Programmable Logic


Solving industry 4.0 challenges with software-configurable I/O

28 September 2022 Programmable Logic

Traditionally, field instruments are connected to the Ethernet domain using legacy analog signalling (4 to 20 mA, 0 to 10 V). This presents challenges for fixed-function I/O modules. System designers need to design multiple modules to cover the different sensors and actuators. Crowded cabling could cause incorrect connections of sensors and actuators to these fixed-function I/Os, and debugging and fixing these faults are time-consuming and require manually reconnecting the loads to the I/O channels. A software-configurable I/O module solves these problems by allowing for efficient use of all channels in an I/O system.

A software configurable I/O system provides a seamless transition from legacy analog signalling to the Industrial Ethernet domain. Software configurable I/O devices can provide any function (analog I/O, digital I/O, RTD) on any channel through remote configuration, which helps ease commissioning. This flexibility, combined with diagnostics capability, allows for remote troubleshooting, thus saving time for technicians. Figure 1 shows the evolution of industrial connectivity from legacy analog signalling to smart, digitally connected sensors with software-configurable I/O enabling a seamless transition.

Analog Devices’ AD74413R software-configurable I/O coupled with the ADP1032 two-channel isolated micropower management unit (µPMU) is one example of a robust software-configurable I/O solution. The AD74413R is a quad-channel software-configurable I/O that is equipped with automatic fault detection and diagnostic capabilities. The ADP1032 is tailored to the AD74413R to provide isolated power and data channels, which allow for a compact and isolated software-configurable I/O system.

Channel flexibility

For industrial applications with varying I/O requirements, system designers need a flexible system that can be quickly configured to adapt to the required demand. The four channels of the AD74413R can be configured into various input and output modes such as:

• High impedance.

• Voltage input.

• Voltage output.

• Externally powered current input.

• Loop-powered current input.

• Current output.

• Digital input logic.

• Loop-powered digital input.

• RTD measurement.

A single set of external discrete components is required to support any function on any of the four channels, offering full flexibility. If an actuator or sensor is not wired correctly, the channel can be reconfigured with a single SPI.

Having all functions available in a single package requires fewer components in the hardware design, which leads to lower assembly and test costs, higher reliability and easier debugging, simplified procurement, and higher channel density compared to discrete implementations of universal I/O.

Fault detection and diagnostic capabilities

The AD74413R is equipped with automatic fault detection and different diagnostic functions to help with fault isolation. Users can interrogate an alert register to determine the exact cause of a reported fault. Users can also enable diagnostic signals to further diagnose the identified fault.

These capabilities allow technicians to remotely troubleshoot any faults occurring in the system. In many existing systems, sensors and actuators may be located far away from the control room and in potentially hazardous areas. In addition, crowded cabling may also make it difficult to determine which cables are connected to which sensor or actuator, making it cost prohibitive and time-consuming to physically rewire these systems. The AD74413R modules provide configurability and diagnostics to determine which sensor or actuator is connected to a particular channel.

Isolated power and data solution

The ADP1032 satisfies the requirement for isolated power and data channels by having two isolated and regulated rails and seven data isolation channels all in one package. This provides a board area reduction up to three times compared to a discrete power and data isolation solution. This allows customers to increase the overall channel density in their modules. The four SPI signals of the AD74413R use the high-speed isolated data channels of the ADP1032, which are optimised for low propagation delays of 15 ns, supporting SPI clock rates up to 16,6 MHz. The low-speed isolated data channels are used where timing is not critical.

Power dissipation

Having a flexible multi-channel system poses a trade-off on the system power dissipation because each channel of the AD74413R software-configurable I/O can be configured to various modes while the power supply for the AD74413R sticks to a single output voltage. The designer must pick the highest AD74413R AVDD supply voltage so that the worst-case condition can be supported with consideration to the load characteristics, to ensure the proper operation of each mode.

Conclusion

The digitalisation of factories brings increased production output, factory utilisation, and labour productivity. However, the transition to the digital factory is a challenge because legacy systems lack 10BASE-T1L-supported sensors and actuators. The AD74413R software-configurable I/O, coupled with the ADP1032, bridges the gap for Ethernet-enabled field instruments. The four channels of the AD74413R are flexible and can each be programmed to eight different I/O configurations. Its fault detection and diagnostic capabilities save time during the debugging and commissioning of a system. The diagnostic capability can also be used to monitor systems for maintenance. Finally, the ADP1032 galvanically isolates the data and power sources, ensuring the safe and efficient transfer of power and data.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Bringing Bluetooth Channel Sounding to automotive and beyond with KW47
Altron Arrow Telecoms, Datacoms, Wireless, IoT
NXP’s new Channel Sounding-certified KW47 and MCX W72 wireless MCUs are set to help automakers with distance measurement, bringing an additional ranging solution for car access and autonomous systems, and will be utilised across a broader spectrum of applications.

Read more...
Wi-Fi 6 and Bluetooth LE coprocessor module
Altron Arrow Telecoms, Datacoms, Wireless, IoT
The ST67W611M1 from STMicroelectronics boasts an all-in-one design which, together with its capabilities, contribute to making it an attractive choice for IoT edge devices requiring a single-chip solution.

Read more...
Wi-Fi 6 plus Bluetooth LE SoC
Altron Arrow Telecoms, Datacoms, Wireless, IoT
Silicon Labs’ SiWx917M SoC is the company’s lowest power Wi-Fi 6 SoC, ideal for ultra-low power IoT wireless devices using Wi-Fi, Bluetooth, Matter, and IP networking for secure cloud connectivity.

Read more...
Simple battery charger ICs for any chemistry
Altron Arrow Editor's Choice Power Electronics / Power Management
The LTC4162 is a highly integrated, high voltage multi-chemistry synchronous monolithic step-down battery charger and PowerPath manager with onboard telemetry functions and optional maximum power point tracking.

Read more...
Microchip enhances TrustMANAGER platform
Altron Arrow DSP, Micros & Memory
Firmware over-the-air updates and remote cryptographic key management provide scalable solutions for addressing IoT security challenges.

Read more...
Adaptive optics’ power solution
Altron Arrow Opto-Electronics
Vicor power-dense adaptive optical modules enable colossal telescopes to look into the past for deep space discoveries.

Read more...
Wide input voltage buck-boost converter
Altron Arrow Power Electronics / Power Management
The MAX77859 from Analog Devices is a high-efficiency, high-performance buck-boost converter targeted for systems requiring a wide input voltage range of between 2,5 and 22 V.

Read more...
High-density power module for AI at the edge applications
Altron Arrow Power Electronics / Power Management
The MCPF1412 power module from Microchip has integrated I2C and PMBus interfaces for flexible configuration and monitoring.

Read more...
When it comes to long-term reliability of RF amplifier ICs, focus first on die junction temperature
Altron Arrow Editor's Choice Telecoms, Datacoms, Wireless, IoT
When considering the long-term reliability of integrated circuits, a common misconception is that high package or die thermal resistance is problematic. However, high or low thermal resistance, by itself, tells an incomplete story.

Read more...
High-performance processor for edge-AI
Altron Arrow DSP, Micros & Memory
The STM32MP23 microprocessor from STMicroelectronics is the latest addition to the STM32MP2 series, designed to meet the demands of industrial, IoT, and edge AI applications.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved