INDUSTRIAL AUTOMATION CABLE

Automation is widely used in manufacturing industries for packaging, food and beverage processing, automotive and other production lines. As there are different types of protocols are used in it. Therefore there is also requirements of different types of cables for them.

RS-485 CABLE

Is Modbus same as rs485?

The RS-485 is a serial data transmission standard widely used in industries. The Modbus is a protocol commonly used when we implementing RS-485 communication.

RS-485 Max speed

RS-485 is a serial communications in which the data transmission speed can be up to 10Mbps.
The RS-485 can handle up to 32 device in this way RS-485 really allowed full automation possible with its ability to connect up to 32 device in a system.

RS-485 Cable

RS-485 have good susceptibility to noise as compare to RS-232 and shielding of RS-485 cable increase its susceptibility to the noise. Maximum Cable length for RS-485 is 1200 meters.
In case of RS-485 cable we use twisted pair cable(which reduce cross-talk and electromagnetic induction).
In case of RS-485 cable we try to make capacitance of wire is very Low(nf).
For half duplex communication we use single pair RS-485 cable, But if we need full-duplex communication in that case we use 2 pair RS-485 Cable.

RS-485 type OF CABLE

Armoured RS-485.

Usually Galvanized Steel Wire are use for armouring.

  

Unarmoured RS-485.

We also called it flexible RS-485.

Difference between standard and protocol?

Standard

Standard are guidelines to be followed when a new design is to be formulated. We can also says that a standard is something that is widely adopted.
For example:-
1-RS-485 is a standard defining the electrical characteristics of drivers and receivers for use in serial communications system.
Although RS-485 define signal level, speed, format of data. But data transmission are not specified by RS-485.
2-802.3u standards for fast ethernet. So if anyone were to design a hardware or software related to fast ethernet, they would have to follow those specifications.

Protocol

Protocol are set of rules for having a conversation between two computers to convery a specific set of information. It is an agreement between the communication parties on how the communication is to proceed.
For example:-
TCP/IP is a protocol which decide number of bits used for communication , size of data chunks, addressing format, etc.

                            Profibus (Process Field Bus)

Profibus is a serial communication standard with Multi-Master(or multi-vendor) System responsible for providing the communication between the field sensors and the control system or the controllers. It was developed in 1989, specifically for industrial automation and promoted by Siemens and widespread all over Europe. PROFIBUS use in high speed synchronised servo application(robotic and NC Machine). It also used to operates even in hazardous environment.
In Profibus there are 2 very popular communication profiles Profibus DP and Profibus PA.

Profibus DP(Decentralized peripheral)

In profibus DP we use a DP(Decentralized peripheral) and connect all peripheral(or I/O modules, sensors or transducers ) from it and from this DP we connect our PLC. Currently, 90 percent of the applications involving slaves PROFIBUS utilize the PROFIBUS DP. Profibus DP general designed for internal use.
Profibus DP cable is mostly voilet in color. But also uses 2-core RS-485 screened twisted pair wiring.

Profibus PA(process Automation)

But if we wants more economical structure then we need to use profibus PA where we use single profibus PA Bus to connect all the peripheral and this bus is connected to segment Coupler(or Converter). This segment Coupler(or Converter) is connected to PLC. The PROFIBUS-PA is the PROFIBUS solution that meets the requirements for process automation by connecting automation and process control systems with field equipment process control, such as pressure and temperature transmitters, converters, positioners, etc. In profibus PA two wire carrying both power and data.

                                Profinet(process Field net)

Profinet is newer protocol that was devloped in 2003 for Real-time Ethernet for industrial Automation. Which follow TCP/UDP Or IP protocol. Profinet is used for High speed operation. It's response time is less than 1 millisecond. So it is ideal for High speed application. Profinet use same physical connection as standard ethernet therefore it is very fast.
Profinet device have 3 different types of address IP ADDRESS, MAC address and a device name.
Profinet cable are mostly green in colour and contain robust shielding. But in some cases we can also use 4-core ethernet screened twisted pair cable also.

                                        Ethernet Cables

We have 3 types of ethernet cables coaxial,twisted pair, optical fiber. But LAN twisted pair cable is most popular out of them. Twisted-pair cable can be used as networking cable or telephone cable. It has two type UTP and STP.

What is the difference between UTP and STP cable?

UTP (Unshielded twisted pair) is a cable with wires that are twisted together to reduce noise and crosstalk, but due to no shielding it can be affected by external interference (or noise). Whereas shielded twisted pair(STP) cables are the cables that can protect us from external as we as internal interference(or noise).

 

It is further divide into Category in short we call then "Cat"
Now-a-days the wire which we are using in Twisted pair mostly comes in 4 pair e.g:-Cat 5E,Cat 6 and Cat 6A

Cat 5E

It supports data transfer speeds up to 1 Gbps with 100MHz Bandwidth. It used mainly used in home for creating local area network. It can be used upto 100 metre.

Cat 6

It supports data transfer speeds up to 10 Gbps with 250 MHz Bandwidth with even less (or no) crosstalk interference, due to the cable's improved insulation. Cat 6 is not prefer to use above 55 metre(for ideal performance).

Cat 6A

It supports upto 10 Gbps internet speed with Bandwidth 500mhz. It Used mainly used in IP CAMERA. It can be used upto 100 metre

Note:-Cat6 and above it prefer for Concealed wiring(Inside Wall).

                                                        KNX

KNX is a standard which is used for smart home automation and building control. It is an open standard for commercial and domestic building automation. By the help of KNX we can easly manage lighting, audio, video, security systems, sensors, etc.
The main advantage of KNX, KNX is not based on a specific hardware platform and a network can be controlled by anything from an 8-bit microcontroller to a PC as we needed and according to network demands.
KNX evolved from three earlier standards; European Home Systems(EHS) Protocol , BatiBUS, and EIB(European Installation Bus or it also known as Instabus).

In case of KNX system we mostly used a twisted pairs of solid conductor wire which is green in color and all the devices are connected for it. This is also known as KNX bus.