Task

To ensure a safe, effective, and sustainable electrolysis process, all relevant process variables must be precisely monitored. The most important of these are temperature and conductivity to prevent overheating, loss of performance, deposits, or malfunctions. Since even the smallest deviations can impair process efficiency and the quality of the electrolyte, the plant is to be equipped with a high precision measuring system that provides stable and error free values and that enables continuous monitoring.

Solution approach

The required measuring system is implemented using innovative IO-Link sensors from JUMO. They not only ensure accurate temperature and conductivity measurements in real time, but also offer a digital interface for simplified planning and startup. Instead of complex wiring with separate lines for energy and sensor data, a standardized cable with M12 plug connectors is sufficient, as it transmits both current and digital measured values. As a result, wiring requirements are reduced by up to 50%, depending on the size of the plant.

The sensors can be parametrized centrally while configurations can be saved and transmitted quickly to other devices as required. This saves time, facilitates integration into the control environment, and increases flexibility for adjustments or enhancements. Extensive diagnostic data in real time allows deviations or wear to be detected early on and effectively resolved. In addition, IO-Link technology enables remote diagnostics and remote maintenance so that operators and service technicians have access to all relevant sensor information at any time without having to be on-site.

Project outcome

The project impressively demonstrates how IO-Link is sustainably transforming industrial automation − hydrogen production in particular − while opening up new dimensions of transparency, efficiency, and process reliability. System complexity is reduced, plant availability is increased, and competitive advantages are established. Ultimately, the result is a model project that shows how digitization and sustainability go hand in hand and that can drive the energy transition forward.