those devices to the automation system.

IO-Link technology plays a pivotal role in improving equipment repairs and reducing maintenance costs, thanks in large part to its capability to provide detailed diagnostics that contribute to an increase in OEE. IO-Link facilitates the communication of crucial machine process data, including analog values and switching states. It also handles the transmission of configuration data, such as function activation and deactivation, along with identification data, like device manufacturer IDs.

Moreover, IO-Link allows for easy access to machine parameters, including sensitivity, switching thresholds, and diagnostics. This feature is particularly beneficial for maintenance personnel, enabling them to receive early warnings, such as when a power supply is at risk of tripping due to a voltage overload. Machine operators can proactively adjust the voltage setting while the machine is operational, ensuring that production continues without interruption. This capability not only guarantees greater equipment uptime but also enhances the overall utilization of the machine, making IO-Link a valuable tool in industrial settings.

Industrial systems require powerful and robust power supplies that offer not only reliable power outputs, but also maximum functionality features like adaptability and preventative functionality.

The Phoenix Contact QUINT POWER 4^th generation power supplies with IO-Link are engineered with adaptability, power, preventive awareness, and robustness (Figure 1).

Figure 1: The Phoenix Contact QUINT POWER 4^th generation power supplies with IO-Link are three-phase input devices with screw connection, DIN rail mounting, and an output of 24VDC / 20A (p/n 1151048) and 40A (p/n 1151047). (Source: Mouser Electronics)

These fourth-generation industrial power supplies offer maximum functionality and superior system availability through IO-Link and Selective Fuse Breaking (SFB) technology. QUINT power supplies feature the unique combination of preventive function monitoring and a robust power reserve in a compact size.

These powerfully communicative QUINT power supplies are ideally suited for ensuring the maximum availability of industrial and building automation systems and can be quickly and easily integrated or parameterized in your control environment using fieldbus or IO-Link.

• Adaptable: These power supplies are highly adaptable and designed to meet specific power requirements. They allow for easy output voltage adjustment, even for multiple devices, using NFC technology and QUINT POWER software. This feature simplifies the process of customizing settings like output voltage, reducing the risk of errors.

• Powerful: QUINT POWER supplies are distinguished by their powerful output characteristics—the strongest in the market. They maintain stable output voltage even under increased load conditions on account of features like static boost, which allows delivery of up to 25 percent more than nominal power. The dynamic boost feature can provide up to 200 percent of nominal power for short durations—up to five seconds—ensuring stability during high inrush currents from heavy loads.

• Preventive: By offering preventive monitoring capabilities, these power supplies allow maintenance personnel to monitor application load status directly from the device without additional instruments. They feature three signal contacts for comprehensive monitoring, including a bar graph display, and can adapt to increasing loads over time, offering an adjustable threshold for pre-warning signals to prevent overloads and potential downtimes.

• Robust: Designed to withstand both electrical and mechanical stress, these power supplies are equipped with a protection circuit, including a gas arrester and varistor, to safeguard against transient overvoltage. Their robust design extends to their metal housing and stainless steel cover, ensuring durability against mechanical stress.

The QUINT POWER supplies from Phoenix Contact, equipped with IO-Link and SFB technology, significantly enhance manufacturing efficiency, productivity, and equipment reliability. By offering advanced features like adaptability, powerful output characteristics, preventive monitoring, and robust construction, these power supplies greatly contribute to Overall Equipment Effectiveness, ensuring minimal downtime and optimal performance in industrial settings.

Sources:

Arnold, Nils. 2023. “Understanding Machine Downtime: A Key Factor in Manufacturing Efficiency.” ADTANCE, March 7, 2023. https://www.adtance.com/en/blog/2023/understanding-machine-downtime