Taking control voltage distribution to a new level Innovative ideas for panel building

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Weidmüller Information & News | No. 19

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Rock stars aren’t always showyRockStar® ModuPlug offers more for less

Wanted – a complete solution for small wind turbines Found – an automation partner

More best connections insideLet’s connect.

WIN !

Dear readers

P 

anel confi guration and assembly are the core areas of expertise for many of our customers. On a daily basis, they focus on fi nding effi cient ways of achie-ving the required functions, the ideal integration

into the corresponding systems, the timely commissioning of the system and much more besides. Their success is evidence of the perfect intermeshing of all the process steps. The better the basic planning, the more seamless the sub-sequent operation will be. In this respect, digitalisation and automation are playing an increasingly important role.

How do we as a component manufacturer fi gure in the game? The answer is: At all stages and right from the start!

“Data consistency” is the magic word that links the planning, installation and operational phases of the panel building. The intelligent parts data in our “Weidmüller Confi gurator” soft-ware gives panel builders extensive support during project management and can be fully integrated in all commonly-used engineering tools. Complete data transparency and availability across all stages of the process is a basic pre-requisite for implementing Industry 4.0 in panel building ope-rations of the future. Starting with the product selection and the creation of a virtual prototype through to the automated production and installation, end-to-end available data models are a cornerstone of digital production.

In the current edition of WIN!, you can read how Industry 4.0 is becoming ever more relevant for us, whether this is in relation to panel engineering, to device-independent programming or to application-specifi c condition monitoring solutions for wind energy. Sources of inspiration on this and other topics are also available, in addition to reading our customer magazine, from visiting SPS IPC Drives, where you will fi nd us in booth B 351 in hall 9.

I hope you fi nd this issue stimulating and enjoy reading it.

Let’s connect.Kind regards,

José Carlos Álvarez TobarChief Sales and Marketing Offi cer

| Editorial2

Discover: PV on TVWhat is behind Goldbeck’s biggest photovoltaic project to date? And what is Weidmüller’s contribu-tion to the long-term success of the system? A documentary on the Discovery Channel provides answers to these questions.

Sandridge, England, early morning. The project team from Goldbeck and Weid-müller gather with the camera crew at the 50 megawatt photovoltaic park.

And right on cue, after just a short time, the sun’s rays break through pre-viously cloudy sky. Under perfect light and weather conditions, a fascinating documentary is fi lmed including the background, details and interviews about the renewable power generation plant.

The result will be shown on Discovery Channel in December. Under sparkling blue skies, Stuart Roper, Weidmüller UK Industry

Development Manager and the team of experts from Weidmüller and Goldbeck report on the successful “Sandridge” project.

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In BriefNews and trendsThe latest information about products, services and events

In FocusTaking control voltage distribution to a new level Huge space savings and reduced cabling work when powering operating equipment – Weidmüller delivers on this promise with Klippon® Connect.

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In ActionDistributed safety, compactly bundledWith u-remote, Zink KÖRNER was able to construct a compact safety I/O solution with integrated cooperation.

Wanted – a complete solutionWith Weidmüller as their automation partner, S4E considerably speeds up the engineering and commissioning work required for their small wind turbines.

In DetailGoodbye, platform-independent programmingWeb-based engineering is already allowing for innovative solutions for the industrial automa-tion of the future.

Rock stars aren’t always showyRockStar® ModuPlug solves space problems by offering increased functionality with a reduced installation space, which in turn also helps keep the weight down.

Act instead of reactBLADEcontrol® increases revenue and reduces cost risks thanks to continual rotor blade monitoring and ice detection.

More power, more profi tMaximum cost effectiveness with the highest quality and performance – Weidmüller meets these requirements with its 1,500 V generator combiner boxes.

Imprint

Editor Weidmüller Interface GmbH & Co. KG,Global Market Communication, Klingenbergstraße 16,32758 Detmold, GermanyEditorial offi ce Julia BusseLayout Mipe Media Design StudioContact win@weidmueller.dePictures Weidmüller Group, Zink KÖRNER GmbH (p. 12 + 13), © Monty Rakusen/Getty Images (p. 15)

© 2016 by Weidmüller Interface GmbH & Co. KG.Reproduction and publication, in full or in part, onlyallowed with express permission by the Editor.

The next print edition of WIN! will be appearingin April 2017.

3Content |

WIN! on the web and as a newsletterThe online version of our customer magazine WIN! keeps youregularly updated with news and stories from the world ofIndustrial Connectivity:▶ www.weidmueller.com/win

You can also register therefor the WIN! newsletter, whichprovides you with the latestarticles four times a year.

Top supplier of plug-in connectors in the USAWeidmüller returned excellent results in the customer satisfac-tion fi ndings of the Bishop Reports 2016.

Bishop & Associates Inc, the research organisation that specialises in the glo-bal market for electronic connectivity technology, has published the fi ndings of its 2016 survey of the US American connector industry. Weidmüller came in fourth in the “Best Overall Perfor-mance” category, thereby demonstra-ting the customer-centric nature of its connector portfolio.

Some 400 participants, of which 46 % were engineers and 57 % manufactu-rers of electronic components, evalu-ated a total of 52 manufacturers. The ranking list for the best overall result

was determined through 11 questions covering areas such as product quality, price competitiveness and lead times.

“We were particularly happy with the result because it refl ects the opinion of our partners, our customers and our users”, reports Dennis Kräft, Device Connectivity Business Unit Manager at Weidmüller. “It is a great confi rmation of the fact that we take the demands of our customers very seriously when we are developing our products and solutions.”

Best climate with the right connection systemFast and safe with worldwide application: the Power and Signal connectors from the OMNIMATE product range fully demonstrate their strengths in Blue e+, the new generation of cooling equipment from enclosure expert Rittal.

“A prerequisite for the fl exible opera-tion of our equipment in all standard networks around the world was com-pliance with international regulations such as UL and CSA,” explains Jörg Knetsch, project manager for research and development at Rittal, a leading provider of enclosure air conditioning.

The components used need to meet both device-specifi c requirements and

adhere to international regulations. This is why Rittal relies on Weidmüller for the selection and de-sign of the connection system used in its air conditioning units with an input voltage range of 110 V (single-phase) to 480 V (three-phase). A solution based on the OMNIMATE Signal and Power connectors BLF/SL-SMT 5.08 HC and BVF/SVF 7.62 HP made from the specially developed material Wemid enabled all the relevant stan-dards to be met, such as IEC 60335-1.

Read the complete story online: ▶ www.weidmueller.com/win-rittal

BVF 7.62HP impresses with its one-handed operation and automatic latching. The powerful panel feed-through terminal block SVF 7.62HP can even cope with thick enclosure walls

Monitoring relays extend the ACT20 familyAfter the ACT20M with a 6 mm width, the ACT20X for intrinsically safe applications and the ACT20C for commu-nication-enabled applica-tions, the ACT20P monitoring relays have now extended the ACT20 family.

Thanks to its universal power supply and its global approvals, the new ACT20P monitoring relay can be used uniformly in many different applications for limit monitoring. The products are characterised by their wide range of alarm functions, high repeat accuracy and measurement sensitivity, absolute reliability and simple operation. And the best thing about the innovation is that users only need one product to cover their limit monitoring needs.

4 | In Brief

Pulling togetherWeidmüller and HUBER+SUHNER are bundling their competencies in the area of interface and cabling solutions for rail vehicles. In this way, both partners are using the potential for synergies that their complementary product portfolios offer.

“Modern applications are being rushed to market so that train operators can fulfil the demands for operating effici-ency and safety as well as for pas-senger comfort,” says Alum Thomas, Market Unit Manager Railway from HUBER+SUHNER. “We have found the right partner with Weidmüller, in order

to be able to develop globally innova-tive solutions for ever more complex systems.”

The strategic cooperation with HUBER+SUHNER, the Swiss market leader for railway cable, is based around cabling solutions for rail vehic-les. The global offering includes cable sets consisting of cables and plug-in connectors as well as complete sys-tems for the connection of power, sig-nals and data. Weidmüller delivers the technical know-how for the connectors, HUBER+SUHNER delivers an extensive cable portfolio. In this way, the two specialists in electrical connectivity

offer railway industry customers well thought out complete solutions and a comprehensive range of complementa-ry services.

“We are very optimistic when it comes to our perspectives in the area of railway engineering,” reports Dirk van Vinckenroye, Executive VP Industry Automation & Solutions. “Together, we are striving to deliver high quality and reliable products and processes. The collaboration with HUBER+SUHNER enables us to offer our customers even more solutions in this demanding segment.”

New strategic partners in the railway sector (from left): Dirk van Vinckenroye, Executive VP Industry Automation & Solutions at Weidmüller; Drew Nixon, Chief Operating Officer Global Sales at HUBER+SUHNER; Detmar Saalmann, Global Industry Development Manager Transportation at Weidmüller and Patrick Riederer, Chief Operating Officer Low Fre-quency at HUBER+SUHNER at InnoTrans 2016 in Berlin

5In Brief |

Successful at the world’s leading exhibition for wind energyWeidmüller showcases its automa-tion solution for small wind turbi-nes for the first time in Hamburg.

More than 65,000 m2 of exhibition space, upwards of 1,200 exhibitors presented their products and services at this year’s WindEnergy Hamburg.

turbines attracted a lot of interest to Weidmüller’s booth.The offering covers hardware, soft-ware, engineering for the tower and the nacelle together with services and provides the platform for further appli-cations such as the area of megawatt farms.

Read how the real-life automation solution impressed the visitors, on pages 18-19.

Steffen Niggemann (left) and Daniel Müther from the Weidmüller Exhibition team are delighted by the good visitor reaction at WindEnergy Hamburg

Weidmüller is strengthening its ac-tivities in the wind-energy sector by its takeover of the company that will now be operating under the name of “Weidmüller Monito-ring Systems GmbH”.

German Designer Award: Weidmüller Industry 4.0 Cockpit didn’t just impress visitors to the Hannover Messe, it also stood out through the quality of its design.

The Industry 4.0 Cockpit that we show-cased at the Hannover Messe 2016 was a demonstration of the central controls for a production facility of the future. The visually ambitious sample application clearly attracted the atten-tion of visitors to the stand.

“Industrial Analytics, Cloud Services, Energy Management, Digitalisation and Networking along with Data Consis-tency were all exhibited as bundled application areas. This was linked to a range of networked applications and demonstrators, which the visitors could access via displays on the Industry 4.0 cockpit,” explains Stefan Kühn, who

The merger extends Weidmüller’s so-lution portfolio in respect of Condition Monitoring Technologies for wind po-wer installations. These systems, under the BLADEcontrol® brand, monitor the condition of rotor blades in particular

and include, for example, the possibility of detecting ice build-up on the blades.

“We were impressed by the company, as it is both a pioneer and a market leader in the fi eld of detecting damage to rotor blades in wind power installa-tions. We won’t just benefi t from the innovative technology, but also from the expertise of our new colleagues too,” added Jörg Timmermann, Chief Financial Offi cer of the Weidmüller Group and responsible for mergers and acquisitions.

Read about how BLADEcontrol® ensures economical wind energy generation on pages 20 and 21.

Weidmüller Group acquires Bosch Rexroth Monitoring Systems

After signing the contract in Detmold (from the left): Ulrich Haag, Stefan Frühauf (both from the Bosch Group) together with Dirk van Vinckenroye, Jörg Timmermann and Jochen Rafalzik (all from the Weidmüller Group)

Designer industrial networking

was the Market Communications Ma-nager supporting the project.

The award of this year’s German Design Award underlined the fact that the Industry 4.0 Cockpit was not only informative but that it also had out-standing design qualities. Annually, the German Design Council evaluates high-quality submissions from the world of Product and Communication Design that all in their way, are trend-setters on

the international design landscape. The jury, made up of international experts in their fi eld, gave the Weidmüller exhi-bition appearance a “Special Mention” award in the Fair and Exhibition catego-ry. This confi rmed that Weidmüller had very successfully risen to the particular challenge of incorporating demanding into an excellent design.

The Industry 4.0 Cockpit with its intelligent design brought networking to life for the visitors to this year’s Hannover Messe

6 | In Brief

A virtual journey through Norwegian fjords: Traffi c engineering expert Detmar Saalmann from Weidmüller tests a ship simulator

Increasing globalisation impacts rapidly growing transport of persons and goods between continents. More and more ships are being built and de-ployed to handle the increased volu-

me of transport. And this means that a higher level of automation and the deployment of high-tech on board has become essential. “Weidmüller supports shipbuilding with a global sales network and tailored solutions for connections and signals on board”, exp-lains Detmar Saalmann, Global Industry Development Manager Transportation at Weidmüller. “We are made aware of current trends and developments through our closeness to our custo-mers. So in June of this year, we organi-sed a roadshow that took us the length and breadth of Norway to meet with our partners and exchange ideas and experiences. It was a win-win situation for both sides.”

PROtop is the power supply of choice when it comes to reliability, service life and energy effi ciency.

High-end power supplies must per-form effi ciently and reliably, even in challenging industrial environments.

Innovative power supplythe most demanding of applications

High power reserves, long service life and optimal protection against surge voltages, vibrations and extreme tempe-rature conditions are all a requirement.

PROtop benefi ts from unique pulse energy reserves thanks to new DCL

On the roadWeidmüller engages in dialogue with partners in Norway about cur-rent developments and solutions for the shipbuilding industry as part of a roadshow.

choice when it comes to reliability, service life and energy effi ciency.

High-end power supplies must per-form effi ciently and reliably, even in challenging industrial environments.

and optimal protection against surge voltages, vibrations and extreme tempe-rature conditions are all a requirement.

PROtop benefi ts from unique pulse energy reserves thanks to new DCL

7In Brief |

technology. Ideal for reliable pulse triggering of circuit breakers or as an additional energy supply for powerful motor starts.

Taking control voltage distribution to a new levelCombined load monitoring and potential distribution

looking into as part of a large-scale pro-ject. Together with research partners such as the Heinz Nixdorf Institute, Weidmüller carried out a complete deconstruction of the value chains in-volved in panel construction, and broke

them down into their individual steps. As part of the project, users from the fi eld of machinery and plant enginee-ring, the energy sector and the process and railway industries were visited, and research was carried out into the pre-

Huge space savings and reduced cabling work when powering operating equipment – Weidmüller delivers on this promise with Klippon® Connect. Tailor-made potential distributor terminal blocks and a modular concept with integrated electronic load monitoring add real added value at all stages of panel building. The web-based Weidmüller Confi gurator makes the confi guration and request process a great deal easier.

W hat effi ciency potential is revealed during the process from the planning of a panel through to its

integration in ongoing operation? This is the question that Weidmüller was

distribution to a new levelCombined load monitoring

Weidmüller’s new PUSH IN terminal blocks with practical features as well as tailor-made solutions for identifi ed panel applications are the result of a broad market analysis

8 | In Focus

Planning Installation

Operation

cise nature of the processes related to panel building, and how exactly these panels are used on site. As a result of this research, a number of recurring customer problems emerged – or from

Weidmüller’s perspective, potential for more added value at all sta-

ges of panel building.

“One of the identifi ed customer problems

that we have been working on in-

tensively relates to having an optimal power supply for consumers in the panel,” explains Pro-duct Mana-ger Wolfgang Weltermann. “Up until now, this was

something that had to be set up

by users themsel-ves, but we have

now solved this problem by develo-

ping specially adapted application products for

surge current protection and structured distribution within the

limits of control voltage circuits.”

More control parts, less space

With rising numbers of control func-tions and increasingly complex machi-nes, the number of components nee-ding to be supplied with power in the panel is also increasing. At the same time, system designers are demanding increasingly small dimensions from their panel builders, such as in the case of localised control boxes designed for inconspicuous incorporation into the system design.

“The installation width of the necessary control parts is something that can’t be compromised on, meaning that users are keen to make space savings

with the terminal blocks. This results in complex structures that are diffi cult to retrofi t and that offer barely any fl exibi-lity,” says Weltermann, referring to his own practical experience. “In light of this, we developed a solution designed specially for applications where space is tight, allowing for unprecedented levels of clarity. The new concept invol-ves central potential distribution with the option of direct cabling for all of the positive and negative potentials of the various devices.”

Up to 50 % space savings on the terminal rail

Up until now, terminal blocks for potential distribution and electronic load monitoring were always installed separately. In the new maxGUARD sys-tem, the two terminal blocks are both integrated into a single 24-V control voltage distribution system. This combi-nation, which is currently unique on the market, saves time during installation, increases safety against failure and reduces the amount of space required on the terminal rail by up to 50 %.

The wide range of single and multi-channel variants and the large number of different potential distribution termi-nals and additional components mean that it is always possible to create a customised solution. Less cabling work is required between the load monito-ring and potential distribution terminals thanks to the unique cross-connectors, and the specially developed ope-rating, testing and connec-tion elements allow for safe access to all voltage potentials

and load circuits during commissioning and maintenance.

“During the market analysis, we had a real lightbulb moment in relation to the issue of checking and testing, and we recognised that there is a major backlog in this area,” says Weltermann. “Our solution: uniform, integrated test connections designed to speed up error analysis. All new products within our updated Klippon® Connect terminal block range are now fi tted with this feature. In the case of maxGUARD, the potential distributors also have practical disconnecting levers for simple galvanic isolation of the load circuit for testing and checking purpose.”

If the customer wants just potential dis-tribution without electronic protection, Weidmüller’s Klippon® Connect appli-cation products AAP are the perfect solution. The modular system with two cross-connection channels can be com-bined to create a clear block solution, and the coloured pushers designed to help distinguish between the potentials help to prevent incorrect wiring and reduce time and costs. Maintenance and modifi cation task are particularly easy thanks to the clear assignment and marking of the contact points, while the AAP’s alternating structure

this research, a number of recurring customer problems emerged – or from

Weidmüller’s perspective, potential for more added value at all sta-

ges of panel building.

“One of the identifi ed customer problems

that we have been working on in-

tensively relates to having an optimal power supply for consumers in the panel,” explains Pro-duct Mana-ger Wolfgang Weltermann. “Up until now, this was

something that had to be set up

by users themsel-ves, but we have

now solved this problem by develo-

ping specially adapted application products for

surge current protection and structured distribution within the

limits of control voltage circuits.”

More control parts, less space

9In Focus |

The innovative combination of load monitoring and potential distribution saves time during installation, increases fail-safeness and reduces the amount of space required on the terminal rail by 50 %

Planning Installation

Operation

»Our concentrated practical knowledge has been incorporated into the Weidmüller Configurator.«

10 | In Focus

helps ensure that the perfect solution is found, by allowing the user to simply specify the number of positive and ne-gative potentials to be distributed, and to select the required cross-section and marking scheme. The user will then receive a proposed solution showing all components and accessory parts. An additional option is planning using an ECAD system. In this case, the products can simply be transferred to the Confi-gurator, where the accessories are then added, the manufacturing documentati-on compiled and the structure logically checked. The parts list can then be exported back to the ECAD system. The composition in the Configurator is performed completely in 3D, thereby gi-ving a realistic impression of the future result right from the planning stage. As a result, accurate planning structures can be presented to the end customer before the manufacturing process has even begun.

Extra efficiency in planning, installation and operation

“Extra efficiency in planning, installati-on and operation – we arrived at this objective due to the increasing com-plexity of processes relating to panel production,” Weltermann concludes. “Our application program for control voltage distribution and the Weidmüller Configurator are just two examples of how we are consistently putting this objective into practice.”

with two potentials on one block crea-tes huge space savings. The PUSH IN technology, also used in maxGUARD, opens up rationalisation potential in the cabling process.

Up to 75 % time saved during planning

“Every application within the panel has its own specifications, and can basi-cally be triggered in an extremely wide range of different ways. So which solu-tion is the most precise and the most economically efficient? It was not only in the development of our application-specific product solutions for panels where we addressed questions like this one. The cumulative expertise from the decades of experience that our product experts have in the field, and also from the wide-reaching market analysis relating to panel building, has also been incorporated into the Weidmüller Confi-gurator,” says Weltermann, speaking of yet another market innovation. “Rather than going through individual steps, the web-based software solution takes users seamlessly through the entire pa-nel building process, thereby bridging the gap between the planning stage and ongoing operation.”

The Weidmüller Configurator sup-ports panel builders in the structured selection, configuration and requesting of assembled terminal rails. Automatic filter functions and seamless documen-tation ensure that typical errors, such as those relating to compatibility, are prevented right from the outset, which ultimately results in time savings of up to 75 % over the entire engineering process.

In the area of control voltage distri-bution, for example, the Configurator

Have a look at Klippon® Connect online!Find out all about the benefits of customised applica-tion products in the field of panel building: ▶ www.klippon-connect.com

The product data from the Weidmüller Configurator offers comprehensive support during project planning and can be fully integrated into all common engineering tools

11In Focus |

Distributed safetyCompactly bundled

I

t takes 40,000 muscles to move an elephant’s trunk. This powerful multi-functional organ was the inspiration behind the name given

by Zink KÖRNER to its automatic cen-trifugal galvanising system. The “Zinc Elephant³” coats small parts and bulk goods such as screws in large volumes. With its powerful furnace and quick automated handling of the baskets and frames, the system can achieve a throughput rate of up to fi ve tonnes per hour.

“At the heart of this circular piece gal-vanisation system is a handling system with three arms, which carries out all of the processes between the fi lling and emptying of the baskets without the need for any manual interventions,” explains Manuel Pierug, Service/Com-missioning Manager at Zink KÖRNER. “The gripper arms pick up the baskets

and frames, submerge them in the zinc bath, centrifuge them and then transport them to the water bath for rinsing. In order for the high cycle rate to be maintained, it is essential that all process steps work in perfect harmo-ny. To prevent our ’elephant’ standing idle in the event of a fault or during maintenance work, the multiple safety circuits ensure that even sub-sections can be brought to a safe condition as required.”

Integrated safety in the smallest of formats

The confi gured safety functions include the emergency off function, the door locking mechanisms and the option of controlling the furnace in the event of a

The more intelligent and networked a system is, the more important it is to use a state-of-the-art safety solution. With u-remote, Zink KÖRNER was able to construct a compact safety I/O solution with integrated cooperation.

12 | In Action

gas or burner failure, for example. The digital u-remote I/O module for PROFI-safe made it possible to link the locally distributed safety devices in a fl exible manner using state-of-the-art fi eldbus technology.

The safe 4DI-4DO modules combine various safety functions over a width of just 11.5 mm, meaning that they can be incorporated into the standard u-remote station while taking up mini-mal space. With the “Zinc Elephant³”, this allows the stations in the local pa-nels on the gripper arms and those in the central control consoles to commu-nicate with the safety control system in the main panel.

“The high packing density of the u-remote system has made the plan-ning and installation of the safety soluti-on signifi cantly easier for us, as space is always scarce when it comes to extensive systems with a large number of signals,” says Pierug. “We are now saving 6 mm per module compared to previous solutions. With 25 modules in the main panel and over 50 modules in total, these space savings are really signifi cant.”

Diagnostics via remote access

The u-remote web server was able to really shine during the commissioning of the “Zinc Elephant³”. The option to force inputs and outputs meant that processes and procedures could be simulated before system delivery, even without a connected PLC. As a result,

sub-panels could be commissioned at this early stage, thereby signifi cantly reducing the time required to get to the commissioning stage.

“Using the web server, we were able to gain remote access to the system when it was already installed at the customer’s premises and carry out remote I/O checks and diagnostics,” Pierug continues. “This was a major be-nefi t for us as our customer was based 400 km away from us, and would be even more signifi cant with our global customers based even further afi eld, such as in Russia.”

Find out more about u-remote!You will fi nd all product details, application examples and services under:▶ www.weidmueller.com/u-remote

1 The safe 4DI-4DO modules are fi tted in locations such as the central control consoles, from where they communi-cate with the safety control system in the main panel

2 In addition to the u-remote modules, further Weidmüller components such as the economical PROeco switching power supplies or the PPV potential distributor terminal blocks also help to space within the panels

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2

13In Action |

I

ndustry 4.0 stands for networking and self-organisation, but this doesn’t mean that the intelligent production of the future will operate

completely independently. It will be more a case that the role of humans and their interactions with systems will change. Functions that will play a key role here include mobile communica-tions technology, smart devices and Cloud services, which are becoming noticeably prevalent in the field of ma-chine construction.

“Until now, programming and diag-nostic work on machinery has been performed using software installed on Windows-based PCs that are connec-ted by cable to the hardware in ques-tion. In practice, this equates to a high level of dependency: on the location, the device and not least on the opera-ting system. For example, there will be initial compatibility issues with every new version of Windows,” explains Michael Matthesius, Global Industry Development Manager for Machinery. “As a partner in the field of automation

technology, we are therefore striving to address the question of how to stand out from the rigid platform of PC-based programming. And for us, the solution to this problem lies in focusing on a key information acquisition tool – the web browser. Regardless of the device being used, we see standardised, web-based technology as paving the way for us to develop the automation solution of the future.”

Relocating the engineering tool to the product itself

In concrete terms, the key to ensuring device independence lies in relocating the engineering tool from a PC, for example, to the device control unit itself. This opens up a range of connec-tion options: the engineering software can be accessed either directly, via a network or via a Cloud, with the option of offline programming without any connected hardware. Weidmüller is fully exploiting the possibilities offered by web-based engineering within its automation solution, which when ex-

panded to include control components, constitutes a further development of the established “u-remote” remote I/O solution.

“The engineering tool integrated into the control unit has been set up such that the programming is based on IEC 61131-3, the globally applicable standard for programming languages for programmable controllers. The structures and commands are therefore commonly known and can be applied immediately,” explains Product Mana-ger Detlef Grundke. “With the aim of reducing complexity, we are continuing to focus on consistently intuitive opera-tion, which we achieve by means of a design optimised for all possible display sizes and state-of-the-art web-based interfaces. Pre-assembled function blocks can be combined really easily on graphic interfaces using the drag-and-drop function, meaning that we can now talk about parameterization rather than programming.”

Goodbye, platform- independent programming Hello, web-based engineeringMore open, easier and more flexible – that’s what the automation of the future is expected to look like. Device-independent programming using a PC, tablet or access via the Cloud is already allowing for innovative solutions for the industrial automation of the future.

14 | In Detail

Towards the Smart Factory togetherIndustrial Connectivity goes onto the network – be there as well:▶ www.weidmueller.com/industry40

Mobile devices such as tablets allow for location-independent and mobile operation as part of the Smart Factory

15In Detail |

Rock stars aren’t always showyAnd metal doesn’t need to be heavy

W

hether modular produc-tion lines for customised production, extensive wind parks connected to data

storage systems or state-of-the-art me-ans of transportation with increasing amounts of communication techno-logy: the demands in terms of system functionality are becoming greater and more complex in all indus-tries, while the available installation space is getting smaller rather than larger.

In the area of connector technology, this has contributed to the long-standing trend for maximum packing densities, with customers looking for more functions with less installation space. RockStar® ModuPlug addresses this demand by enabling the fl exible combination of different transfer media within an application-specifi c interface. New and more compact inserts allow for a signifi cantly increased functional density compared to previous solutions.

Half the pitch size, twice the module slots

“Up until now, there were two standard module widths in the area of heavy-du-ty connectors: ‘Single 1.0’ and ‘Double 2.0’. We have broken away from this standard, and are opening up new dimensions with the intermediate sizes of ‘Half 0.5’ and ‘Single Plus 1.5’,” exp-lains Hubert Palm, Product Engineer at Weidmüller. “The four different module widths make for unprecedented levels

of fl exibility and allow for the const-ruction of particularly space-saving connector solutions.”

One example of how the RockStar® ModuPlug makes the most of limited space conditions is the compact data module, which features the tried-and-tested standardised M12 technology stripped down to the bare essentials. “Thanks to the protective function

provided by the housing, we were able to leave out the threads, meaning that we could fi t two circular components into a rectangular space,” says Palm, smiling, as he describes the secret be-hind the increased packing density. The module has space for up to two Cat-6A cables, each 10 GBit. This is setting new standards in the transfer of extremely high data rates in the smallest of spaces, meaning that the

RockStar® ModuPlug offers more for less. The modular connector system solves space problems by offering increased functionality with a reduced installation space, which in turn also helps keep the weight down.

16 | In Detail

ans of transportation with increasing amounts of communication techno-logy: the demands in terms of system functionality are becoming greater and more complex in all indus-tries, while the available installation space is getting smaller rather than

In the area of connector technology, this has contributed to the long-standing trend for maximum packing densities, with customers looking for more functions with less installation

ModuPlug addresses this demand by enabling the fl exible combination of different transfer media within an application-specifi c interface. New and more compact inserts allow for a signifi cantly increased functional density compared to previous solutions.

Half the pitch size, twice

“Up until now, there were two standard module widths in the area of heavy-du-ty connectors: ‘Single 1.0’ and ‘Double 2.0’. We have broken away from this standard, and are opening up new dimensions with the intermediate sizes of ‘Half 0.5’ and ‘Single Plus 1.5’,” exp-lains Hubert Palm, Product Engineer at Weidmüller. “The four different module widths make for unprecedented levels

ModuPlug makes the most of limited space conditions is the compact data module, which features the tried-and-tested standardised M12 technology stripped down to the bare essentials. “Thanks to the protective function

hind the increased packing density. The module has space for up to two Cat-6Acables, each 10 GBit. This is setting new standards in the transfer of extremely high data rates in the smallest of spaces, meaning that the

Intelligent use of installation space

PowerThe clearances and creepage dis-tances required for the transfer of 100 amps can easily be accom-modated in the new “Single Plus 1.5” module width, and in just three-quarters of the installation space previously required.

SignalsThe integrated double module for 36 signal contacts offers a 50 % higher signal density at a measu-rement voltage of 250 V compa-red to fi xed-pole standard inserts.

DataThe compact high-speed bus module receives both megabit and gigabit data inserts, and allows for the integration of up to two Cat-6A cables in one module, each with 10 GBit.

production requirements of the future are already being met today.

Users of the RockStar® ModuPlug have the option of either using more functio-nal modules within the same installati-on space or having the same functions as before but with a smaller frame and housing. In addition to space savings, the latter option also helps to achieve

weight savings, making it particularly suitable for applications in the fi elds of railway engineering and wind energy.

Set up a space-saving confi guration now!Design your customised connector combination with the selection assistant for the RockStar® ModuPlug:▶ www.weidmueller.com/moduplug-assistant

Good bye, waste of space: the halved pitch size makes twice the number of module slots available

17In Detail|

DataThe compact high-speed bus module receives both megabit and gigabit data inserts, and allows for the integration of up to two Cat-6A cables in one module, each with 10 GBit.

nal modules within the same installati-on space or having the same functions as before but with a smaller frame and housing. In addition to space savings, the latter option also helps to achieve

Set up a space-saving confi guration now!Design your customised connector combination with the selection assistant for the RockStar® ModuPlug:▶ www.weidmueller.com/moduplug-assistant

Wanted – a complete solution Found – an automation partner With open and powerful real-time control over two processor cores and an application-specific software library, 4 Energy GmbH (S4E) considerably speeds up the engineering and commissioning work required for their small wind turbines.

Never stop!Find out more about the Weidmüller automation solutions for small wind turbines here: ▶ www.weidmueller.com/wind

18 | In Action

One part of the automation solution for S4E: the specially designed top box

A a consultant in the field of wind energy, S4E wanted to give its customers more than just presentations. In fact, the

experienced consultancy company has also endeavoured to offer effective and practical solutions in the form of viable organisations or finished products. In order to design and commission wind power installations in a more efficient manner, the company recently entered into a strategic partnership with Weidmüller.

“The task was to develop a complete automation solution, including two operational panels – the top box and the bottom box,” recalls Marc Liebert, Industry Development Manager of the Wind division at Weidmüller. “As we worked together to create the require-ments catalogue, we were able to draw on the experience we have both gained over numerous wind-energy-related projects. The result was a complete solution for the open, transparent and flexible automation of small wind turbines that are constructed by S4E itself.”

Comprehensive library made up of pre-assembled functional modules

The first stage of the partnership invol-ved a period of joint planning, which saw Weidmüller provide a special library of pre-assembled software mo-dules for the automation of wind power

installations, covering around 80 % of functions that are currently being re-quested. The available solutions include those for the quick and easy implemen-tation of pitch and nacelle control, as well as tower functions, condition mo-nitoring and a wide range of physical tasks. The “Wind Library” allowed S4E to cover the majority of the required functions right from the outset, and the remaining modules were modified or re-programmed and implemented in close collaboration with Weidmüller.

Continuous communication

At the heart of the installation is an innovative control system with multiple processor cores and operating systems for the purpose of creating a clear sepa-ration between real-time requirements, system services and safety aspects. Furthermore, this multi-core solution also guarantees defined cycle times, and in combination with programming processes that comply with IEC 61131, also ensures a future-proof, high-perfor-mance and standardised platform for visualisation and real-time applications. The “Zenon” system from Copa Data with scalable function and output was selected for the operational manage-ment of the wind park.

In order to ensure that the components of the different systems could be con-nected without any problems, one of the key demands made of Weidmüller

was that it could guarantee open com-munication. This includes the reliable exchange of data by the safety control-ler, which Weidmüller carried out via PROFINET. Additional expansions can be easily incorporated via the corres-ponding modules of Weidmüller’s I/O system u-remote.

Fully checked and delivered ready for use

The solution developed by Weidmüller is fully checked and delivered ready for use, thereby simplifying the logistics, assembly and commissioning work to be carried out by S4E. Weidmüller has a very well-equipped application room for wind energy automation solutions, where all programmed functions are put to the test on real modules prior to delivery. Customers can therefore rest assured that the installation will work faultlessly during operation.

The first joint project with the new automation solution has now been successfully implemented and is in the final phase for the prototype test. “We are sure that there will be many more joint projects in the future,” says Thomas Schubert, Managing Director of Solutions 4 Energy GmbH.

The panels for the top and bottom box are planned, assembled and tested at Weidmüller, so are delivered ready for use

19In Action|

F or motorists, it goes without saying that their cars are per-manently monitored by a range of different sensors. Diagnostic

functions inform drivers in good time of any changes before they turn into prob-lems. Continual monitoring is a way of

protecting investments imperceptibly in the background, thereby increasing the reliability and operational safety of the vehicle.

When it comes to wind power installa-tions, however, many operators are still

deciding not to make use of continu-al rotor blade monitoring, choosing instead to carry out visual inspections. And while this may save money in the short-term, it will become a costly risk as time goes on.

Repair and replacement costs are effectively redu-ced as a result of early damage detection

Act instead of react For economic wind energyExpensive surprises? Unnecessary downtime? Things of the past with state-of-the-art conditionmonitoring solutions that can sustainably reduce the Cost of Energy (CoE) of wind power installations. Weidmüller’s BLADEcontrol® system increases revenue and reduces cost risks thanks to continual rotor blade monitoring and ice detection.

20 | In Detail

prepare concrete action recommen-dations for the operator. In order to do this, they draw on the experience of around 4,000 operating years from the over 1,500 systems currently installed.

In addition to damage to the rotor blades themselves, BLADEcontrol® can also detect aerodynamic imbalances, loose parts in the blade and misalign-ments of the hubs or pitch. The monitoring system therefore makes an additional contribution to the long-term operational reliability of the installation. An investment in continual rotor blade monitoring will also pay itself off in particular due to the in-creased availability during the winter months, when the key ice detection function with automatic restart will really come into its own.

Detecting damage in good time

“The rotor blades in particular are put under a great deal of stress as a result of storms, icing, lightning and gusts of wind,” explains Hans Schlingmann, Head of the Energy Solutions division at Weidmüller. “Damage can often oc-cur and go unnoticed, and is frequently only detected during routine checks, by which point there will already be a large amount of repair work required.”

This can be actively addressed through the use of a conditionmonitoring system, which measures and analyses changes to natural rotor blade vibra-tions on an ongoing basis. As a result, the underlying problems behind service calls can be detected in good time, and repair measures can be planned in a proactive manner.

Eliminating risks

“Our BLADEcontrol® monitoring system continually monitors the condition of each individual rotor blade, and shows this information to the operators in the form of an online overview: green for normal function, yellow for minor damage and red for serious damage,” says Schlingmann about the intuitive traffi c light logic.

When critical conditions are detected, the system sends a signal to the instal-lation control unit, which stops the ins-tallation and thereby prevents damage such as blade breakages, for example. In parallel to this, all evaluations are also transmitted to the Weidmüller Mo-nitoring Centre, where experts analyse the data and use trend analyses to

»Our BLADEcontrol® monitoring system continually monitors the condition of each individual rotor blade.«

The sensitive BLADEcontrol® sensor system detects dama-ge right from its initial stages. The monitoring system has been certifi ed by Germani-scher Lloyd (now: DNV GL) continuously since 2008

Hans Schlingmann, Head of Energy Solutions, on the special features of BLADEcontrol®:

What makes ice detection with BLADEcontrol® so safe?

BLADEcontrol® measures icing right where it occurs: on the rotor blades. Up until now, icing has often been detected by an ice sensor on the nacelle. However, the tip of the blade can be up to 60 metres away from this sensor, and moves through the icy air at up to 250 km/hour, meaning that the icing conditions at the rotor blade are completely different to those at the nacelle.

What makes the measurements with BLADEcontrol® so accurate?

The measurement accuracy is based on the patented implemen-tation of a basic physical princip-le: the frequency of the natural vibration of the particular rotor blade will reduce proportionally to the increasing ice mass. Thanks to the highly sensitive sensor system and special evaluation method, the system can achieve a measurement resolution for the thickness of the ice in the milli-metre range.

What makes rotor blade monitoring with BLADEcontrol® so profi table?

Due to the preventative effect, the investment costs for the moni-toring system have been shown to pay themselves off within a few operating years. The cost of replacing a single rotor blade in the 45-metre class costs over ten times as much as the total costs of an installed BLADEcontrol® system.

21In Detail |

Achieve the optimum results!Here, you will fi nd out how you can operate wind power plants effi ciently with BLADEcontrol® and other solutions:▶ www.weidmueller.com/wind

T he success of a photovoltaic system depends not least on its economic effi ciency. And gro-wing competitive pressure will

make this aspect even more important in the future. An effective way of increa-sing a plant’s profi tability is to increase the system voltage.

Around 20 panels can be connected in series at 1,000 V, but 30 are possible at 1,500 V – a signifi cant increase in profi tability when the operating time is taken as a whole. This approach also reduces the complexity of the entire photovoltaic system and the associated operating costs. As fewer components

and materials are required, the ins-tallation and maintenance costs are considerably lower. In the photovoltaic market, these benefi ts have led to a greater demand for more powerful components – and this is an area in which Weidmüller excels.

“The overall design of our generator combiner boxes is based on quick and easy installation. The fact that we deli-ver our solutions ready for connection and individually tailored to customer requirements makes them easy to

More power, more profi tSolutions for up to 1,500 VMaximum cost effectiveness with the highest quality and performance – Weidmüller meets these requirements for the design and construction of photovoltaic systems with its 1,500 V generator combiner boxes.

22 | In Detail

solar panels. A separate feed line is thus rendered superfl uous.

Even when subjected to extreme temperature conditions of –25 to +70 °C the Transclinic 16+ 1K5 provi-des reliable monitoring of each string and supports voltage measurements up to 1,500 V. This means that preven-tive maintenance is guaranteed and problems affecting the overall yield of the solar park can be avoided from the outset.

A secure connection between photo-voltaic modules, inverters and combi-ner boxes is provided by the WM4 C connectors. A high current-carrying capacity enables the components to support loads with a rated current of up to 35 A. Twist protection prevents the plug from twisting during installation in the enclosure.

Highest quality standards

To achieve long service life and increa-sed safety, we have employed the latest protection mechanisms. All the compo-nents of the 1,500 V generator combi-ner box are certifi ed to IEC 61437-2, IEC 61439-2 and parts of IEC 62093 and meet the latest safety standards,” adds Martínez on the subject of quality and investment security.

“We also set very high standards when it comes to the validation and subse-quent examination of the components used. Our generator combiner boxes easily support temperatures up to +50 °C. More than 42 million panels are installed worldwide with a com-bined output of over 8.4 GWp. The stable yield of the respective photovol-taic plants speaks for itself.”taic plants speaks for itself.”

Reduced maintenance requirements ‣ lower operating costs

Reduced complexity‣ fewer components

Smart design ‣ simple installation

High quality standards‣ high level of reliability

All the components of the 1,500 V customised combiner boxes are perfectly matched to produce a successful photovoltaic system

23In Detail |

install in the fi eld,” explains Juan Francisco Martínez, product manager at Weidmüller.

Monitoring and measuring for optimum performance

“Because the solar park uses many function-critical compo-nents, these products need to be reliably monitored from the outset. With 1,500 V systems, in particular, it is advisable to monitor each string to ensure that performance degradati-on in the system due to the PID effect can be quickly identifi ed and countermea-sures implemented. In this way, the system remains constantly profi table,” exp-lains Martínez.

Incorrect switching and the shading or soiling of panels can also only be detected if the string performance is constantly measured. Weidmüller provides the Transclinic 16+ 1K5 precisely for this purpose. The integrated moni-toring system can be optionally supplied with power directly from the

Bring long-term success to your photovoltaic installation!With our tailored connection solutions:▶ www.weidmueller.com/pv

Order number: 2492540000/11/2016/SMKC

Made in GermanyWeidmüller Interface GmbH & Co. KGKlingenbergstraße 1632758 Detmold, GermanyTelefon +49 5231 14-0Telefax +49 5231 14-2083info@weidmueller.comwww.weidmueller.com

Your local Weidmüller partner canbe found on our website:www.weidmueller.com/countries

Weidmüller – Your partner in Industrial Connectivity

As experienced experts we support our customers and partners around the worldwith products, solutions and services in the industrial environment of power,signal and data. We are at home in their industries and markets and know thetechnological challenges of tomorrow. We are therefore continuously developinginnovative, sustainable and useful solutions for their individual needs. Together weset standards in Industrial Connectivity.