How Does Multi-Protocol Remote I/O Simplify Machine Control and Support OEE?

Simplifying machine control using remote I/O begins on the factory floor, extends through the control network, and ultimately reaches into the control cabinet and the Cloud. Consolidation is a key consideration and can be supported using multi-protocol I/O blocks.

Different protocols, such as Ethernet, IO-Link, and Modbus RTU, are optimized for specific applications. Instead of running individual cables for every machine, sensor, and actuator back to a central controller, remote multi-protocol I/O systems utilize a single network cable to aggregate data from multiple field devices that use different protocols. That consolidation significantly reduces wiring, lowers costs, and improves system flexibility, scalability, and maintenance.

The data aggregation supported by consolidation is also needed to simplify implementation of overall equipment effectiveness (OEE) calculations. OEE is a comprehensive measure of manufacturing process efficiency that combines availability, performance, and quality. OEE provides crucial data for making informed, data-driven decisions to optimize production processes, leading to lower costs, increased output, improved product quality, and enhanced profitability.

This article reviews how Banner Engineering multi-protocol blocks support remote I/O connectivity and OEE in the entire industrial network, from machines, sensors, and other field devices on the factory floor, all the way up to control cabinets and the Cloud.

Using OEE metrics can provide clear, data-driven insights into factory performance. This can result in improved productivity, reduced costs, enhanced quality, and more informed overall decision-making.

OEE is based on an elegant equation with powerful implications (Figure 1).

• Availability measures the percentage of planned production time with the time the equipment is running = actual run time / planned production time. If a machine was scheduled to run for 24 hours (1440 minutes) but only ran for 20 hours (1200 minutes) due to unscheduled stoppages, availability would be 1200/1440 = 83.3%.
• Performance measures the actual speed of production compared to the maximum rate = (maximum cycle time x total produced) / run time. If a machine has a maximum cycle time of 1 unit per minute and 1200 minutes of run time, and it produced only 1000 units, performance would be (1 min/unit x 1000 units) / 1200 min = 83.3%
• Quality measures the percentage of good units = good units / total units produced. For example, if a machine produced 1000 units, but 20 were scrapped or needed rework, the quality would be 980 / 1000 = 98%
• OEE = 83.3% (Availability) × 83.3% (Performance) × 98% (Quality) = 68.0%

Figure 1: The mathematics underlying OEE are simple, but the implications of OEE are deep and broad. (Image source: Banner Engineering)

Challenges for implementing OEE on the factory floor

Obtaining the necessary data to implement OEE can be challenging. Collecting accurate, real-time data from all machines is a key challenge. That can be especially true for older machines and islands of automation.

Manual data entry not only slows down data collection but can also result in data entry errors and inaccuracies, such as misclassifying downtime and defects, leading to incorrect or distorted OEE measurements.

Timely, accurate, and comprehensive data are keys to effectively implementing OEE programs. This extends beyond the factory floor and includes integration with existing systems, such as enterprise resource planning (ERP) or computerized maintenance management systems (CMMS), predictive maintenance programs, and other advanced Industry 4.0 systems. Remote I/O solutions, especially those including edge processing capabilities, can be a valuable tool for implementing OEE.

Remote I/O solutions

Remote I/O hubs position I/O modules closer to field devices, such as sensors and actuators, by connecting them to a controller via a single network bus. This reduces wiring costs, simplifies integration, and enhances higher availability.

Key network devices for supporting multiprotocol remote I/O solutions include multi-protocol Ethernet blocks, IO-Link masters, IO-Link hubs, and Modbus RTU I/O blocks, and more (Figure 2).

Figure 2: Examples of the many remote I/O configurations available from Banner Engineering. (Image source: Banner Engineering)

Several of these remote I/O devices have IP67 ratings for use in challenging industrial environments, and the masters and controllers include edge processing and data storage that can simplify integration into OEE applications. Examples include:

• Four independent Modbus master ports in the DXMR90-X1 can be used for connecting multiple devices and converting the Modbus data to common industrial Ethernet protocols like EtherNet/IP and PROFINET.
• Up to four IO-Link devices, such as sensors, hubs, and lighting, can be supported using the DXMR90-4K functions as a master and controller that features built-in protocol conversion to communicate with a wide variety of industrial control systems, including EtherNet/IP, PROFINET, Modbus/TCP, and Modbus RTU. For applications with up to eight IO-Link devices, designers can turn to the DXMR110-8K, which offers the same protocol conversion capabilities.
• Eight-port discrete I/Os can also be supported using the R95C-8B21-MQ that converts discrete signals from connected sensors and devices into the Modbus protocol.

Converters for connecting sensors are also critical. Legacy sensors with a 4-20 mA analog current output can be connected to an IO-Link network using the S15C-I-KQ inline converter. Sensors that produce discrete NPN or PNP outputs can use the S15C-B22-MQ inline converter for connection to a Modbus network.

Hubs can be used to consolidate signals on the factory floor. The R90C-4B21-KQ is a 4-port discrete IO-Link hub that can connect non-IO-Link discrete devices into an IO-Link system, consolidating and transmitting their signals to an IO-Link Master. It has IP ratings of IP65, IP67, and IP68.

In-cabinet IO-Link hubs

In-cabinet IO-Link hubs offer another powerful and cost-effective tool for implementing OEE, enhancing data collection, minimizing downtime, and simplifying maintenance. By centralizing multiple discrete and analog sensors, the hubs streamline wiring and enable direct, real-time access to the detailed performance and diagnostic data required to implement OEE.

When in-cabinet IO-Link hubs are needed, designers can turn to Banner’s IC70 series. These hubs simplify the integration of individual sensors and actuators into a control system, eliminating the need for additional I/O modules.

Integrated delay modes and port monitoring can implement basic logic functions without relying on the system’s programmable logic controller (PLC), thereby speeding up setup and simplifying programming. The status LEDs support real-time diagnostics, ensuring fast and accurate troubleshooting and minimizing downtime.

Model IC70-16P-K (Figure 3) is designed for PNP devices, while the IC70-16N-K is designed for NPN devices. Both feature 16 channels, have an IP20 environmental rating suitable for use in control cabinets, and can be mounted on a standard 35 mm DIN rail.

Figure 3: This in-cabinet IO-Link hub is rated for IP20 and can connect up to 16 PNP devices. (Image source: Banner Engineering)

Wireless connectivity and OEE

Wireless connections to the control cabinet and the Cloud can be critical when implementing OEE. By eliminating the limitations of wired systems, wireless connectivity can increase operational flexibility, scalability, and efficiency.

Banner offers wireless I/O solutions that accommodate various automation protocols, including Modbus/TCP, Modbus RTU, and EtherNet/IP for communications between PLCs, HMIs, or other local hosts. These wireless controllers can interface with local serial ports, local I/O ports, and local ISM radio devices, and connect them to the Internet using a cellular connection or a wired Ethernet network connection.

The DXM700-B1 and DXM1200-B2R1 controllers both offer wireless communication using Banner’s Sure Cross DX80 Wireless Gateway or MultiHop radio with 900 MHz or 2.4 GHz ISM bands available for long-range communication. They have industry-standard RS-485, Ethernet, and USB communication ports.

Both include an internal logic controller with action rules and ScriptBasic programming capable of developing simple or complex solutions to process, log, and control data to/from multiple wireless radios and sensors. They also feature integrated, programmable LDC screens and LED indicator lights (Figure 4).

Figure 4: DXM1200-B2 controller (left) and DXM700-B1 Controller (right). (Image source: Banner Engineering)

Both controllers can connect to cloud services, such as Banner's Connected Data Solutions (CDS), for data visualization and analysis, and utilize a 300 MHz M7 processor with 16 MB of onboard memory. They can send email and text message alerts, support data logging to an external microSD card (up to 8GB), and both operate on the same 12 V_DC to 30 V_DC power supply.

The key differences lie in their application environments. The DXM700 features an IP20-rated housing, providing moderate protection for indoor installations, and utilizes DIN rail mounting. The DXM1200 features an IP67-rated enclosure, providing robust protection against dust and water, and is suitable for harsh outdoor conditions, allowing for panel or wall mounting.

They also have different Ethernet connections. The DXM700 has an RJ45 jack and uses a standard Ethernet cable. The DXM1200 has a more robust, industrial-grade M12 (D-code) connector designed to withstand vibration and environmental stress.

Conclusion

Banner Engineering multi-protocol remote I/O masters and controllers, particularly the DXMR wired series and DXM wireless solutions, include edge processing capabilities that allows them to consolidate and process data locally, which is crucial for implementing OEE and other Industrial Internet of Things (IIoT) applications. Banner also offers inline protocol converters and in-cabinet IO-Link hubs that simplify wiring, enable remote configuration and monitoring, and reduce costs. They allow for efficient integration of both legacy and modern devices.

Recommended reading:

1. How to Rapidly Design and Deploy Smart Machine Vision Systems
2. How to Design a Modular Overlay Network for Industry 4.0 Data Processing Optimization in the IIoT
3. Optimizing Industry 4.0 Communication Architectures using Multi-Protocol I/O Hubs and Converters
4. Using Cybersecure PLCs with Integrated Safety for High-Speed Industrial Automation
5. How Multi-Sensor Asset Monitoring Can Improve Performance in Industry 4.0 Factories and Logistics and in Datacenters