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Designing a modular overlay network for data processing optimisation in the IIoT

Paige West

Data processing optimisation in Industry 4.0 and the Industrial Internet of Things (IIoT) systems to support lean manufacturing can be accomplished through condition monitoring, predictive maintenance, overall equipment effectiveness (OEE) analysis and tracking, diagnostics, and troubleshooting.

The problem in many instances is that legacy equipment was either not designed to be connected or may use any of a number of a variety of communications protocols, making it expensive to replace them all. To ensure maximum effectiveness and obtain actionable machine data, it’s simpler and more cost-effective in many instances to implement an overlay network that can connect existing automation islands and legacy equipment.

Designing such an overlay network is a challenging undertaking. It requires a controller that can receive signals from sensors and other devices that use a variety of communications protocols, combine those signals into a unified stream of useable data, and export that data to edge computing resources or the cloud. The system needs adapters that can connect directly to sensors, indicators, and other devices. Converters are needed to connect previously incompatible device types, including legacy equipment.

In addition, to ensure reliable operation, filters are required to protect data communications from electrical noise and transients. All of these components should meet IP65, IP67, and IP68 environmental standards for operation in industrial settings, and the solution needs to be easy and cost-effective to implement.

This article briefly discusses the problems of connecting legacy equipment to the IIoT. It then introduces the architecture of the Snap Signal family of hardware and software tools from Banner Engineering and how it addresses those challenges. It presents examples of Snap Signal devices including the DXMR90 controller, associated converters, adapters and filters, as well as application considerations when implementing wired and wireless edge computing or cloud connectivity.

Connecting legacy equipment to the IIoT

Many factories predate the appearance of the IIoT and Industry 4.0, and it’s often not possible to interconnect all of the equipment and machines into a single network, resulting in islands of automation. Even if not isolated on an ‘island,’ legacy equipment can be difficult to interconnect as a result of inflexibility arising from the use of proprietary communication protocols, non-standard connectors and cabling, and other factors.

Figure 1: A Snap Signal overlay network provides a modular architecture to connect legacy equipment and islands of automation with edge or cloud computing resources. (Image source: Banner Engineering)

A Snap Signal IIoT overlay network can provide a quick, flexible, and cost-effective way to connect legacy equipment and islands of automation by capturing and converting various non-compatible data communications protocols into an easy to distribute standard, able to be delivered to edge or cloud compute resources for analysis and action (Figure 1).

There are several key components needed to deploy flexible and reliable IIoT overlay networks:

Figure 2: Consolidated data can be transmitted with a wired or wireless connection to edge computing resources or to the cloud such as Banner’s CDS (screenshot above). (Image source: Banner Engineering)

Controller for consolidating multiple data streams

The programmable controller and data converters are key elements in designing an overlay network. The DXMR90 industrial controller from Banner serves as the central communications hub that combines signals from multiple Modbus ports into a unified data stream that is forwarded using industrial Ethernet protocols. For example, the model DXMR90-X1 includes four Modbus masters and supports concurrent communication with up to four serial networks (Figure 3).

Figure 3: Ports on the DXMR90 include a configurable Modbus port 0 (on the left side), Modbus master ports (1 to 4 on the bottom), configurable Modbus port 0/PW for RS-485 and incoming power (top right), and a D-coded Ethernet port (bottom right). (Image source: Banner Engineering)

The DXMR90 is a highly integrated communications controller that features:

Converters connect devices in IIoT networks

Efficient data conversion is needed to blend legacy equipment and islands of automation into an overlay network. For this function, designers can use Banner’s small plug-on S15C series in-line converters to convert condition monitoring and process-sensor data from a variety of formats into digital IO-Link data (Figure 4). For example, the S15C-MGN-KQ is a Modbus master to IO-Link device converter that is user-configurable to read up to 60 registers and write up to 15, with predefined Modbus registers automatically sent over IO-Link.

Figure 4: The S15C series in-line data converters can convert various types of signals including discrete, analog, and others to industrial protocols like Modbus, IO-Link, PWM and PFM. (Image source: Banner Engineering)

S15C converters measure 15 millimetres (mm) in diameter with an over-moulded IP68 housing and M12 connectivity, and they use the same power supply as the connected device. Use of S15C converters eliminates the 20-metre (m) IO-Link communication limitation since they can be installed at the end of a Modbus link, near the IO-Link master.

The S15C line of converters includes eight models:

Wiring adapters and filters complete the network

In addition to a controller and data converters, designers need wiring adapters and noise filters to quickly deploy flexible and cost-effective overlay networks. In-line wiring adapters, such as Banner’s S15A-F14325-M14325-Q, connect directly to a sensor, indicator, or other device to redirect wiring and isolate signals as needed to match specific application needs (Figure 5). These wiring adapters are available in standard and custom configurations.

Figure 5: S15A adapters such as the S15A-F14325-M14325-Q use an M12 connection for easy installation and can reroute wiring as needed to match specific application requirements. (Image source: Banner Engineering)

S15F in-line filters like the S15F-L-4000-Q are also important elements in an overlay network (Figure 6). They can easily solve challenges with electrical noise and transient voltages that can negatively affect network performance. Like the S15A adapters and S15C converters, these filters have M12 connections and are packaged in an over-moulded configuration that meets IP65, IP67, and IP68 standards. Installation of an S15F in-line filter can result in improved signal integrity and less need for network troubleshooting.

Figure 6: S15F in-line filters like the S15F-L-4000-Q can be readily used to protect devices from electrical noise and transients, and their M12 connection makes for easy installation wherever needed in the network. (Image source: Banner Engineering)

Snap signal network design and deployment

The design and deployment of a Snap Signal overlay network begins with the identification of the data sources to be monitored. It then needs to be determined if any new sensors or indicators should be added to supplement existing devices. Steps in the design of a Snap Signal network include:

Snap Signal is a true overlay network and does not require the replacement of any existing hardware. The modular plug-and-play Snap Signal architecture makes installation easy:

Conclusion

Overlay IIoT networks can support designers needs to connect legacy equipment and islands of automation into industrial networks enabling the collection of actionable data to support increased productivity across existing factories. The design and implementation of such an overlay network is complex, but as shown, it can be greatly simplified using Banner Engineering’s topology and Snap Signal line. The line includes the DXMR90 industrial controller, data converters, wiring adapters, filters and other elements needed to implement an IIoT overlay network and distribute it to edge computing resources or to the cloud. The programmable, modular, and flexible design of the Snap Signal network architecture supports the addition of new devices and future proofs the installation.

Original source: https://www.digikey.com/en/articles/how-to-design-a-modular-overlay-network-for-industry-4-0-data-processing-optimization-in-the-iiot