How shifting to modular machine design enables Industry 4.0 strategies

By Paul Jones   |   September 22, 2021

The rise of networked connectivity is changing the way we organise many aspects of our lives, from being based on hierarchies to being based on peer-to-peer relationships. We see this in everything from social media to the changing nature of work, to IT networking: the idea of a central authority that commands the actions of passive agents is being rapidly eroded in many contexts.

One area in which this shift is taking a little longer is in the design of large machinery, for example production equipment for factories or handling systems for warehouses. These complex systems are often designed on a centralised model, in which a core programmable logic controller (PLC) provides top-down control through several layers of networking to actuators in the machine, with sensor signals being passed back up through the same network hierarchy. This approach concentrates intelligence at the core, separates the networking of the information technology equipment from the operating technology equipment, often has weak security, and allows little in the way of direct peer-to-peer, machine-to-machine communications.

The shift to modularity

At the same time, the increasing complexity of machines, time to market pressures, and customers’ desire for customised solutions, are driving a shift to more modular machine designs. Many customers want the equipment they buy to use energy and resources more efficiently, to offer flexibility and be able to support mass customisation. Some also want to be able to radically repurpose their machinery to suit changing market demands, and to be able to decommission it in an environmentally responsible way at end of life. This, combined with the rise of Industry 4.0 strategies, which aim to bring the advantages of rich connectivity and detailed data collection and analysis to an industrial setting, are together driving a shift away from command-and-control machine architectures to a more peer-to-peer approach.

Machines built on this principle will use a distributed control architecture that moves processing, intelligence, and safety management closer to the point of need, and which enables dynamic real-time processing. Each device in the peer-to-peer network will have more intelligence, doing away with the need for costly central PLCs as well as the need to wire everything back to those controllers so that sensor data can be interpreted and actuator commands issued. This approach will also make communication between peer devices within the machine much simpler. And it will make it easier to integrate the operating technology of the machine with enterprise-level applications that need to collect and analyse the data that the machine is creating.

Figure 2: A more decentralised, peer-to-peer approach to factory automation

To make this possible, factories and warehouses will replace conventional Fieldbus with Ethernet-based Fieldbus networks, which will bring IP-based networking to such facilities at low cost and with high reliability. This will enable the creation of a single local area network, with Internet access if appropriate, borne on wired or wireless infrastructure as needed. This should improve control of production, resource management, operational transparency, and efficiency.

The shift to modular machine design, enabled by peer-to-peer architectures and IP-based networking, will also demand greater use of open protocols, to enable mix and match solutions and easy integration of technology from multiple sources. Open architectures will give machine builders the freedom to customise their offerings, bringing in the latest technologies, and will enable customers to add or replace devices within their machine ecosystem as their needs change.

Making the connection

Figure 3: Modular connectivity solutions
designed for use in harsh environments

Modular machines will need new interconnect strategies to match the shift from a hierarchical to a peer-to-peer architecture. Current machines may have hundreds or even thousands of power, signal, and data endpoints, each of which needs to make a reliable and secure connection to a power panel or control cabinet. Creating the wiring harness to provide this connectivity can involve stripping hundreds of wires, soldering and or/crimping them to contact shells, and then assembling the connector into its final form. Each connection represents a potential point of failure, so the machine must be fully wired, and each connection tested and approved before the whole thing is taken apart again for shipping to the customer site. Commissioning the machine onsite then involves rewiring the machine and ensuring that the disassembly and reassembly process hasn’t damaged any of the connections. Routine maintenance on such traditionally architected systems can also mean disconnecting and reconnecting hundreds of contact points to address an issue – with the attendant risk of creating further issues while doing so.

The obvious solution to the complexities of wiring up modular machines is to turn to modular connection systems. These can offer important advantages, such as a reduction in the time it takes to commission, troubleshoot, and repair a machine, good mechanical stability and performance, and the opportunity to work to IEC standards. Modular connectivity, coupled with some forward-thinking design, should also make it easier to configure, modify, or expand machines and lines. Molex has a broad portfolio of modular on-machine and in-cabinet power, signal, and data connection solutions, like those shown in Figure 3 right.

While modularity may change the architecture of a machine’s interconnect, it is unlikely to change the fact that production floors can be harsh environments, subject to dirt, fluid splashes, vibration, impacts, and electromagnetic interference. Molex offers heavy-duty connectors to ensure reliable performance in such demanding conditions, with locking mechanisms to provide a secure seal and stabilise the coupling to protect it from accidental disconnection. For example, Molex Brad M12 connectors are mainly used for power, while its M12 connectors are used to connect sensors and other I/O devices. There’s even a Brad Ultra-Lock series that can make or break an IP67, 68 or 69K connection with a simple push or pull action.

Figure 4: The Brad M12 cord sets and rugged MPIS Safety Box
simplify wiring in harsh environments

Molex also makes HarshIO modules, which support all major industrial communications networks and protocols. They have status LEDs for network availability, power, and I/O. Brad IO-Link Master Modules on EtherNet/ IP and PROFINET combined with IO-Link Digital Hubs provide Fieldbus connectivity in harsh environments, extending IO- Link communications to sensors and actuators.

Future challenges

As machine designers get to grips with reconfigurable machine architectures they will have to implement both distributed control systems and more flexible primary/secondary and publisher/subscriber communication strategies. There will also be a host of what we might call infrastructural issues to deal with, such as ensuring that such flexible machines will remain safe to operate and work alongside. Designers may also have to consider the implications of integrating the operating technology network with the information technology network: how will those two functions work together on one network? And if they are working together, what steps need to be taken to ensure their continuing security? The security issue will be made even more complex with the implementation of machine-to-machine communication, and remote operation and access systems.

With all these challenges to address, manufacturers will want to work with connectivity systems and distributed computing modules that give them the flexibility to reconfigure their production lines quickly to meet changing demand. In future, Molex plans to augment its offering of ruggedised IP67 devices to simplify wiring while improving reusability and portability; the deployment of advanced sensors, such as motion safety, required for collaborative robots; and zero-touch provisioning and asset-management services that can update devices, machines, and systems on demand.

It’s all a long way away from the command-and-control strategies of traditional machine design.

As the technology in today’s factories continues to develop, Molex and Avnet Abacus are on hand to support your evolving connectivity requirements. Discover the Molex components enabling smarter factories, or if you’re ready to take the next step you can reach out to our team of field application engineers to discuss your design.

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Paul Jones

As Supplier Development Manager, Paul is responsible for supporting and managing key supplier relati...

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