Modular Machines
Modular machines combine standardized system modules into flexible machine designs and enable decentralized automation, easy expansion, and rapid commissioning
Quick read
Modular machines are machine designs consisting of standardized, combinable modules that allow for flexible adaptation to different applications. Modular machines can be configured into various machine types by combining individual modules, thereby leveraging economies of scale for manufacturing and expansion. TURCK supports modular machines with decentralized I/O components in IP67 and IP20 solutions for control cabinets, IP67 safety controllers, field PLCs, and I/O systems with integrated logic control. Modular machines benefit from standardized interfaces for mechanics, power supply, communication, and compressed air. Modular machines use Ethernet-based communication to link modules and can connect different Ethernet protocols via IP67 connectors. Modular machines are increasingly shifting automation and control functions to the field level, thereby enabling self-sufficient machine modules and decentralized automation architectures.
Why build machines modularly?
The core concept of modularity in mechanical engineering is to divide complex machines into modules so that they can be assembled individually using an increasing number of identical parts. The variety of machine types is achieved through combinations of these modules. Thanks to the economies of scale achieved in this way, modular machines can be manufactured more quickly and cost-effectively. In addition, they can be commissioned more quickly and expanded more flexibly.
To ensure that units can be combined quickly and easily, standardized interfaces are needed: mechanical ones, as well as those for power transmission, communication, and, if necessary, compressed air. Modularity is not a characteristic that can be answered with a simple “yes” or “no.” Rather, it follows a spectrum ranging from low to absolute modularity.
Decentralized automation promotes modularization
Point-to-point wiring in the central control cabinet makes consistent Modularization impossible. Replacing a module or expanding a machine is made more difficult by these centralized structures. Machine modules require self-contained structures. These can be implemented in small on-site control boxes attached to the module using IP20 components.
However, wiring and installation are usually more complex than with IP67-rated components, which can be installed directly on the machine without any additional protective measures. However, if certain components are not available in IP67 or if there are specific requirements regarding hygienic design, food compliance, or chemical resistance, IP20 solutions in protective enclosures are often the only viable option.
IP67 automation components facilitate the interconnectivity of modules. Decentralized I/O components designed for installation directly in the field allow signals to be collected right at the source on the module and transmitted from module to module via an Ethernet connection—without the need for a control cabinet. This reduces installation costs and shortens commissioning times for the end customer.
IP67 adapters translate between Ethernet protocols
Machines and modules using different Ethernet protocols can be connected directly in the field with minimal effort using so-called spanners. The use of industry-standard communication protocols makes commissioning and interconnectivity easy and efficient. This is particularly true for modular machine design.
Decentralized safety concepts
Even applications that require safe automation can be planned and implemented using a modular design strategy. This means that, using the same approach for power and data supply, any safety signal from sensors or emergency stop switches can be collected simply and efficiently.
Safety functions can also be controlled decentrally by IP67 safety controllers directly at the modules. This avoids long cycle times to central safety controllers, which ultimately allows for smaller safety distances on the machine. You can find more benefits of decentralized safety solutions on our technology page dedicated to machine safety.
Modularization of control solutions
Consistent modularization also requires the relocation of various control functions to the machine module. These functions can be performed either by I/O systems with integrated logic control or by true compact PLCs. Both product groups—I/O modules and controllers—can be designed in IP20 for installation in control cabinets or as IP67 variants for direct field mounting—with the cabinet-free IP67 variant offering significant benefits in terms of wiring and flexibility. Offloading safety logic to the I/O module can offer additional benefits, such as faster execution of safety functions or an overall more cost-effective safety architecture, since no central safety controller or F-CPU is required.
The on-site controllers communicate with higher-level control systems or HMIs for monitoring, documentation, or visualization. The selection of the appropriate control solution depends on the type and size of the machine. This helps avoid oversized control solutions. The effort required of the user remains minimal, while the machine’s efficiency increases. Since the local logic module preprocesses the data, only relevant process information needs to be transmitted to higher-level control systems.
Shifting intelligence to the field level
The shift of intelligence to the field must be implemented in the software during the engineering phase. As self-contained systems, the machine modules process the inputs from neighboring modules and use them to determine their actions. Depending on a module’s complexity, this can be handled by I/O components with logical functions or by field PLCs. At the interface between two machine modules, only the information necessary for the neighboring module is then transmitted.
Offloading software functions can offer many benefits:
- Reducing the load on the main communication link
- Reducing the load on the main control system—up to and including complete replacement
- Module tests prior to commissioning and integration
- Integration of third-party modules is made easier because the central control system can
remain unchanged. Easy system expansion
The more consistently machines are modularized and intelligence is decentralized, the more the rigid structure of the automation pyramid begins to falter. Hierarchies are becoming more permeable, particularly at the sensor/actuator, I/O, and control levels.
Benefits
Modularization as a driver of progress
It stands to reason that Modularization will also gain a foothold in mechanical engineering. Other industries have already made the transition from artisanal production to mass production. When items are produced in series, efficiency gains can be achieved through economies of scale. Repetitive processes are automated, freeing up employees for creative, higher-value-added tasks. Modularization, as a driver of innovation, is now setting the machinery and plant engineering sectors in motion as well.
Rapid Time to Market
Modular machines meet many of the expectations placed on industrial companies today. They:
- streamline ordering processes
- shorten delivery times
- increase flexibility for both the customer and the manufacturer when machines are
expanded or relocated
Downloads and Products
Modular Machines in Practice: Added Value for Your Application
Efficient and robust solutions for real-world applications—designed for demanding operating conditions and proven in everyday industrial use.
Modular Machines at TURCK: Frequently Asked Questions
1. What are modular machines, and why are they used?
Modular machines consist of standardized machine modules that can be flexibly combined. Modular machines can be configured into different machine types by combining individual modules. TURCK describes modularity as a way to manufacture machines more quickly and cost-effectively, perform commissioning faster, and expand them more easily.
2. What role does decentralized automation play in modular machines?
According to TURCK, modular machines require self-contained structures within the individual modules. Decentralized automation allows signal acquisition and control tasks to be relocated to the machine modules. To achieve this, IP20 components are used in control cabinets, or IP67-rated decentralized components are installed directly on the machine.
3. Which TURCK components are suitable for modular machines?
Modular machines can be implemented using decentralized I/O components rated IP67, IP67 safety controllers, field PLCs, and I/O systems with integrated logic control. TURCK describes these components as the foundation for machine modules with their own signal processing, control, and safety logic.
4. How do modules in modular machines communicate with each other?
Modular machines use Ethernet connections to link individual modules. Decentralized I/O components collect signals directly at the point of origin and transmit them between the modules. TURCK also describes IP67 connectors that can connect machine modules using different Ethernet protocols directly in the field.
5. Which Ethernet protocols can be used to establish connections between modular machines?
Modular machines can interface different Ethernet protocols with one another. TURCK describes IP67-rated adapters that translate between PROFINET, EtherNet/IP, and Modbus TCP. This allows modules with different communication standards to be connected within a common machine architecture.
6. How is machine safety implemented in modular machines?
Modular machines can perform safety functions decentrally within the individual modules. TURCK describes the use of IP67 safety controllers that control safety functions directly at the module level. Safety-related signals from sensors or emergency stop switches can be detected using the same concept for power and data supply.
7. What role do control systems and software play in modular machines?
Modular machines distribute control functions across the individual machine modules. TURCK describes the use of I/O systems with integrated logic control as well as field PLCs. The machine modules process inputs from adjacent modules independently and transmit only the information required by other modules.
8. How do modular machines support visualization and higher-level control systems?
Modular machines use local controllers to perform functions within the module. The controllers communicate with higher-level controllers or HMIs (human-machine interfaces) for control, documentation, or visualization. TURCK describes this architecture as a way to distribute control tasks as needed.
9. What cost or licensing models does the source mention for modular machines?
The source code contains no information regarding licensing models or software costs for modular machines. TURCK describes technical concepts for the Modularization of machines, decentralized automation, and communication between modules. No economic key figures or licensing information are provided.
10. In what applications are modular machines used?
Modular machines are used in a variety of industries. Examples from the source text include modular production lines, conveyor systems, machines with safety-critical automation functions, and systems that need to connect different Ethernet protocols. A pharmaceutical company might use modular skids, while a machine builder might combine flexible production modules.