Pavla Borovianova, Industry Manager at LAPP, highlights the challenges and future prospects of decentralised cable solutions and shows approaches for the successful implementation of this transformation.
Decentralised systems are becoming increasingly important and are slowly replacing centralised systems. What are the main differences between centralised and decentralised cable solutions in conveyor technology?
Centralized cable solutions bundle the controls and power distribution at a single point. This means that all motors are supplied with power, control, and data lines from the central control cabinet.
In decentralised systems, on the other hand, the controls are located closer to the motors or modules. Frequency converters mounted directly on the motors are used to control and regulate the motors. These connect the motors either via daisy chain connections or via branches using junction boxes. This reduces cable requirements by up to 90%.
Decentralised solutions therefore reduce cable requirements. What other advantages do these systems have over centralised ones?
One advantage directly related to the reduction in material is greater flexibility. Modular conveyor systems in particular often require systems to be converted quickly and easily or adapted to new requirements. In such cases, decentralised cabling proves to be extremely advantageous.
Another aspect that is particularly important in modular conveyor systems is increased efficiency. The reduced cabling effort simplifies installation, saving both time and money.
An additional technical advantage is the improvement in electromagnetic compatibility (EMC). Positioning the controllers closer to the motors means that shorter cable runs are required, which reduces interference and optimizes EMC.
Pre-assembled cables are often used to take full advantage of decentralised cabling. LAPP offers customised solutions for this as part of the ÖLFLEX ® CONNECT program – from individual pre-assembled power and control cables to patchcords and complete cable harnesses. Our experts work closely with customers to develop customised cable solutions. The aim is to ensure an optimal product selection, reliable connection technology, and an efficient procurement and logistics process.
Many systems continue to operate with centralised systems. What are the challenges involved in switching from centralised to decentralised systems, and what specific cabling solutions does LAPP offer in this area?
The transition from a centralised to a decentralised system requires careful planning in order to optimally integrate the existing infrastructure. In addition, planning, installation, and maintenance must take into account that the control system is moving closer to the motors. Data communication is also decentralised in a decentralszed cabling system. Almost all products from the LAPP portfolio are used for data transmission.
We offer components for all Industrial Ethernet protocols as a complete solution, including patch cords, cord sets, and remote I/O devices from the ETHERLINE® and UNITRONIC® series.
In addition to the cable systems already mentioned, LAPP also offers hybrid cables that combine power and data transmission. How important is this technology for decentralised systems, and what influence does it have on the installation and operation of conveyor systems?
Hybrid cables, which enable power, signal, and data transmission simultaneously – so-called single-cable technology for connecting frequency converters and servo motors – play an important role in decentralised cabling architectures.
The use of this single-cable technology significantly reduces system complexity. At the same time, connection costs are reduced due to lower cabling requirements, while installation time is also shortened due to the smaller number of components required.
Do you believe that decentralised cable solutions will completely replace centralised architectures in the long term, or will there continue to be applications where centralised solutions are preferred? Are there any other developments that make decentralised systems even more attractive?
Decentralised systems will replace centralised architectures in many areas because they are more efficient and flexible. Nevertheless, there will be applications where centralised solutions are preferred, especially in small systems or where specific technical requirements apply.
LAPP is currently working with partners on another innovation: a DC microgrid for drives in conveyor technology. The connection to a flat cable is made without tools using piercing technology. This solution significantly reduces installation times, minimises sources of error during installation, and lowers operating costs over the entire life cycle of a conveyor system.
LAPP: Your partner for the future of intralogistics
Rely on LAPP’s expertise to optimise your intralogistics processes and prepare them for the future. Our connection solutions and our expertise in connection technology make us your reliable partner in an increasingly digitalised and automated world. With LAPP at your side, you can concentrate on your core competencies while we ensure that your logistics are always one step ahead.
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