[Editor's Note] As a way to build smart factories in industrial sites, a digitalized system design method based on IIoT is being adopted. Motors are essential components involved in factory production efficiency, and it is important for equipment manufacturers to innovate their motor load management systems to increase efficiency. Schneider Electric presents the digital motor management system 'TeSys Island' to easily support the entire process from equipment engineering, manufacturing, and delivery. Our magazine arranged a meeting with Schneider Electric Manager Oh Jeong-hoon to hear about the introduction and introduction case of the digital motor starter TeSys Island.

■ Why building a digital motor management system is important

Motors break down for a variety of reasons, including equipment aging due to long-term use and equipment failure. If even one motor breaks down, it affects the entire production line and has a significant impact on productivity.

To solve this problem, smart motor control centers (MCCs) are being introduced worldwide. It is estimated that about 70% of companies currently have digital motor management systems. Smart MCCs are also being considered in industrial settings due to labor shortages and rising fuel costs.

*Motor Control Center (MCC): When using many motors in power plants, plants, industrial facilities, etc., they are controlled in a centralized manner. At this time, an MCC is configured in the electrical room or equipment room to control the motor operation and stop status.

Schneider Electric's digital motor management solution, Tesis Island, is a product based on digitalization in line with the Industry 4.0 trend that combines IT and OT, and can help customers build smart solutions.

■ TeSys Island features and advantages over other companies

Tesis Island Tesis Island is a digital motor starter product that integrates an electric motor protection relay (EOCR) and an electronic contactor. A single device performs multiple functions, including switching, motor starter, and application control.

While existing products only perform the roles of an electronic contactor, contactor revision function, and relay, Tesis Island performs the roles of four devices: an electronic contactor, an overload relay, overcurrent protection, and a meter for measuring current, voltage, and power in a single device.

In addition, motor-related data values such as current, voltage, power, and temperature can be communicated to another upper PLC via a bus coupler. Up to 20 motor starters were previously used, but they can be connected with a ribbon cable and integrated into one bus coupler to connect to a PLC with one communication port.

While third-party devices require installation of devices for communication connections on each line, Tesis Island can be used simply without unnecessary hardwiring as it is integrated into a single bus coupler.

It also complies with Level 2 of the 'Achilles Communications Certification', an international certification that evaluates the network security of industrial devices.

There is no mandatory safety rating in Korea, but demand for it has been increasing recently in conjunction with the Serious Disasters Act. The Tesis Island meets the highest safety rating, C3 Performance Level 2, when using a C starter.

Tesis Island simplifies programming by applying the 'Avatar' concept to control the PLC with a single communication line. The number of cables used is reduced because the communication module is directly connected to the PLC without the need for separate hardware by setting it by function rather than by device.

The Tesis Avatar is controlled by the Bus Coupler, which is the brain of Tesis Island, and the Bus Coupler manages communication between the PLC and Tesis Island. It is also highly compatible with third-party PLCs, so it can be easily integrated into third-party automation systems.

■ Domestic and international TeSys Island introduction cases

Tesis Island was introduced to several companies considering the application of smart MCC. For example, Sonny's, an American conveyor car wash equipment company, adopted Tesis Island for its next model with smart MCC.

There are numerous loads that require power, such as conveyors that pull vehicles or various scrubber arms that clean vehicles. More than 40 central motors in a 40m conveyor tunnel can generate loads.

Sony has implemented Schneider products to minimize downtime and maximize energy efficiency in its car wash tunnel system.

By checking data values and operating status in real time through HMI, operators can remotely access cabinet information and solve problems. In addition, non-technical people can easily restart the system through the HMI screen.

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