The manufacturing sector is transforming faster than ever before, accelerated by the continued rise of Industry 4.0 and digital transformation. However, amid all this change, one critical but often overlooked constant remains: Power.
In the age of digital transformation, power is no longer a “basic utility” but rather a critical enabler of smart manufacturing.
“Smart automation requires smart power to succeed. We see manufacturers around the country investing heavily in digitisation, connectivity and smart technologies, but what is often overlooked is the foundation upon which all of this innovation depends: the power infrastructure,” said Supriya Suhale, category manager for Beckhoff Automation Australia.
“When power systems communicate with control architecture, they’re no longer isolated black boxes but rather active contributors to machine intelligence. That’s exactly what our customers are asking for.”
Redefining power’s role in Industry 4.0
More than a simple ‘on/off switch’, smart factories require efficient, flexible and intelligent power infrastructure.
“Traditional, static power systems can no longer keep pace with today’s demands. Stable, monitored power delivery sources are now required to support the massive data throughput that keeps smart systems running efficiently,” Suhale added.
Suhale highlights a range of power solutions, including diagnostic capable power supplies that support logging, alarm handling, trend analysis and remote maintenance along with protocol support.
“Technologies like distributed power nodes, DC/DC converters at the field level and UPS systems with segmented protection have been crucial in ensuring that systems can operate effectively, even in times of power disruptions,” she explained.
“These technologies ensure that critical operations stay online while allowing non-essential systems to safely shut down, reducing risk and increasing essential uptime.”
To build a robust and scalable smart power infrastructure, Suhale adds that manufacturers should embed strategic design principles from the outset. Some of the most effective best practices include:
- Designing for visibility: prioritise systems with diagnostic feedback and integration capabilities with SCADA/PLC platforms for real-time monitoring.
- Planning for segmentation: separate critical and non-critical loads, enabling the use of redundancy or UPS for essential operations, while safely powering down auxiliary systems during outages.
- Balancing centralisation and decentralisation: evaluate where distributed power nodes or field-mounted converters can enhance performance, reduce cable losses, or simplify maintenance.
- Sizing for efficiency: avoid under or over sizing by following thermal derating guidelines and factoring in ambient conditions to ensure optimal operation.
- Preparing for future upgrades: choose modular components with standardised interfaces like EtherCAT or IO-Link to support the integration of future smart devices.
“These design choices aren’t just about reliability, they’re about empowering continuous improvement, extending system life, and preparing for what’s next,” Suhale noted.
Smart power: smarter long-term savings
When it comes to investing, Suhale said businesses should not focus solely on the upfront cost of equipment but should rather factor in the Total Cost of Ownership (TCO).
“Beyond the purchase price, real savings come from reduced energy bills, less maintenance, fewer breakdowns and greater future scalability,” she said.
Implementing high efficiency power supplies, integrated energy monitoring modules and smart UPS systems help drive down energy losses, reducing maintenance needs and minimising unplanned downtime which in turn leads to major savings and a quicker return on investment.
“Implementing these systems can lead to real-world benefits such as identifying high draw components, optimising duty cycles and triggering alarms when thresholds are breached,” Suhale added.
Conversely, relying on oversized, static power supplies, non-redundant UPS setups, or ignoring load balancing can drive up costs through breakdowns, energy loss and premature wear.
To truly futureproof investments and maintain a competitive edge, manufacturers must approach power infrastructure strategically.
Suhale outlines a comprehensive checklist of critical design and investment considerations that support long-term operational and business goals. The critical considerations needed to futureproof power infrastructure are:
- Redundancy for critical loads: ensure backup options for PLCs, drives and essential systems to avoid costly downtime.
- Modular design: use modular components to simplify expansion, upgrades and maintenance.
- Diagnostic capability: select systems with local indicators and fieldbus communication for real-time monitoring and troubleshooting.
- Smart UPS protection: protect critical devices with UPS systems that support segmented output and safe shutdowns.
- Real-time energy monitoring: monitor energy usage at the machine or panel level to reduce waste and optimise performance.
- Fieldbus compatibility: support standard protocols like EtherCAT or OPC UA for seamless integration.
- Right sizing and thermal derating: match power supply size to real-world conditions to prevent overload and extend system life.
- Overcurrent and short circuit protection: use fast acting protection to enhance safety and system reliability.
- Load balancing: distribute loads evenly across power supplies to increase efficiency and durability.
- Efficiency standard compliance: choose products certified to EN 61000, IEC 62368 and other relevant standards.
- Industry specific certifications: ensure suitability for specialised environments with certifications like DNV GL or IECEx.
Enabling smarter, greener decisions
“Smart power is also smarter for the planet. Factories that integrate energy efficient solutions are better positioned to meet their sustainability goals and most importantly, reduce their environmental footprint,” Suhale explained.
“Energy efficiency comes down to machine level energy transparency. Providing customers with the ability to analyse energy consumption per axis, per process and per I/O group puts the power in their hands.
“Another big benefit of smarter power solutions is future scalability. These systems allow customers to scale their systems without the need for a big redesign or costly downtime.”
Beckhoff Automation says it is uniquely positioned to support this transition, offering a comprehensive portfolio of intelligent power solutions, from modular power supplies and energy efficient terminals to advanced UPS systems with One Cable Technology. These solutions are engineered to integrate seamlessly, scale effortlessly, and deliver actionable insights for continuous improvement.
“We pride ourselves on empowering manufacturers through solutions that can be easily monitored and scaled with precision,” Supriya added.
“Taking a strategic approach to power infrastructure offers long-term financial advantages and sustainability. A smart power strategy cannot be overlooked. It is an investment in operational efficiency, uptime, sustainability and long-term business growth.”
