Completely Wireless Real-Time Sensors for Smart Factory Applications by Andreas Hennig, Fraunhofer Institut für Mikroelektronische Schaltungen und Systeme

1. © Fraunhofer
COMPLETELY WIRELESS REAL-TIME
SENSORS FOR SMART FACTORY
APPLICATIONS
6th M2M Alliance Academic Day, Cologne 2017

2. © Fraunhofer
CONTENT
 Introduction
 Applications and Requirements
 Wireless Real-Time Data Transmission Scheme
 Wireless Energy Transmission Scheme
 Conclusion

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Introduction
Industry 4.0
 Flexible equipment and machines
 Functions are distributed in the
network
 All participants are connected
across hierarchical levels
 Communication takes place
between all parties involved
 The product is part of the network
 Access to the connected world
(Source: Plattform Industrie 4.0)

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Industry 4.0
Communication Layer
 Networks in the industry 4.0 communication layer
(Source: Plattform Industrie 4.0)

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Wireless Communication
Motivation
 Increasingly large number of sensors expected
 Cabling no longer practical
 Need for sensors in moving machine parts
 Cabling is critical in harsh environments
Source:Pctipp.ch
"Wireless communication
enables the networking of all
production units. It will play a
key role in the realization of
industry 4.0"
(ZVEI Positionspapier*)
*)ZVEI; „Industrie 4.0: Auf dem Weg zur smarten Fabrik
– die Elektroindustrie geht voran“

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CONTENT
 Introduction
 Applications and Requirements
 Wireless Real-Time Data Transmission Scheme
 Wireless Energy Transmission Scheme
 Conclusion

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Condition Monitoring and Real-Time Prozess Control
Project MoSeS-Pro

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Condition Monitoring and Real-Time Prozess Control
Sensor Signals and Data Volumes
(Source: ZEMA Saarbrücken)
 Application Example Projekt MoSeS-Pro

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Industrial Networking
Requirements
 Industrial applications and corresponding requirements
(Source: VDE (ITG), Positionspapier »Funktechnologien für Industrie 4.0«)

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CONTENT
 Introduction
 Applications and Requirements
 Wireless Real-Time Data Transmission Scheme
 Wireless Energy Transmission Scheme
 Conclusion

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Wireless Sensor
Project MoSeS-Pro
 System block level diagram
(Source: Fraunhofer IMS)

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Wireless Data Transmission
Radio Technologies
 Suitability of available standards for industrial applications
(Source: VDE (ITG), Positionspapier »Funktechnologien für Industrie 4.0«)

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Wireless Data Transmission
IO-Link wireless
 Novel communication standard for industrial
production
 IO-Link is a well known standardized IO
technology (IEC 61131-9) for communication
with sensors as well as actuators (via 3 or 5-
wire standard cables)
 IO-Link wireless is an extension of the IO-Link
standard
 IO-Link Community:
 Technical WG »IO-Link wireless«
 Fraunhofer IMS is a member since 2016
 Public review started in September

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Wireless Data Transmission
IO-Link wireless
 System topology wired and wireless
(Source: Fraunhofer IMS)

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IO-Link wireless
Properties
 Scalable number of nodes (10 - 100 participants)
 Constant time frame for all participants: 5 ms
 High reliability: packet error rate < 10-9
 Short telegrams, bandwidth: 1 MHz (1 Mbit / s, gross)
 Scalable range
 Use of parallel systems within a production hall
 Low energy consumption
 Autarkic supplied sensors
 Based on IEEE 802.15.1 (physical layer, bluetooth)

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IO-Link wireless
Properties
 W-Master cell (up to 40 W-Devices per W-Master, overlap possible):
(Source: Fraunhofer IMS)

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IO-Link wireless
Properties
 Use of the license-free 2.4 GHz band:
 78 channels, bandwidth 1 MHz
 Frequency hopping
 Constant time frame: 5 ms (3 x 1,664 ms)
 Two re-transmission with channel change
(Bildquelle: Fraunhofer IMS)

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IO-Link wireless
Methods
 Frequency hopping
 Coexistence mechanisms like dynamic adaptive black listing
 Re-transmissions in each slot
 Error protection coding

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IO-Link wireless
Implementation
 Implementation of IO-Link wireless protocol:
 Physical layer
 Modulation: GFSK
 Frequency hopping
(f = 2402, …, 2478 MHz)
 TX power: ≤ 10 mW (EN 300 328)
 Gross data rate: 1 Mbit/s
 Data link layer
 Packet-, message assembly
 Synchronization, acknowledgement
 Verification with software defined radio
(Source: Fraunhofer IMS)

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CONTENT
 Introduction
 Applications and Requirements
 Wireless Real-Time Data Transmission Scheme
 Wireless Energy Transmission Scheme
 Conclusion

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Wireless Energy Transmission
Charge&Go Concept
 Mobile sensor on deterministic path
 Wireless power transmission ≥ 10 W at “charge” position
 Autarky energy supply during operation “go”
 Power consumption of sensor ≥ 50 mW
»Charge« (s) »Go« (s)
2,1 348
1,0 204
0,5 111
0,2 47
0,1 24
(Source: Fraunhofer IMS)

22. © Fraunhofer Vertraulich
Wireless Energy Transmission
System Overview
 Inductive energy transmission:
 Frequency band: 119 kHz to 140 kHz (EN 300 330)
 Storage and storage management:
 Super cap, dedicated controller
 Data transmission:
 System conditions (available energy, error indication, etc.)
(Source: Fraunhofer IMS)

23. © Fraunhofer Vertraulich
Wireless Energy Transmission
Realization
 Requirements:
 Short coupling time, distances 0 mm to 5 mm, robust in metal
environment, flat design
 Specification:
 Size of receiving coil: 45 mm x 45 mm x 4 mm
 Frequency: 125 kHz
(Source:FraunhoferIMS)
(Source: Fraunhofer IMS)

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Wireless Energy Transmission
Results
 Transmitted Power: 15 W into 1,5 Ω (Rin of super cap charger)
 Available energy: 12,5 J (TCharge = 1 s)
 Capacity: 2 x 1F
(∆UC = 3,2 V, Tgo = 348 s))

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CONTENT
 Introduction
 Applications and Requirements
 Wireless Real-Time Data Transmission Scheme
 Wireless Energy Transmission Scheme
 Conclusion

26. © Fraunhofer
Conclusion
Completely Wireless Real-Time Sensors
 Wireless communication enables the networking of all production units
 It will play a key role in the realization of industry 4.0
 Standard for robust wireless real-time communication
for industrial production needed
 The novel IO-Link wireless standard will fulfill requirements
 “Charge and Go” is a potential approach to supply wireless sensors
wirelessly with energy