Benefits of segmentation using a ProfiHub B5+R in a Motor Control Center (MCC)

1 June 2022

Unplanned downtime and network failures are some of the major triggers of lost productivity, causing delays, unhappy customers, and a loss of revenue. No matter what the industry, if a switch, connector, or network cable should fail, replacing these components represents only a fraction of the costs associated with production downtime. Therefore, reliable network infrastructure is critical to ensuring optimal network performance.

Production processes, machinery, and devices in industrial plants are often arranged in a typical line topology, this is also known as a daisy-chained network. A daisy-chained network is used to direct the connection of network nodes where one node of the network is connected to the next node in a line topology.

The daisy-chained network has one inherent flaw: if any link between any two devices fails, the entire network will go down. Daisy-chained PROFIBUS DP networks are more susceptible to breakdowns since one faulty device can affect the entire segment resulting in complete network failure.

The introduction of a ProfiHub B5+R in a daisy-chained network helps to isolate devices to specific channels, so if a fault arises in one of these channels, it does not affect the entire network. This greatly simplifies fault-finding and as a result, reduces downtime.

IDX re-segments a daisy-chained PROFIBUS DP network using a ProfiHub B5+R

An MCC based in a South African mine contacted IDX to investigate consistent network issues they were experiencing, such as intermittent bus communication failures. Upon examining the system, our IDX engineers discovered that one device was falling off the bus, and as a result, every device connected to the bus was affected, causing communication failure. These issues were due to a faulty device, which was connected to a line topology.

In addition, due to the design of the network and the industry, the MCC experienced a large amount of electromagnetic interference (EMI), caused by incorrectly wired devices, faulty connectors, and PROFIBUS cabling not properly being grounded. There were also incorrect terminations within the network, causing an impedance mismatch by creating unnecessary additional resistance (over terminations) in some segments and a lack of resistance in other segments (under terminations). These issues resulted in intermittent network failures, increased downtime, and loss of revenue due to affected plant production.

We installed a PROFIBUS B5+R to re-segment the network devices into multiple channels as opposed to the existing one, isolating the problematic devices into their own channel. By re-segmenting the network, IDX engineers created a star topology apposed to the existing line topology, which reduced downtime, simplified fault-finding and created additional transparency within the network as the ProfiHub has LED diagnostics, clearly indicating if a specific segment is experiencing a bus fault, if the termination is on or off, and if it’s in data exchange.

IDX followed best practices by re-segmenting the devices in this network, and this resulted in close to zero downtime after the installation.

Use Case

Line to star topology

Current topology – Line topology with multiple repeaters, creates a high-risk network environment as the entire network can be dropped by any faults experienced within the segments.

Required topology – Star topology (as above) utilising ProfiHubs to create logical segregation and improved network stability.

Other problems – It is very difficult to trace cables within the network. The new topology will be more logical, documented, and easier to fault find and trace.

Method of re-segmentation – Mark all panels on that network with a sticker, then run cabling between panels within each row. Each row should have an individual channel on the ProfiHub.

About the ProfiHub B5+R

Figure 1:  ProfiHub B5+R

The ProfiHub B5+R is a DIN rail mount multi-channel repeater with five galvanically isolated channels. Each ProfiHub has 6 channels, one for the incoming communication, and 5 for the outgoing communication. This robust network component is used to design reliable, flexible and object-oriented networks. It allows for wide-ranging star or tree topologies and longer spur lines for PROFIBUS DP installations in IP20 environments.

This device is essential to obtain better control during the maintenance of a network as it makes fault finding less time-consuming by indicating failed channels with an error light on the corresponding channel.

A ProfiHub B5+R allows for a maximum of 31 devices in a channel with a maximum total of 125 devices, but it is advisable to stick to a maximum of 24 devices per channel to ensure optimal performance. As an economic solution, the B5+R saves costs through the reduction of traditional PROFIBUS repeaters, reduction of downtime and the simplification of fault-finding.

Figure 2: ProfiHub connections

For more information on the ProfiHub B5+R, click here.

In today’s competitive market, production costs, lead times and optimal machine utilisation are major concerns for highly competitive businesses. Reactive maintenance, performed only when equipment fails, results in loss of revenue, high production costs and significant service downtime, also creating unnecessary stress for engineers, production SLAs and companies as a whole. Preventive maintenance is intended to eliminate breakdowns through regular proactive maintenance.

The shift from reactive and preventive maintenance to proactive and predictive maintenance should be the direction that businesses strategise in. Based on the condition-based monitoring technology, the traditional fail-and-fix practice should eventually be replaced by the new predict-and-prevent paradigm.

At Industrial Data Xchange, we offer extensive expertise in industrial maintenance and asset management, with a focus on keeping your plant operating at peak performance. Our qualified site services team provide on-site preventive and predictive maintenance for improved asset health. Speak to one of our engineers today if you’d like to know more about the ProfiHub and how it can help you.

<a href="https://blog.idx.co.za/author/dhashika/" target="_self">Dhashika Ramgolam</a>

Dhashika Ramgolam

Marketing Manager

Dhashika has nearly twenty years of experience across the construction, engineering, fitness, mining and software development industries. Her hobbies include reading, baking, playing scrabble and watching movies.

Show your love!

Recent Posts

Driving Productivity with LineView Training

In light of our partnership with LineView Solutions, our team has taken up the opportunity to equip themselves with insights into the LineView system and its impact on the industry. “LineView is a production line monitoring and recording system that automatically...

Exciting New Launch: Onsite ProfiDay

IDX is excited to announce the launch of our onsite ProfiDay offering. This is available to all industries and companies that utilise PROFIBUS and/or PROFINET within their industrial communications systems. What is ProfiDAY? An exclusive onsite program offering...

Introducing our Partnership with LineView Solutions

We are excited to announce our partnership with LineView Solutions, a leading UK-based company specialising in smart factory solutions for optimising production processes. LineView developed a cutting-edge software suite designed to automatically gather data from the...

Optimise PROFIBUS and PROFINET Network Performance

As a field technician handling PROFIBUS and PROFINET systems, it is crucial to recognise the common errors that can result in costly downtime. From improper network configuration to neglecting regular maintenance, these mistakes can greatly affect system performance...

Delighted Customer Shares Experience

We recently assisted a client in rectifying damage to the Anybus ABC4090 Communicator caused by incorrect power usage onsite. We arranged for the device to be sent to HMS in Sweden for repairs, and they restored it before promptly returning it to us. Here are some...

Price Decrease on PROFIBUS Connectors

PROFIBUS connectors play a crucial role in industrial automation and data exchange systems by facilitating smooth communication between devices and networks. We are pleased to announce a significant price decrease on all our PROFIBUS connectors. Thanks to recent...

PROFIBUS Standards: Functional bonding and shielding

Electromagnetic Interference (EMI) and earthing issues can significantly impact the performance of your network. By following these six proven recommendations, you can ensure that your network is always up and running.

PROFIBUS Standards: Terminations

What is the Volts Direct Current (VDC) required for optimal operation of a PROFIBUS DP termination circuit? Get the answers you need in our latest video on PROFIBUS Standards: Terminations. Don't miss out on this essential knowledge to boost your system's performance!

PROFIBUS Standards: Segment Cable Lengths

Finding the perfect balance between PROFIBUS cable length and network speed is crucial. While longer cable segments might seem tempting, they can lead to signal degradation and slower speeds. Conversely, too short segments might limit your layout options. Striking the...

Sign up for our newsletter

Get exclusive updates and a sneak peek into our world every two months. Stay connected, stay informed.

Related Posts

Our expertise lies in establishing, maintaining, and leveraging plant data for business benefit. Through our innovative solutions, we work alongside you to streamline processes, enhance efficiency, and reduce costly downtime.

CONTACT US

Main: +27 (11) 548 9960
Sales: +27 (11) 548 9970

SOCIAL MEDIA

Copyright @2024 Industrial Data Xchange. All rights reserved.