u-remote - Remote IO System Modernization with Weidmüller

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⌚Timestamps:
00:00 - Intro
00:50 - Challenge
02:43 - Solution
05:38 - u-remote
08:36 - Wrap Up

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In this case study, we will look at the value of modernizing remote I/O systems based on the experience of a leading industrial company specializing in the storage and distribution of bulk liquid products.

To respect this company’s privacy, we will not use their name but we can tell you that this company operates 114 facilities in over nine countries around the world.

At their Amsterdam facility, this company was running a bulk liquid terminal using an aging DCS.

This Distributed Control System was built up from two controllers with 17 I/O racks on a Profibus network. These I/O racks interfaced with over 700 I/O points on different devices including pumps, tanks, and motor-operated valves.

Although this system was working, the company faced several challenges which were becoming worse with each passing year. The main challenges associated with the original remote I/O system were:

1) Spare Part Availability: Although the Distributed Control System was still supported by the manufacturer; it was becoming increasingly difficult for the company to find spare parts in stock.

2) Limited Functionality: Operational technology has taken major leaps forward in recent years. Automation manufacturers are constantly innovating and introducing new features into their products.

3) Network Limitations: Like many others, the company wanted to collect more data from their field devices to analyze and optimize their system’s performance.

The company understood that it was time to upgrade its remote I/O system to a modern system that leveraged state-of-the-art technology.

As a starting point, the company made a list of what its ideal solution would look like. The features that were mentioned on the company’s wish list included: Ease of Use, Small Footprint, Maintenance Friendly, and Cost-Effective.

1) Ease of Use: The new remote I/O system had to be easier to use and have more functionality than the old system.

2) Small Footprint: The company wanted to collect more data from field devices, which meant increasing the number of I/O points per I/O rack.

3) Maintenance Friendly: The remote I/O system had to be built with reliable hardware that would function without failure for a long time.

4) Cost-Effective: The remote I/O system should be cost-effective. The company knew that they wanted a lot of features but felt that a modern remote I/O system should be affordable and its cost should reflect the amount of value that the remote I/O system offered.

At Hannover Messe, they came across Weidmüller’s remote I/O system, u-remote.

This system seemed to meet all of the company’s needs and after several consultations with Weidmüller’s applications engineering team, the company decided to upgrade its facility using Weidmüller’s u-remote system.

Since Weidmüller’s u-remote I/O system is compatible with most industrial networks including Profinet, EtherCAT, Ethernet/IP, and Modbus/TCP, Weidmüller’s application engineering team was able to work with the company to determine what industrial network was best suited to their needs.

Ultimately, the company settled on an Ethernet-based network that used the Modbus/TCP communication protocol.

After switching to a Modbus/TCP network, the company could focus on upgrading the density of each remote I/O rack. u-remote I/O modules are incredibly thin at 11.5 mm per module and each u-remote I/O station supports up to 64 modules with a single power supply.

Since they could fit more I/O modules per rack, the company was able to reduce the number of remote I/O racks in the Distributed Control System from 17 racks to 11. The end result was a system with fewer points of failure and spare parts requirements.

‪@WeidmuellerGlobal‬

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Learn more about u -remote:
https://www.weidmueller.com/int/produ...

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