Reduced cabling and installation costs
Factors such as simplified cabling and the number of interfaces required have a direct effect on the material and installation costs. Just the correct positioning and sizing of remote I/O systems in a decentralised architecture may already open up opportunities for achieving significant cost reductions in machine design.
Large applications often and quickly become very complex and inflexible, making it more difficult to scale the system architecture. If the machine is not designed and configured to be modular and easy to customise right from the outset, even small updates can require extensive intervention. And that, in turn, increases the long-term operating costs. Remote I/O systems that can be easily expanded and further developed can help increase the flexibility of complex applications. A well thought-out, decentralised architecture enables additional modules to be seamlessly integrated without needing extensive new adaptations. Fieldbus integration in common PLC systems such as PROFINET, Ethernet/IP or EtherCAT is of course a must. However, consistent and seamless interoperability between different communication protocols and field devices throughout the industrial network must also be guaranteed. A high number of IP addresses can also increase not only the complexity of the network, but also the administration effort and the probability of configuration errors.
The right remote I/O
The use of expensive fieldbus nodes in remote I/O systems should also be minimised. Solutions such as a standardised communication language at field level can help to reduce the number of fieldbus headers required without compromising the performance of the machine. Integrating IO-Link technology can also lead to a reduction in costs for machine design, as it is cheaper and is based on commonly used communication technologies that can be easily incorporated into existing system structures.
Combine the two worlds of electrics and pneumatics
Valve terminals can also be connected to the control system of your application. They enable the pneumatic functions to be controlled centrally. By combining several valves on a single unit, the space requirements are minimised and it simplifies installation. This also results in a reduction in material and installation costs. With the right remote I/O modules, you can position your valve terminals both centrally and decentrally in the space. Ideally, you should use a hybrid approach by combining both options and thus avoid the risk of oversizing and the associated costs.
A complete overview
Unforeseen downtimes and costly repairs are the biggest cost factors in running operations. Data monitoring is therefore an important topic. Predictive maintenance and real-time diagnostics allow potential problem areas to be recognised at an early stage before serious failures occur. Systematic monitoring and regular maintenance not only reduce operating costs, but also extend the service life of the machines.
