Analogies are powerful methods used to communicate and explain new concepts, making them more memorable and easier to understand. Several years ago, I delivered a presentation on the topic of Software Configurable Input and Output (SWIO) solutions. I could see that the audience was being politely attentive, but not grasping the topic.
So, I turned to one of the engineers, who was dressed in typical engineering fashion, yes, a white coat. In the chest pocket of his white coat, the engineer had a variety of multiple-coloured markers and etching pens. I asked him what they were all for, and in a detailed engineering response, he clearly outlined that each had an important, unique function.
I then put it to him, “What if one pen could perform all functions?” I think he was as much surprised as upset that I would dare suggest that he discard his pens, which I felt he wore with pride. Why change a tried and trusted solution that was memorable and well understood?
Advantages of Configurability
Let’s assume that each coloured pen represents a specific Industrial Input/Output (I/O) hardware function. The functions can vary from driving an actuator or relay to reading back a measurement from a sensor or thermocouple. These can be controlled/measured via a voltage or a current parameter. Relating this back to the coloured pens, let’s assume Red represents an IEC 61131-2 compatible Digital Input counter function, Green a 4 – 20mA Analog Out function and Blue a 2-wire Resistance Temperature Detector (RTD). You get the idea.
Now consider this—a single product/solution that can be reconfigured at the same terminal pins to perform all the functions mentioned above. The AD74416H, Quad-Channel, Software Configurable Input and Output with HART Modem, is one of a family of such products.
The advantages of a single solution that provides all the required functions include lower inventory costs and more streamlined procurement. Similarly, a single platform approach enables reuse across multiple end solutions, reducing engineering time by avoiding multiple design and validation cycles.
Figure 1: Single Platform - Multiple Use Cases
Who Determines Market Adoption?
Market adoption of configurable solutions will be influenced by technicians who install, configure, and service I/O units. Technicians, represented by the person in the white jacket I spoke with. Technicians who are highly experienced but may be biased by an element of inertia. Technicians who are part of a declining resource pool.
Industry trends within the smart factory have suggested a transition towards “a dark factory”—one with less manual input for servicing, calibration, and reconfiguration. This will further be facilitated by a shift from hardware configuration on the factory floor toward a more centrally controlled, software approach. SWIO solutions are enabling this transition.
Future Thinking and Overcoming Inertia
Inertia and backwards compatibility are some reasons why customers prefer to stick with what is tried and trusted. Investing in a SWIO or UIO (Universal Input/Output) solution should not be solely considered as a replacement for one fixed-function hardware device with another more configurable one. At t0, a defined function may be all that is required. What’s also important is how this platform solution can be tailored to different end uses throughout its lifetime.
In the industrial end market, new product ramp cycles are typically slower, with incremental changes rigorously tested before deployment. Indeed, the technician who is responsible for ensuring zero downtime is conservative by nature. Even if the multiple pen solution were available, something tells me this engineer would still proudly wear all his multi-coloured pens, like badges of distinction!
Read all the blogs in the Configurable Industrial I/O series.