NDT 2025 , 3 , 7
5of 12
through drive-derived analytics alone [5]. This approach reduces reliance on additional hardware, making NDT applications more cost-effective and scalable. Furthermore, by archiving and analyzing VFD-calculated metrics over time, industries can leverage ML- and AI-driven diagnostics for pattern recognition and predictive fault detection, further optimizing maintenance strategies [8,9]. 4. Accessing VFD Data via Industrial Communication Protocols The user has many options for how data flow from the inbuilt repository of the VFD. Many systems use programmable logic controllers (PLCs), distributed control systems (DCSs), or proprietary controllers, where the drive can be a simple field device exchanging data or a smart device transforming data [17]. The decision to even capture the data versus just having a threshold warning or fault must also be made. The selection of design can depend on the number of VFDs in the applied system, where a standalone VFD without complementary functions can use a program akin to the supplied Python example [19,20] or an existing system in a paper mill, where hundreds of VFDs are controlled by a PLC or DCS, requiring an advanced strategy of integration or replacement [15,21]. It is important to note that PLCs and DCSs can be the center of both collection and transformation through the ML techniques noted earlier or can serve as a bridge to a tertiary system [16]. Additionally, the expanse of the larger system can involve an enterprise solution as part of an Industry 4.0 design where the VFDs and corresponding control become Industrial Internet of Things (IIoT) field and edge devices [12,22]. The complication has become the interchangeable language used where condition monitoring, AI, ML, Industry 4.0, and IIoT have become inseparably entangled [4,8]. In the noted options for flow and control, a protocol is a standardized communi- cation method that enables devices such as VFDs, PLCs, and DCSs to exchange data efficiently [17]. Unlike traditional hardwired input/output connections, protocols such as Modbus, PROFINET, and EtherNet/IP use digital networks to transmit multiple parameters over a single connection, reducing wiring complexity and improving data accessibility [17]. This shift from point-to-point wiring to fieldbus communication enhances real-time control, diagnostics, and system scalability across industrial applications [21]. Using fieldbus to access VFD data offers several benefits [22]. It enables faster response times because multiple parameters such as motor speed, torque, and fault diagnostics can be transmitted in real-time continuous monitoring and predictive maintenance [15]. Field- bus also reduces wiring costs by consolidating signals into a single network, minimizing installation complexity [15,17]. Additionally, centralized supervisory control and data acquisition (SCADA) or cloud-based systems can collect, log, and analyze VFD data re- motely, improving efficiency in industries such as manufacturing, energy, and wastewater treatment [15,16]. By integrating advanced fieldbus protocols, VFDs can synchronize with other industrial devices, optimizing coordinated control in multidrive systems [12]. Designers select different protocols based on factors such as industry standards, speed requirements, and system architecture [15]. For example, PROFINET is commonly used in Siemens-based automation, while EtherNet/IP is preferred for Rockwell/Allen-Bradley PLCs [21]. High-speed protocols such as EtherCAT and SERCOS III are ideal for precision motion control, whereas Modbus TCP/IP remains a cost-effective, vendor-neutral solution for SCADA and remote monitoring [21]. Scalability must also be considered—PROFIBUS and EtherNet/IP support large, complex networks, while CANopen and DeviceNet are used for simpler real-time control [21]. By choosing the correct protocol, industries can ensure seamless integration, optimized performance, and improved reliability in their automation systems (Table 4; [15]).
Made with FlippingBook interactive PDF creator