憑藉該解決方案，機器製造商可基於自動化平台，簡單、模組化地調整或擴展其未來的設計，而不需變更原有結構。 歸功於模組化，通常可在硬體方面節省 5 % 的投入。
最近，一家機器製造商將CPX-AP-I 整合到其用於塑膠板材精加工的機器設計中。 這些零件多為預成型、相對狹長的零件，其上的切口透過沖壓加工而成。 這些操作透過氣動方式完成。 由於各種板材厚度不一，有時還由不同的塑膠製成，而且形狀各異，因此必須針對每種產品及每個切口調整所需的氣動壓力。 最初，他們採用由 PLC 直接控制的比例壓力調節閥。
從集中到分散
機器在氣動沖壓單元的集中控制設計方面曾存在一些不足。 八個比例壓力閥被直接整合到控制櫃內的中央閥島上。 四個沖壓動作在距該閥島相對較短的距離內（ 3 至 5 公尺）進行，另外四個沖壓動作則在機器的對側進行。 對於這四個沖壓單元，需要從控制櫃引出並舖設長度為 10 至 12 公尺的纜線和氣管。 除了較高的材料和安裝成本之外，這也會導致對後部四個沖壓單元的控制精度下降，並使循環時間更長。
這家機械製造商接到四台同型機器的訂單時，便向其技術合作夥伴 Festo 諮詢，瞭解新技術所能提供的可行方案。 更快、更好、更耐用、更便宜？ 在討論過程中，提出將新的 CPX-AP-I 做為對沖壓單元進行分散式控制的可行方案，同時也確保機器能夠「面向未來」。 然而，優勢遠不止於此。
分散式 I/O 系統
為了能夠理解這些優勢，我們首先需要弄清楚 CPX-AP-I 究竟是什麼。 這是一種新型 I/O 系統，專為在現場直接連接大量 I/O 模組和閥島而設計。 該系統可透過最常見的現場匯流排輕鬆整合到主要 PLC 系統中，而無需為單個元件配備現場匯流排節點。 也可整合 IO-Link®，從而方便地連接 I/O-Link 元件，帶來相關的優勢。
下圖顯示此類系統的結構。
This shows that valve terminals and I/O link masters can be integrated directly into the master control system (PLC) regardless of the industrial automation network used. So both pneumatic and electrical modules and with support for all known field buses. In other words, it is no longer necessary to link/ integrate valve terminals via an IO-link master; they can be controlled directly via the AP bus, which improves performance in terms of reliability and efficiency. In addition, this means a saving in the number of bus nodes or components.
Modular structure in a familiar environment
The CPX AP-I offers the possibility of a modular, and therefore easily scalable, design. Adding or removing functionalities, modules or otherwise is possible without the need to modify the existing topology. Changing the bus system is also possible by only modifying the bus node. The Bill of Materials (BOM) and control architecture are fully retained. Furthermore, the machine builder can continue to program in his familiar environment and is in no way affected by the fact that the I/O system works with a proprietary bus system. In terms of numbers, he is certainly not limited, since up to 500 modules can be linked in line, star and tree topology.
Ready for digitisation in the age of Industry 4.0
In addition to the fact that the CPX AP-I can easily integrate components, it also offers the possibility of sending data to the cloud. This is a typical feature that fits into Smart Industry and fully automated Smart Factories. It means that a wide range of data, for example short circuits, IO-link events, number of circuits, cable quality, temperature, voltage, operating hours, etc., can be collected centrally. This data can then be analysed and converted into valuable information in the context of optimisation, cost calculations or, for example, 'smart maintenance'. It makes it possible to monitor various modules and the channels and to give an alarm in time if things threaten to go wrong. Moreover, it enables efficient maintenance planning and steps towards predictive maintenance.
Applied in practice
The machine builder who started this story switched to the CPX AP-I on Festo's recommendation and has now literally seen the benefits with his own eyes. Due to the decentralised design, the group of eight proportional pressure regulators is now divided into two groups of four. The second group is placed on the other side of the machine and is therefore much closer to the punching units. This ultimately saved so much installation time and material that a cost saving of 5% was achieved when four machines were built. He was also able to offer his customer lightning-fast communication for all modules that do not use IO-Link. The figures of 200 MBaud and cycle times of up to 250 µs are impressive. Because two separate cables are used for communication and power supply, he also has the option of working with voltage zones if necessary. Finally, he was relieved that his existing topology could be fully retained. He can easily integrate valve terminals without the need for additional bus nodes or IO-Link masters. The number of interface modules is also limited due to the large number of components that can be linked to a bus module.
Ready for the future
The machines have now been delivered and are running satisfactorily. So well, in fact, that the machine builder has elevated the new remote I/O system to the standard for all new machines that will be developed and built in the future. Only when customers explicitly come up with different specs, will other systems be used. Whether these are for the automotive industry, packaging machines or otherwise. This is what we need" was the final verdict of the (happy) machine builder.