Les 5 causes les plus souvent à l'origine des problèmes rencontrés avec les modules électroniques industriels dans les environnements de production

Unexpected problems in a production line due to industrial electronics, every technical service’s nightmare. After all, stalling production doesn’t make anyone in the company happy. These problems can arise from the failure of a module due to incorrect installation during replacement, for example, or the result of extreme currents/voltages, severe weather or time-related defects. However, a defect is not always the culprit. Problems can also have another cause. What exactly are the most common causes of industrial electronics problems in production environments? You can read all about it in our blog. We also give a number of examples of things we encounter in the field, and tips for preventing these problems. 

 1. Defect due to time-related defects 

Not entirely surprisingly – the list is topped by failure of modules as a result of time-related defects. Electronic components, like all manufactured systems, have a finite operational life. By continuing to use components after this point, the chance of defects increases considerably. It is therefore extremely important to detect and remedy the aging (of time-sensitive components) in time. This is before the electronics actually fail and cause production problems or even unplanned downtime. 

 2. Defect due to overvoltage 

The failure of modules due to overvoltage is number two on the list of most common causes. The so-called overvoltage can be a result of incorrect connection, severe weather such as lightning strikes, power supplies that are not properly adjusted, or due to a blockage in the system, causing a peak voltage. Case study: Overvoltage due to faulty connection is more common than you might expect. One mistake can therefore already cause the module to fail. For example, with many Siemens modules, the connections of the 120-240V AC and 24V DC are right next to each other. Add to that the fact that the signs at the connection look alike, and a problem can arise in no time. 

 3. Problems due to configuration errors in the software 

 We also encounter configuration errors quite regularly in production environments. Most of the configuration errors we see are network related (PROFIBUS and PROFINET). We also regularly encounter malfunctions that cannot be traced back at a glance, and that require extensive faultfinding. 

Case study: We recently helped in a situation where an adjustment was made in the setup of a distribution system (addition of a module), but that was not updated on the drawings of the system. In such cases, there is a high chance that problems and malfunctions will be encountered in the future. Like – in this case – where not recording the replacement of multiple modules caused a lot of time to be lost in detecting the malfunction. 

 4. Problems due to improper backup management 

When modules are replaced (preventively), this does not always work out well. Certainly not when there is incorrect and/or incomplete backup management. When a new module is installed, it often happens that a backup is installed that turns out to be old or incomplete. 

Our tip: Make sure the correct backups are available at all times. In addition, save the backups centrally, and do not forget to save previous versions. This prevents many problems when you replace one or more modules, and backups unexpectedly have to be restored.

5. Issues due to poor performance of specific modules 

Time-related defects do not always necessarily result in the failure of modules. We often see that modules - over time - start to underperform, even though they are not immediately defective. In many cases, this is the result of mechanical parts 'getting tired'. It is therefore important to ensure (preventive) maintenance of the time-bound components within the modules. Reduced performance or failure of the module does not necessarily mean the module is completely unusable for the future. We can give many modules a second or even third life by replacing time-barred components. 

Case study: A clear example of a drop in performance is increased power consumption. If a power supply or regulator is no longer in good condition, it must work harder to meet its specifications. This then results in a higher power consumption. Higher consumption is accompanied by more heat development, which can cause the power supply or servo drive to break down more rapidly. 

 Need help fixing or preventing problems? 

Do you suffer from one or more of the problems mentioned above, or do you want to anticipate these problems before they occur, but don’t know how? We are happy to help you. UNIS Group is your full-service partner for industrial electronics. Contact us on int@unisgroup.com or +31 566 72 61 96 and we will be happy to discuss the possibilities with you.