The digitization of production methods introduces fresh challenges for the industrial automation sector. The Industrial Internet of Things presents significant chances to enhance efficiency and maximize the productivity of machinery and manufacturing processes. Therefore, there is a requirement for straightforward, adaptable, and secure integration of automation platforms with factory IT infrastructures. Simplicity is achieved by utilizing standard protocols, common in the IT sector, that enable automated machines to communicate with supervisory, production control (e.g., MES) and management (e.g., ERP) systems.
Flexibility, conversely, arises from adjusting to diverse applications and usage modes without needing to alter the machine. From a practical standpoint, one must be able to install new applications on devices without altering a single line of code. Likewise, visualization should be adaptable: featuring operator-configurable interfaces that are user-friendly and offer the same “user experience” as in apps and the web.
Ultimately, security necessitates that automation platforms are crafted to satisfy the demands imposed by emerging cybersecurity regulations, including the NIS2 Directive, which is currently in effect, as well as the New Machinery Regulation and the Cyber Resilience Act, set to be implemented in 2027.
G-Mation is an open, scalable platform that implements the IEC 61131-3 standard for PLC programming and provides continuity with the entire application stack developed by Gefran over the years. In addition, it includes an architecture based on Docker technology that allows countless functionalities to be integrated in the form of apps, just as in the case of tablets and smartphones.
This architecture was designed from the beginning to have no impact on process control performance. Many of the PLC configuration and diagnostic features are implemented in the form of apps, with the ability to add new applications through a dedicated web interface.
The entire G-Mation platform is based on the “real time” Ethercat communication protocol: individual I/O modules represent Ethercat nodes, while the P6 PLC can manage two separate Ethercat networks, also supporting ring, star and tree network topologies. Compatibility with existing applications is ensured by the availability of CanOpen and Modbus masters on the PLC as well.
On the connectivity side to Cloud or other Edge devices, the G-Mation P6 implements MQTT, OPC UA and Euromap communication standards, to which are added SQL/non-SQL databases and versatile low-code/no-code communication configuration interfaces.
Finally, the PLC has a built-in web server for generating html pages that can be viewed on browser panels or supervisory workstations, as well as on any control and monitoring PC or tablet. Visualization via html pages is complementary to the use of traditional Java pages, which are already available at launch and ensure continuity with the entire portfolio of applications already developed with Gefran automation platforms. The advantages of html pages include: scalability to any display size without changes to the application code, intuitive user interface, customization by the operator, and a user experience similar to tablets and commonly used web pages.
“Proliferation of data sources, new automation architectures, migration to IT communication standards, integration to the cloud, applications of artificial intelligence…ongoing trends pose potentially very complex challenges for machine builders. These are challenges that must be faced and overcome, as they represent the key to achieving a major leap in productivity and efficiency, enabling OEMs to increase both competitiveness and marginality.” comments Marco Svara, Chief Technology Officer at Gefran, who continues ”But complexity can be simplified. How? By using process controllers that also implement data analysis and transmission capabilities, based on open architectures and designed to be securely integrated with cloud applications.”
In addition to P6 PLCs, Gefran’s G-Mation architecture at launch includes G3 I/O modules, which can be integrated either in the CPU body or in a remote configuration, and V44 and V45 HMI panels, based on Java technology and with the option i PLC integrated. Additional G-Mation product releases will take place later this year.