How industrial-grade Ethernet at the device level helps reduce downtime and improve operational safety and real-time information flow
The introduction of robots and automation equipment in the food and beverage industry has resulted in a wide range of safety, product quality, productivity and profitability. Advances in automated process control and robotics, sensors for automated quality and safety control, and equipment vision system development are leading a more sustainable food industry. However, the food and beverage industry is still lagging behind in introducing innovative factory floor networking technologies, and there are many things to do.
Several factors have prompted manufacturers and processors to adopt more cautious approaches to upgrading their automation systems, many of which have been using the same products for more than 20 years and are hesitant to upgrade to better solutions until their outdated equipment It is no longer available. Although the competition in this industry is fierce, compared with other industries, the impact of the global economic recession is small, so the willingness to make changes is not high. In addition, food and beverage manufacturers face some unique challenges that make it more difficult to implement new systems. These challenges include preventing product contamination, ensuring the safety of consumers and workers, environmental conditions such as temperature, humidity and vibration, stringent cleaning and rinsing steps, and compliance with local government regulations.
However, as manufacturers seek to improve operational efficiency and bottom line profits, they must adopt more advanced factory floor networking technologies.
Connectivity is critical
Some of the key components of these advanced automation systems are cables, connectors, and communication systems that unite everything. In many cases, hardwired solutions are still very common on the factory floor because they are cheaper. However, this method is extremely labor intensive, so the connection system must be easy to install, reliable and safe. Pre-wired wiring boxes save time and help prevent incorrect wiring for applications with high-density input and output connections. In both cases, robustness is critical to withstand the harsh environment of food and beverage plant floors, and electrical shorts due to moisture entering electrical and electronic equipment and devices are a top priority for food and beverage production lines.
Similarly, communication systems such as the open device-level control and information network system DeviceNet for industrial equipment; the standardized global open network communication system Profibus, and the popular industrial communication protocol Modbus, all need to be used in harsh environments. Cables, connectors and sockets for versatility, reliability and signal integrity.
Advantages of migrating to Ethernet
Ethernet was originally designed for use in an office environment, but as companies demanded real-time data from the factory floor and passed it back to the enterprise, Ethernet gained momentum in the factory floor. This is especially important in the food and beverage industry, which typically requires continuous monitoring of the production process to maximize normal production time and meet regulatory requirements. Industrial Ethernet often offers several unique advantages for companies that want to connect their plant floor equipment to a manufacturing enterprise network to gain a competitive advantage:
â— Access information in the enterprise to improve the level of enterprise intelligence
â— Faster data flow with faster data transfer speeds
â— Save costs by improving energy efficiency and resource management
â— Reduce plant downtime by enhancing equipment performance
â— Optimize device performance through collaborative monitoring and control
The main industrial Ethernet solutions are EtherNet/IP for industrial automation, process control applications, robotics, and standard management by Open Device Vendor AssociaTIon (ODVA); PROFINET is for advanced manufacturing and automation The open industrial Ethernet protocol, and Modbus TCP/IP is an extension of the popular Modbus protocol, which is widely used in industrial manufacturing environments. In any case, the underlying infrastructure, including cables, wire holders, switches, protocol stacks, interface cards, and I/O modules, must be very reliable to implement a successful industrial Ethernet network. If the manufacturer removes it from the cabinet and places it on the floor of the shop, it is equivalent to placing these vital components in an extremely harsh environment. General commercial products used in offices are not adequate for these conditions, so the selection of suitable and reliable cables and connectors is very important and is a key factor in maintaining the proper functioning of the shop floor.
Choose the right material for the harsh environment
The extremes of the food and beverage industry are the main reasons why companies are delaying the transfer of Ethernet from the office to the food and beverage factory floor. One of the biggest obstacles is the rinsing process, which is a key factor in preventing the negative effects of contaminants on product quality, but extremely high water temperatures and corrosive cleaning agents and disinfectants can easily damage sensitive electronic equipment. Another factor is the risk of rust and erosion, which can damage manufacturing processes or contaminate products. Finally, extreme temperatures, humidity, and vibration can affect the performance and reliability of your communications infrastructure.
By choosing the right product, food and beverage manufacturers can safely move to Industrial Ethernet. Some features to consider when evaluating different devices, components, and wiring options include:
â— Ingress ProtecTIon (IP) Rating: Rated IP is an international measure, the first number refers to the degree of protection of solid materials (such as dust particles), and the second number defines the degree of liquid protection. In many places on the food and beverage factory floor, an IP67 rating is acceptable, indicating that the product is dust-proof and protected against short-term immersion. However, it is ideal to achieve IP69K rating, indicating protection against dust and high temperature, high pressure water, suitable for occasions where the equipment must be carefully cleaned.
â—Stainless steel construction: The smooth surface of the 316 grade stainless steel joint system limits the area where bacteria can accumulate, helps prevent bacterial growth, and can withstand harsh chemicals and high water temperatures without rusting. In addition, the rugged overmolded cable housing is designed to withstand extreme temperatures and provide additional protection.
Push-to-lock technology: Connectors with a mechanical locking design provide a secure connection that is not available in the thread set. This inherent reliability reduces connector-related in the most demanding environments. Intermittent signal. Less intermittent signals mean shorter downtime and better productivity.
â— DIN Rail Mount/Machine Mount: By migrating Ethernet switches to plant floor equipment, manufacturers can save rack space, reduce cable costs and simplify installation. The heavy-duty enclosure provides protection against water and temperature changes, making it suitable for demanding industrial applications.
The well-thought-out Industrial Ethernet migration allows food and beverage companies to maintain legacy systems while developing innovative applications that support future business growth.
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