Reduced costs for cabling and installation
Factors such as simplified cabling and the number of interfaces required have a direct influence on the material and installation costs. By correctly placing and dimensioning remote I/O systems in a decentralized architecture, it may already be possible to achieve a significant cost reduction in machine design.
Large applications often and quickly become very complex and inflexible. This makes the scalability of the system architecture more difficult. If the user does not design the configuration for modularity and simple adaptation from the outset, even small updates can require extensive intervention. This in turn increases the long-term operating costs. Expandable and growing remote I/O systems can help to increase the flexibility of complex applications. A well thought-out, decentralized architecture enables the seamless integration of additional modules without extensive new adaptations. Fieldbus integration in common PLC systems such as PROFINET, EtherNet/IP or EtherCAT is of course a must. However, consistent, 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 likelihood of configuration errors.
The right remote I/O
The use of expensive bus nodes in remote I/O systems should also be minimized. Solutions such as a standardized communication language at field level can help to reduce the number of fieldbus headers required without compromising the performance of the machine. The integration of IO-Link technology can also lead to a reduction in costs in machine design, as it is cheaper and is based on basic communication technologies that can be easily integrated 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. Valve terminals enable centralized control of pneumatic functions. The consolidation of valves in a single unit minimizes space requirements and simplifies installation. This leads to 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 room. Ideally, you should combine both options to create a hybrid approach and thus avoid the risk of oversizing and the associated costs.
Everything in view at all times
Unforeseen downtimes and costly repairs are the biggest cost factor in ongoing operations. Data monitoring is therefore an important issue. Predictive maintenance and real-time diagnostics allow potential problem areas to be identified 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.
