Distributed automation

Whether it's the production of pharmaceuticals or food, hygiene, safety and 24/7 monitorability are paramount. You can achieve these goals, for example, by automating your plant or machine in a distributed manner. This works for both new and existing installations and does not have to be complicated. Bürkert supports you with optimally coordinated, compact solutions that fit into existing structures and are flexible - after all, you have to think about tomorrow today and also consider future innovation steps in the context of digitisation. Discover just how easy it is to combine our wide range of components and integrate valve islands, control cabinets and process valves into an automation system. We advise you objectively, solution-neutrally and with a lot of experience.

When does the concept of distributed automation come into question for you?

If you need valves arranged densely in the system.
If you want a flexible formation of sub-systems.
If you want to subsequently automate individual process steps.

With the Bürkert system solution, the required components such as control cabinets or field modules and process valves are optimally matched to each other and can be smoothly connected with intelligent components. A pre-qualified platform facilitates both the planning and the engineering effort. The distributed automation concept can be expanded at any time with minimal effort.

Without control cabinet: Process reliability and product quality directly in the field

What is particularly important to you? Fast switching? The lowest cabling and tubing outlay as possible? The innovative AirLINE Field valve terminals from Bürkert offer both. Since you can install them directly near the process, the valves switch extremely quickly due to the short pneumatic travel distances. So you need less compressed air and energy at the same time. Distributed control enables you to quickly and accurately identify faults and to switch off individual modules instead of the whole plant. This saves costs and time.

With control cabinet: Reliable automation in close proximity to the process

Do you want to automate the pneumatic functions of your plant? Bürkert valve terminals in a control cabinet are suitable for this. The valve island allows you to control processes via a network of single valves. This allows you to make your production processes not only more efficient, but also safer. This is because you detect errors at an early stage with the help of well thought-out diagnostic functions - on the unit and at the operational control level.

Manual solutions and their weaknesses

The advantages of automated process steps can best be understood with the help of an example. Therefore, in the following we will look at the extraction process for the production of sugar or sugar syrup: A conveyor belt transports the crushed sugar beet from the cutting machine to the extraction tower, where the juice is extracted. To prevent the beet pulp and the escaping juice from slipping off, the conveyor belt is equipped with adjustable guides that have to be shifted at short notice depending on the quantity and size of the mixture. This makes the passage larger or smaller. In a conventional manufacturing process, employees have to manually operate cylinders to bring the guides into the correct position.

The conveyor belt in top view shows: The adjustment of the conveyor belt to a changed beet pulp quantity or size must be carried out at exactly the right time. When a worker, who inevitably has to be positioned close to the process, manually enables the pneumatic distributor when a problem suddenly occurs, attention and timing are crucial - in other words: the process is prone to error. In the worst case, you waste material and production time.

Grafische Darstellung einer industriellen Anlage zur Produktion von Zuckersirup; Förderband wird von einer Arbeitskraft manuell justiert

Harsh production conditions such as humidity, cold and dust can lead to errors in the process or even destroy the functionality of the components; individual strands can easily corrode and break. If you want to find errors, this is time-consuming with no or too few diagnostic functions, just like the replacement of mechanical and electrical components and renewing their parameterisation.

Grafische Darstellung des elektrischen Anschlusses eines Ventils mit mehradrigem Kabel, Verschmutzungen

Conventional set-ups are often complex and confusing. This is exemplified by the topic of compressed air: In a conventional hosing system, each individual pneumatic piston hangs on the distribution line, resulting in a large number of hose lines and just as many interfaces. The result: High error potential and leakage risk and a lot of effort in operation and maintenance. In addition, specialised personnel such as electricians, who have to be employed by the company or hired from service providers, are necessary.

Grafische Darstellung eines Ausschnittes einer industriellen Anlage zur Produktion von Zuckersirup; Förderband wird von drei Arbeitskräften justiert und gewartet

Process reliability with a distributed automation concept

To automate a manual process step such as the described correction of the conveyor belt, a distributed automation concept with components in hygienic design is an innovative solution. In the example shown here, the cylinders from a third-party supplier are pneumatically controlled with the AirLINE Field type 8653. The feedback signals on the cylinder are simply connected to the ME64 digital input module via an M12 cable. The pneumatic module type 8653 (IP65/IP67) can be placed close to the cylinder for a fast reaction or switching time. The ME63 gateway is connected via EtherNet/IP to the control cabinet and to the central PLC/SCAD system: This has a big advantage: The operator no longer has to go to the cylinder and manually operate a pneumatic distributor. On the contrary: The operator can check centrally whether the cylinder is open or closed and adjust it individually if necessary.

The advantages of the Bürkert system solution

Digital field devices have great advantages. For piston actuation - to stay with the example mentioned - AirLINE Field valve islands are used, which are connected to a central gateway via the Bürkert System Bus (büS) communication interface, which in turn transmits its data to the PLC control system via Ethernet cable. In this way, permanent digital feedback is generated and, if necessary, error messages are transmitted, allowing you to monitor the system and plan predictive maintenance. The valve islands show you the process status with coloured LEDs and provide precise diagnostic messages and information about the end position via the LC display with plain text and icons. This ensures that an error is identified and rectified rapidly, while product quality can be determined correctly after malfunctioning. Thanks to check valves, process reliability is additionally guaranteed. The valve island type 8653 AirLINE Field has been especially developed for applications in process automation.

Grafische Darstellung einer Ventilinsel Typ 8653 AirLINE Field, diverse Symbole

If a unit needs to be replaced, it can be done in a few minutes. You simply disconnect the cable - which is easy thanks to the M12 plugs - and place the new unit in the system. You do not come into contact with electrical components in the process and therefore do not need a qualified electrician. The automatic device replacement function based on büS detects the component change and loads the configuration from the replaced device into the new one, which can go into operation immediately.

Grafische Darstellung eines Förderbandes mit automtisert justierbarer Führung über Rollen und Pneumatik; Ventilinseln und verbundene Ventile , ein Ventil herausgehoben

The valve islands are always placed in the field where they are needed. A lower dead volume results here from the shorter hose lines between the valve island and the cylinder. This results in lower consumption of compressed air to operate the valves and faster switching and reaction times. This reduces operating costs while increasing process reliability. This is the top priority in automation anyway and is supported by many other elements such as check valves and redundancy functions.

Zweifache grafische Darstellung eines Ausschittes aus einer Anlage mit Förderband, einmal – durchgestrichen – mit manueller Justage, einmal automatiserte Variante mit Ventilinsel und Ventil

You need to be able to clean the valves in your automated system regularly to meet the high hygiene requirements of your customers. That is why Bürkert valves consist of a stainless steel valve body that allows high-pressure cleaning, as well as diaphragms of the highest quality that can withstand strong cleaning chemicals. The fast, individually adjustable switching times also contribute to the production quality and speed.

Grafische Darstellung eines Bürkert-Ventils, diverse Symbole

One thing is crucial for a functioning, future-proof solution: the right planning. We listen to you carefully and analyse what you want to achieve with your application. For a customised solution, we combine intelligent concepts and various industrial protocols as required. If there is a more efficient, easier to install and future-proof alternative solution for your application, we can present it to you objectively and consider the pros and cons together.

Grafik mit drei Symbolelementen, die in einem Kreis mit Verbindungspfeilen angeordnet sind: Gruppe mit zwei Köpfen und Sprechblasen, Diagramm absteigend mit Lupe, Diagramm aufsteigend mit Pfeil

Bürkert consulting service based on an example

Solution 1: Hygienic control cabinets with distance to the actual process

Sometimes the environmental conditions are harsh. Dust, humidity, cold or heat can take their toll on automated systems. That is why Bürkert offers the "Hygienic Design" according to IP67 degree of protection in stainless steel. It is not only extremely resistant to cleaning agents, but also seals off the valve islands in the control cabinet against all environmental influences. In addition, the completely enclosed control cabinets, which are usually located relatively far away from the actual process, provide a plus in work and process safety by preventing employees from accidentally loosening wires or other elements.

Advantages due to distance from the process:

Completely enclosed control cabinets are located away from the process for safety reasons
Valve islands are perfectly protected from environmental influences in the control cabinet
Process safety increases because accidental operating errors are ruled out

Schaltschrank mit intelligenten Prozessventilen

Solution 2: Small control cabinet and distributed devices directly in the field

The counter design is: as close as possible to the process. The smaller control cabinets of this solution require less space in the system and can therefore be placed in the immediate vicinity of the action. The field devices that are to benefit from the fast valve switching times are also located there. Wiring and piping are particularly compact, so less compressed air is needed to operate the valves. At the same time, the automation system is extremely flexible: If further cylinders are to be connected later, this solution enables simple and fast integration.

Advantages of distributed devices:

Small control cabinets can be positioned close to the field devices and the actual production process
Short wiring ensures fast valve switching times and low compressed air consumption
Flexible concept enables further cylinders to be connected at a later date

Schematische Darstellung eines Ausschnitts einer Anlage mit Ventilinseln und verbundenen Ventilen

In the specific example, the customer chose solution 1, because his plant is exposed to harsh weather conditions. Which is your solution? We will be happy to provide you with consultation.

Process automation in practice

Many of our customers already successfully control their plants with Bürkert solutions for distributed automation. In the following user reports, you will learn how you can digitise, optimise and make production processes particularly safe with distributed automation.

Flyer Process control - Distributed automation

Central plant control for efficient and safe production

3.9 MB

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Decentralised automation

Your food or pharmaceutical production processes must be efficient, safe and hygienic. To ensure the processing of valuable raw materials without residues and cross-contamination, to ensure constant product quality and not to risk downtime, digital process monitoring is essential. The easiest way to achieve this is with decentralised automation solutions that can control intelligent components locally and react quickly. To ensure that such a valve technology of short distances fits optimally into your existing machine or system concepts, we advise you objectively and have solution-neutral offers ready for you. In the process, we reduce everything you can do without to a minimum: complexity, risk and engineering effort. We will be more than happy to advise you!

Control Cabinets