The document discusses the development of completely wireless real-time sensors for Industry 4.0 applications, highlighting the need for wireless communication due to the impracticality of cabling in harsh environments and moving machine parts. It introduces the Io-Link wireless standard, which enables reliable industrial communication and emphasizes the 'charge and go' concept for wireless energy transmission to power mobile sensors. The conclusion underscores the importance of robust wireless real-time communication for the successful implementation of smart factory technologies.

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

3. © Fraunhofer
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«)

13. © Fraunhofer
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)

18. © Fraunhofer
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))

25. © Fraunhofer
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