connect four... - Control Design

Transcription

controldesign.com
CONNECT
FOUR...
...or More Machines and Share the Data. With Internet
and Cellular Technology, You Can Monitor and
Manipulate Machines From Just About Anywhere
NEW EYES
FOR OLD
MACHINES
NOVEMBER 2011
NO HISSING
AT NEW
PNEUMATICS
OPTIONS
CD1111_01_Cover.indd 16
SaaS FOR
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CONTR
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CONTRLDES_1111_Control Design 10/19/11 10:34 AM Page 1
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© COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
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©2011 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.
Other product and company names listed are trademarks or trade names of their respective companies. 01197
Barrett_107B.indd 1
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CONTENTS
NOVEMBER 2011
FEATURES
24 Cover Story
Connect Four...
...or More Machines and Share the Data. With Internet and Cellular
Technology, You Can Monitor and Manipulate Machines From Just
About Anywhere
Volume 15, No. 11
Dan Hebert, PE, senior technical editor
33 Measurement, Sensing & Vision
Put the Screws to Tough Vision Apps
New Machine Vision Testing Makes Vintage Machines Perform
24
Better and Satisfy Demanding Customers
Joe Feeley, editor in chief
38 Product Roundup
All-Inclusive or Else
Pace Quickens for Integrated Machine Automation Software
Development Platforms
COLUMNS
13
7 ControlDesign.com
23 Embedded Intelligence
Less Is More. Or Is It?
In Redundancy We Trust
9 Editor’s Page
37 TechFlash
Pragmatic Beliefs
Control the Air
11 Live Wire
50 OEM Insight
Connections of Three
Generations
Think Small. Get Big Results
HOT BUTTONS
33
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by
Putman Media, 555 West Pierce Rd., Suite 301, Itasca, Illinois 60143.
(Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at
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Editorial and Executive Offices, same address. Printed in the United States.
©Putman Media 2011. All rights reserved. The contents of this publication
may not be reproduced in whole or part without consent of the copyright
owner. POSTMASTER: Send address changes to Control Design, Post Office
Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To apply
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CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, INDUSTRIAL
NETWORKING, PHARMACEUTICAL MANUFACTURING and PLANT SERVICES. CONTROL DESIGN assumes no responsibility for validity of claims in
items reported. Canada Post International Publications Mail Product Sales
Agreement No. 40028661. Canadian Mail Distributor information: World
Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada
N9A 6J5. Printed in the United States.
CD1111_05_TOC.indd 5
13 OEM Spotlight
16 InDiscrete
A Route to Lean
Manufacturing
Machine Production Set to
Hit New Records
15 Feedback
44 Real Answers
Readers React to
Alarms and Volatility
of STEM Jobs
Take E-CAD to the Cloud?
47 Product Showcase
CONTROL DESIGN EXCLUSIVE
46 Co-Simulation Sparks Motion Software
November 2011 Control Design
5
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Special to the Web
controldesign.com CD1111_07_WebTOC 7
necessary time polishing its
food during Thanksgiving and
appearance and behavior. Read
Christmas Eve, and less drink-
this article at www.ControlDe-
ing on New Year’s Eve is not only
sign.com/operator to find out
better, but it could mean more.
what you should consider when
The less-is-more theory
might result in me giving more
designing an OI.
When it comes to streamlin-
meaningful gifts to my family
ing or simplifying interfaces,
and keeping my healthy diet
less is not necessarily more.
and fitness program on track—
Industrial designers advise
not to mention keeping lots
their peers to take the time to
more dollar bills in my bank ac-
think through design changes.
count. However, try convincing
Throughout different stages of
the kids that less is more when
the design you always should
I buy them fewer gifts. Try tell-
test the interface and re-
ing my mother-in-law that the
search what you can or should
less of her rich, buttery dishes
not take out of the design.
and sugary desserts I eat, the
Remember that whatever
better it is for my health.
changes you decide on should
During the holidays, the lessis-more concept never tends
not affect the interface’s usability or functionality.
to work, but there are some
As an end user, can you
times and places where less
imagine using an HMI where
does more. When it comes to
the help screens were re-
designing interactive interfaces
moved just for the benefit of
or HMIs, fewer things could be
a simpler design? How about
a good thing.
if the indicators for required
Take for example our article
fields on complex forms were
“Operator Interface for the Op-
removed? What if all the word-
erator,” written by Filamatic’s
based labeling from buttons
Jack Chopper. He says that
were replaced with confusing
machine manuals don’t always
iconography? How would this
get read, so industrial design-
impact your job?
ers should design the operator
Visit www.ControlDesign.
interface in such a way where a
com/lessisnotmore and share
manual isn’t required.
your experiences that showed
I’m sure you can relate. How
[email protected]
Machine Condition
Monitoring Center
Machine builders designing
increasingly complex
mechanical and electronic
systems can stay competitive.
http://www.ControlDesign.
com/knowledge_centers/ni
designer, you should spend the
fewer gifts for Christmas, less
•
Industrial Communications
Solution Center
System integrators and end
users can access reliable
and cost-effective serial-toEthernet, industrial Ethernet,
industrial wireless and
embedded computer solutions.
http://www.ControlDesign.
com/knowledge_centers/moxa
machine, Chopper says. As a
trying to convince myself that
managing editor, digital media
To download PDF papers,
go to ControlDesign.com/
whitepapers.
meaning of the holidays. I’m
•
Embedded Computing for
Industrial Applications
Embedded computers
can reduce cost and time,
and provide an efficient
environment for your
industrial application.
That operator interface is
your customer’s view of your
Katherine Bonfante
The Internet of Things
See why the Internet is
changing the future of the way
we live and work.
As I prepare for the holiday
festivities, I ponder the real
CONTROLDESIGN.COM
Buying a Vision System: 10
Questions You Must Ask
See the critical questions and
tips you need to evaluate
specific product features.
Less Is More. Or Is It?
you that less is not always
many times have you bought
more. Let us know if your navi-
unassembled furniture and
gation buttons suddenly went
tried to put it together without
missing from your interface,
reading the instructions first?
or if your abort command sud-
If you were able to assemble
denly changed from something
the piece without having to
simple like a click of the mouse
use the manual, you felt like a
to performing 20 different key
superstar, right?
strokes at once.
7
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10/26/11 5:13 PM
Pragmatic Beliefs
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
Editorial team
editor in chief
Joseph Feeley
[email protected]
I’ll probably invest a couple
but we don’t change our energy
of these columns in passing along
producing and consuming habits,
a few highlights from Schneider
then we’ve screwed the planet. 2)
Electric’s annual media event,
If we can do something about it,
which was held just outside Chi-
and we choose to do so, then our
cago in October.
predecessors get to live here a lot
This one starts with a game.
longer. 3) If we can’t do anything
Ready? OK, let’s play “Who’s the
about it, nor choose to try, then
Pragmatist?”
que sera, sera. 4) Even if climate
Joe Feeley
to change it, we ultimately end
managing editor
editors in attendance to encourage
up with a more efficient, less
Aaron Hand
[email protected]
their respective brands’ energy-
costly, less fossil-fuel-dependent,
consuming audiences to accept
cleaner working and living en-
Katherine Bonfante
[email protected]
climate change (no matter what
vironment. I see two very good
the cause) and strive to operate in a
outcomes there.
senior technical editor
more energy-efficient mode.
managing editor, digital media
Andy Gravitt, Schneider senior
•
Aaron Davis, Schneider’s chief
vice president for industry busi-
marketing officer, tried the argu-
ness, offered another pragmatic
ment the way 17th century French
reason to be energy-efficient,
columnist
scientist, philosopher, probability
even for companies with a culture
Jeremy Pollard
[email protected]
fan and all-around BMOC Blaise
driven by short-term results. Com-
Pascal framed his pragmatic argu-
panies aren’t earning any money
editorial assistant
Lori Goldberg
[email protected]
Design/Production
senior production manager
Anetta gauthier
art director
Derek Chamberlain
Subscriptions
customer service
888/644-1803
circulation
audited December 2010
Air & Gas Compressors 933
Engineering & Systems
Integration Services
7,783
Engines & Turbines
1,548
Food Products Machinery
1,612
Industrial Fans, Blowers
& Air Purification Equipment
591
Industrial Heating, Refrigeration
& Air Conditioning Equipment
1,192
685
Industrial Process Furnaces & Ovens
Machine Tools
6,915
Materials Handling, Conveyors
& Conveying Equipment
1,357
Metalworking Machinery
3,511
Mining Machinery & Equipment
476
Oil & Gas Field Machinery & Equipment 1,146
Packaging Machinery
835
Paper Industries Machinery
395
Printing Trades Machinery & Equipment 481
Pumps & Pumping Equipment
916
Rolling Mill Machinery & Equipment
156
Semiconductor Manufacturing
Machinery904
Textile Machinery
231
Woodworking Machinery
242
Other Industries & Special Industrial
8,119
Machinery & Equipment NEC
TOTAL40,028
ment about belief in God.
It’s a two-by-two decision matrix: Columns are God exists; God
doesn’t exist. Rows are Belief in
“So why not look at some
of these opportunities that
give you a real payback?”
God; Non-belief.
So what are the potential out-
on all the cash they’ve squirreled
comes? Pascal offers that if God
away. “So why not look at some of
exists, and you believe in God, well,
these opportunities that give you a
it seems that there’s a big payoff
real payback instead of earning 1%
waiting for you down the line. If
on equity investments?”
God doesn’t exist and you believe
The fastest way to save energy
God exists, then you’ve probably
overall is at point-of-use. Every unit
lived a decent, charitable life and
of energy not consumed reduces
have been greatly appreciated for it.
energy production at the genera-
Now, if God doesn’t exist and
tion point by three units, given all
you believe God doesn’t exist, it’s
a push. But watch out for that last
the inefficiencies along the way.
Next time, I’ll tell you about a
one: if God exists and you don’t
panel discussion that included
believe, then a potentially uncom-
a machine builder. We spent
fortable eternity awaits. Only one
some time talking about how
bad outcome in four possibilities,
sustainability and energy affects
and two pretty [darn] good ones.
Machine Builder Nation.
The corresponding climate
argument, Davis said, is this: 1)
If climate change is real and we
really can do something about it,
CD1111_09_Edit.indd 9
[email protected]
Dan Hebert
[email protected]
editor in chief
change isn’t real but we still try
ment team speakers exhorted the
•
Jim Montague
[email protected]
Most of Schneider’s manage-
executive editor
editor’s page
controldesign.com
9
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10/26/11 5:13 PM
Connections of Three Generations
The company now produces a wide range of
their futures on success as rock stars or sports
modular connectors, circular connectors, PCB
legends. But my kids and their friends seem to be
connectors and adapters, fiberoptic data links, I/O
doing just that. I have yet to hear one of them men-
cable assemblies and more. The North American
tion joining the family business or following in
team recently won an award for the Han-Yellock
their parents’ footsteps. It’s particularly refreshing
connector, with its improved functionality. Asked
these days to celebrate a company that is not only
what the next 25 years might bring for North
standing up to the test of time, but bringing the
America, Philip Harting envisioned a migration
next generation along for the ride.
to more active and value-added connectors and
cable assemblies. Along with the increased intel-
bers of the Harting family when they flew out
ligence, however, Dietmar Harting clarified, “We
from their home base in Espelkamp, Germany, to
will stay in the connectivity business.”
celebrate the 25th anniversary of the connector
tions in Belgium, the U.K., Italy, the Netherlands,
members put emphasis not only on the second and
Norway, Austria, Sweden, Switzerland, Spain,
third generation of Hartings running the 66-year-
the Czech Republic, Russia, Japan, Singapore,
old company—not to mention the fourth genera-
China, Hong Kong, Taiwan, Brazil and the U.S. The
tion that will hopefully follow in their footsteps—
company has about 3,600 employees worldwide,
but also the importance of the people throughout
some 1,600 of which are in Germany, and will have
the organization, reminding attendees of the long
sales of about €471 million ($647 million) this year.
history behind the connector giant. It’s a colorful
Moving forward, Harting sees more potential in
history including stories of pigs and jukeboxes,
and their eye is on maintaining a leading position
in the connectivity business, regardless of what
technology that ultimately will entail.
Dietmar Harting, president and partner, told
an interesting history of the company that his
he 66-year-old company has a
T
colorful history that includes stories
of pigs and jukeboxes, with a vision of
connectivity leadership.
parents Wilhelm and Marie Harting began in
countries like Brazil, Russia, India, China and to
1945. Like his parents before him, Dietmar now
some extent South Africa, Philip Harting said.
runs the company along with his wife Margrit,
When Philip Harting joined the company in
who is senior vice president and partner for Hart-
2005, eager to travel, he had a choice of going to
ing. Their two children, Philip Harting and Maresa
the U.S. or to Asia. Since U.S. management was
Harting-Hertz, are senior vice president of con-
going well, he went to Hong Kong, a gateway for
nectivity and networks and senior vice president
new opportunities. Today Asia makes up about
of finance, controlling and tax, respectively.
23% of the company’s sales, with a target of
In the early days, Harting bartered for its
greater than 30% by 2014-15, he said. In China,
business, trading sausage from the pigs that the
challenges are focused on protecting intellectual
Hartings raised for supplies of copper wire. They
property. Production there is for products at least
bought licenses from RCA and produced record
15 years old so that newer products cannot be
players, jukeboxes and the like, investing the
copied, Dietmar Harting said.
money they made from those sales in connec-
In the U.S., which accounts for 8-9% of sales,
tors. Other products the company dabbled in
the challenges are different. When Harting first
ranged from electric cookers to cigarette vending
came to the U.S. in 1968, they were struck by the
machines. Shortly before he died at the age of 52,
sheer size of the country, Dietmar Harting said.
Wilhelm Harting decided to concentrate only on
“You have to know what you want to do there;
connectors, throwing all other product lines out,
what you can bring to the country,” he said, add-
Dietmar Harting said.
ing that the competition is very strong here.
controldesign.com CD1111_11_LiveWire.indd 11
[email protected]
At a press luncheon in St. Charles, Ill., family
Harting established its first European subsidiary
in France at the start of 1979, and now has loca-
•
company’s North American subsidiary.
managing editor
I recently had the pleasure of meeting mem-
•
connectors, including industrial connectors,
Aaron Hand
many of my companions when I was a kid banking
LIVE WIRE
Maybe I’m just getting old, but I don’t recall so
11
10/28/11 2:25 PM
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An Electrocomponents Company.
10/26/11 5:13 PM
A Route to Lean Manufacturing
OEM SPOTLIGHT
Accuracy of a Smaller CNC Router Provides More Flexibility
AS A SMALL machine builder
in Cartersville, Ga., CAMaster
(www.camaster.com) makes
CNC routers and plasma cutters primarily for cabinetry,
woodworking and sign making,
not to mention hobby lines in
everything from life-size chess
pieces to Star Wars replica costumes. Customers range from
small shops in South America
to globally recognized names
like Fender, which uses CAMaster machines to make guitar
necks, and Bose, which relies
on the larger machines for its
huge stadium speaker boxes.
Simplicity has always been
THE STINGER’S KISS
CAMaster’s president is a firm believer in KISS —keep it simple, stupid.
what sells for CAMaster, says
Joey Jarrard, president and
expertise, so CAMaster uses
got us as close as we could get
co-owner. He’s a big believer in
third-party control software.
to the performance of servos as
the KISS motto—keep it simple,
“They spend all day thinking
far as smoothness of movement
stupid. “Some of the larger
about their control software,”
and speeds we wanted to see,”
machine manufacturers, they
Jarrard says. “I can fall back on
he says. But where the servos
really have gone out of their
their knowledge.”
cost about $1,000 an axis, he
way to make everything as com-
There are other cases where
says, the SoftStep motors are
more like $300 per axis.
plicated as possible,” he says. “I
Jarrard has been happy to fall
was an end user before. I ran a
back on somebody else’s exper-
cabinet shop for about six years,
tise, such as a relatively new
of motors, the motor staying
and it was very frustrating.”
microstepping technology from
cooler—it all goes hand in hand
Testra. CAMaster uses servo
with a top-quality machine,” Jar-
the learning curve out of its ma-
motors from Teknic for its larger
rard says. “The motion is fluent.
chines, keeping the controls and
Cobra line of CNC routers be-
The machine doesn’t growl or
interface as simple as possible.
cause they enable the machines
jerk—it’s smooth, with very well
“One screen is all they have to
to run quickly, at a high amper-
engineered movement.”
function with,” Jarrard says.
age for larger jobs. The Stinger
“They can have 10-20 buttons
line of CNC routers, however,
to offer a smaller router with
on it sometimes, but it’s just one
have traditionally had stepper
performance close to a servo-
screen. It’s very easy to navigate;
motors to reach a better price
based machine can even enable
very easy to learn. My 11-year-
point for smaller customers.
solutions to a big company like
CAMaster instead tries to take
old son can run our machines.”
Microstepping technology
“The cut quality, quietness
Jarrard says that being able
Bose, which is focused on a
has improved the smoothness
“lean manufacturing” program,
with about 12 employees, two
and accuracy of steppers, but
using smaller machines that are
of whom are controls engineers.
can still be subject to vibration,
easier to run and easier to main-
Larger competitors often write
noise and harmonic resonance
tain. It provides manufacturing
their own control software, Jar-
issues. Testra’s SoftStep tech-
flexibility because Bose can grab
rard says, but he prefers to let
nology was very quiet, smooth
anyone off the floor to run that
other companies provide that
and accurate, Jarrard says. “It
machine, Jarrard says.
CAMaster is a small company
controldesign.com
CD1111_13_Spotlight.indd 13
13
10/28/11 2:26 PM
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10/26/11 5:13 PM
Where I live (near Schaumburg, Ill.) is “Motorola
Jack Chopper wrote a good article (“Turn Off That
country.” I can’t even begin to recount the number
Alarm!” September ’11, www.ControlDesign.com/
of people I know with high-level math skills who
alarmoff), but he missed the real point of design-
have had their careers turned upside down over
ing an alarm and monitoring system or an operat-
the past 10 years. Motorola has a great history and
ing system, and they are in no way the same thing.
has had a huge impact globally, especially with
I agree with the principle of three levels of
Mikel Harry and his team developing Six Sigma;
alarms. A flashing yellow should not be an audible
but it has not succeeded in providing “quality” jobs
alarm, but rather to let the control room know
for its STEM employees.
something is out of tolerance. The next should be
What U.S. employers really want is the availabil-
visual and audible with an attention alert, and
ity of cheap STEM skills; i.e., they want
should be used only for something that is not
new college grads because they cost
getting better or that can cause major problems if
less. Consider for a moment what it
action is not taken.
costs to live in an area where there is
The last resort is the red flashing and audible
alarm that tells the control room that an emer-
a significant high-tech infrastructure:
• Typical housing runs $350K for a
gency or backup pump has started. This is where
family of four. If you finance 80%,
the danger is high. The other thing to think about
you carry a $280K mortgage. As-
is the audible level of the alarm. Never make it so
suming an interest rate of 6.5%,
loud as to wake the dead—so loud that the crew
that’s $18K a year just in interest.
wants nothing more than to make the noise stop—
so they can think or take action.
Don’t assume, but rather ask, as the list of failsafe actions might take place automatically, even
when it might drain a tank or shut down a critical
With the principal, figure $25K.
• Groceries, clothes, utilities, etc.
roughly equal housing cost. That’s another $25K.
• Property taxes on most homes in my neighborhood are now pushing $10K per year.
piece of machinery. Never think you can just auto-
• If you buy a car every six years and spend $30K
mate something and save on good, trained, quali-
on it, you have to lay away $6K a year to afford
fied people. Lastly, and most importantly, be sure
it. It’s at least $3K a year to keep it on the road.
the key people are a part of the
• Add $5K annually to give to charity.
design and testing as well as
• The two kids will cost $120K apiece to put
commissioning, and be sure
that what is in the system is
correct and set properly.
Phantom alarms or incor-
through college in 15 years. Figure $16K annually has to be put away for their educations.
• Social Security won’t cover nearly what it does
today, so the average person should put away at
rect alarms are what cause
least $10K annually in their younger years, with
major shutdowns, system
hopes that they can catch up later.
failures and costly shut-
So now we are up to $100K required to live the
downs. Don’t turn off the
middle class lifestyle. To earn that, assuming a
alarm, but rather make the
35% tax rate (federal, state, social security, sales),
right alarm.
the jobs have to pay at least $150K combined for
CLARK DODGE, president,
CED Consulting, www.cedconsulting.com
FEEDBACK
Turn On the Right Alarm
the couple. Likely that means two working parents,
which adds another $12K per child in daycare to
the expenses. Now we are talking around $175K in
A Career in Law?
combined income required to maintain a middle
In “How to STEM Employment Concerns” (August
class lifestyle. That is more than $87K apiece.
’11, www.ControlDesign.com/STEM0811), I think
I don’t hear many employers itching to pay
you hit the nail on the head (at least partly) with
STEM grads $87K a year. They want to pay $45K-
comments about the volatility of STEM jobs. In a
$50K a year. Now do you see why the bright kids
lot of companies, the first place they look to cut
are opting for law school?
when things get tough financially is in the technical ranks, because those positions pay the most.
controldesign.com
CD1111_15_Feedback.indd 15
JOHN TIESSEN, global materials & applications science,
Sun Chemical, www.sunchemical.com
15
10/28/11 2:45 PM
was one of the hardest hit by
MACHINERY PRODUCTION TO SURPASS HIGHS
the economic downturn, but
U.S.
according to a recent report
U.S. Historic
High
from IMS Research (www.
imsresearch.com), worldwide
machinery production is set
to eclipse its previous record,
set in 2008. Machinery produc-
Germany
Germany
Historic High
Japan
tion will see record growth this
Japan Historic
High
year, with worldwide aggregate
revenues showing a better
2007
2008
2009
2010
2011
2012
2013
2014
IMS RESEARCH, JULY ‘11
THE MACHINE SECTOR
Revenue ($M)
INDISCRETE
Machine Production Set to Hit New Records
than 10% rise, IMS Research reported, and the trend will likely
comfortably surpassed its 2008
the figure details the three
“The latest indicators are
levels last year, and looks set
countries that have tradition-
that growth is slowing slightly
to continue its strong perfor-
ally dominated the machinery
from the highs seen last year—
mance, IMS Research detailed.
sector. Machinery production
continue through at least 2014.
The decline in 2009 was
in the U.S. and Germany is ex-
consider the magnitude of the
more severe in the Americas,
pected to recover and set new
bounce back seen in 2010—
and the subsequent recovery
levels this year and next, but
but there still appears to be
was more gradual. Nonethe-
Japan is still not expected to
solid growth on last year,” said
less, 2011 is predicted to be
reach its 2007 peak within the
Andrew Robertson, market
a record year for machinery
forecast period of the report.
analyst for IMS Research.
production there as well.
Even with growth in 2010 of
hardly surprising when you
The 2009 downturn was most
almost 40%, production is still
regional basis, however, the
severe in Europe. Although Ger-
not expected to recover to pre-
recovery story is a varied one,
many’s upturn has been fairly
recession levels before 2015.
Robertson noted. Output from
strong, other countries such
Asia-Pacific declined in 2009,
as Spain, Greece and Portugal
immune from the effects of the
but not to the extent that it
have continued to struggle. IMS
current economic uncertainty,
did in Europe and the Ameri-
Research does not expect ma-
machinery output, for the time
cas. Although Japan’s output
chinery production in Europe
being at least, appears to be far-
plunged in 2009, China and
to surpass pre-recession levels
ing better than the markets and
India continued to see growth.
until after next year.
economy in general,” Robertson
When considered on a
With Japan’s tremendous
growth in 2010, Asia-Pacific
Illustrating differences
in the dips and recoveries,
“Although no industry is
said. “Whether it will continue
to do so is yet to be seen.”
MHIA Downgrades Orders Forecast
in Fragile Economy
MATERIAL HANDLING equip-
from the Material Handling
conditions,” said Hal Vandiver,
ment orders grew more than
Industry of America (MHIA,
MHIA executive consultant.
17% in the fi rst half of 2011, but
www.mhia.org).
“Given slow GDP growth,
“Consumers and inves-
unemployment is likely not
for the year and 7% in 2012,
tors are skeptical regarding
to improve over the next 18
according to new predictions
improvement in economic
months, supporting concerns
are forecasted to grow just 11%
16
CD1111_16_21_Indiscrete.indd 16
Control Design November 2011
controldesign.com
10/28/11 2:30 PM
cale
ge s
Ima
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CD1111_FPA.indd 17
10/27/2011 9:10:31 AM
10/28/11 3:06 PM
indiscrETE
consumption have been down-
havior. Industrial production
MHIA has reduced its fore-
activity appears to be soften-
cast for new orders, shipments
graded to reflect the growing
ing and factory operating rates
and domestic demand for
sentiment that U.S. and global
(utilization) are forecasted to
2012, Vandiver noted. “Fore-
economies are fragile.”
Manufacturing Technology Orders Double
With a year-to-date total of more than $3.4
orders still up substantially over last year, there
billion, U.S. manufacturing technology orders
is clearly optimism within the industry as firms
more than doubled over 2010. August numbers fell
are seeing future growth opportunities that merit
from July, down about 9% to less than $461 mil-
new capital investment.”
lion, but show an increase of more than 88% over
All regions of the United States show signifi-
August 2010, according to the U.S. Manufacturing
cant year-to-date growth over 2010, but a couple
Technology Orders (USMTO) report compiled by
took big hits in August orders compared with July.
the Assn. for Manufacturing Technology (AMT,
The Western region, though double where it stood
www.amtonline.org) and the American Machine
year-to-date in 2010, saw manufacturing technol-
Tool Distributors’ Assn. (AMTDA, www.amtda.org).
ogy orders fall more than 50% from July to August
“Despite news reports that wider economic
this year. The Southern region, up 81% year-to-
growth may be stagnating, the manufacturing
date, fell 23% month-to-month. The Northeast
technology industry is sustaining its momen-
and Central regions both experienced growth in
tum,” said Douglas Woods, AMT president. “With
August—more than 30% in the Central region.
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CD1111_FPA.indd
19 1
CD_Eth2_Mar11 o.indd
10/26/11
5:14 PM
2/22/11 1:12
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Optimism
Takes a Dive
DESPITE MANUFACTURING
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PCIe Serial I/O
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A committee of industry
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© 1986-2011, Sealevel Systems, Inc. All rights reserved.
10/28/11 2:30 PM
In Grant Thornton’s first
Business Optimism Index of
and customer satisfaction.
21% of manufacturers say they
When asked what public
will increase hiring in the near
the year, 60% of those surveyed
policy initiative would make
future, and 35% say they plan
looked favorably on the coming
business leaders most optimis-
layoffs. More than half of the
six months; but in the third
tic about the country’s future, a
executives are least optimistic
quarterly survey, only 13%
job creation program was most
about the reduction of effective
expect the situation to improve.
popular (46%), followed closely
corporate tax rate having a posi-
That’s a considerable drop from
by deficit reduction (43%). Only
tive effect on the economy.
the 40% that were optimistic in
May. In fact, 40% believe the U.S.
economy will actually get worse
over the next six months, up
from just 3% in February.
Almost all of those surveyed
in February (91%) were at least
somewhat optimistic about their
own businesses. That stands at
just over half in the latest survey, down from 80% in May.
“Manufacturing has been
one of the few bright spots in
the economy since the end of
the recession, generating more
than 300,000 new jobs since
December 2009, according to the
National Association of Manufacturers,” said Jim Maurer,
partner and practice leader of
Grant Thornton’s Consumer and
Industrial Products Practice in
Chicago. “Strong export growth
in 2010 and the first half of
2011 helped increase revenues
and create jobs. However, the
slowing global economy coupled
with a lack of confidence in
domestic and global economic
policy has caused senior manufacturing executives to turn
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CD1111_FPA.indd 22
10/26/11 5:14 PM
MOL-3
In Redundancy We Trust
tomers’ data and documents. Some of the docu-
(www.bccorp.com) in Barrie, Ontario. He’s a smart
ments are there for his web services as well.
dude, not real tall, but he has a tall vision for his
company and his software.
My July column on the cloud had a thought
The customer logs into the service cloud server,
and a secure (single-factor authentication) connection is created to the server based on a single
from Scott Clayton of IzonData that stressed the
request. Once the request is serviced, the port
importance of a redundant Internet option if a
and connection are dropped.
company’s connection goes down.
Burkitt had a suggestion. I should take my data
and document server and put it with a “real” cloud
vendor that has all the bells and whistles for full
redundant paths, hardware and 24/7 coverage.
He had issues with his Ontario provider with
minor outages for various reasons, not the least
of which is that there typically is one fiber from
Barrie to Toronto.
Whew. All worked like a charm.
Tom is a detail-oriented guy. The vendor for his
servers was on the U.S. West Coast. They were
totally checked out, and he was very comfortable
with the answers he got about redundancy.
Big Lesson: Trust with verification. Not two
weeks later, a customer called Tom on his hotline
asking why he couldn’t retrieve any reports.
as diverse as the U.S. since we only have a few ven-
Imagine his surprise when he couldn’t get an an-
dors of bandwidth to choose from, and it remains
swer from his new, secure, redundant provider.
an Achilles heal for mission-critical software like
Burkitt’s claim-management software.
His customers are worldwide. They have the
time backups to a local server so that customers
could get at it.
•
option to keep their data on their own servers, or
It was all hands on deck at BCCorp to bring over
all kinds of data (not publicly available) from real-
server that can serve a variety of stuff to clients.
The cloud has become a buzzword, and Tom
and I had an opportunity to discuss that. “Data
should never be part of the public cloud, but ser-
It is a common perception that cloudbased services are more robust, since
they take all issues and need for
redundancy into account.
vices can be,” he says.
As we know, a private cloud is really nothing
A hurricane was about to hit Manhattan. It
more than an Internet-enabled server typically
had already had hit North Carolina and adjusters
housed in the company’s network center. A public
couldn’t get to their data and documents. A router
cloud could be hosted by Amazon.com or IBM.
had blown up. Asked where the redundant path
Burkitt says his customers house their data and
was, the vendor responded, “We were getting to
documents on dedicated database servers and
that in a few weeks.” You can imagine the response.
dedicated file servers hosted by BCCorp, and they
BCCorp now has mirrored sites in the U.S.
access this data and documents via web-based
and in Canada, with full redundancies that were
front end from anywhere. He tells me that the
thoroughly verified. That West Coast vendor
key to his software is that each individual data
moved its upgrade plans forward and now has
or document request is authenticated individu-
actual full redundancy.
ally, which allows for some pretty cool security
[email protected]
to have BCCorp host them in a dedicated space at
its hosting site. Think of it as an Internet-enabled
Jeremy Pollard, CET
Our telecommunications backbone might not be
So it was set to go, and the transfer of customers, data, documents and web services went live.
embedded intelligence
Tom Burkitt founded Burkitt Computer
Be very careful with any cloud implementation,
features of which he is very proud. This allows for
private or public. Make sure you know what you
web access in the public domain.
are getting and get proof of the redundancy.
He felt it was time to move to the cloud for his
web services. It is a common perception that cloud-
jeremy Pollard has been writing about technology and
based services are more robust, since they take all
software issues for many years. Publisher of The Software
issues and need for redundancy into account.
User Online, he has been involved in control system
He set up a scalable server system for his cuscontroldesign.com CD1111_23_EmbedIntel.indd 23
programming and training for more than 25 years.
23
10/28/11 2:31 PM
by Dan Hebert, PE, Senior Technical Editor
W
ith new 4G technology and cellphone
To Phone or Not to Phone
apps, cellular connections now rival the
Dan McGarry, IT administrator at Komax Solar (www.
speed of hardwired connections. This new
komaxsolar.com) in York, Pa., agrees with Youney. “We
equivalence is encouraging industrial machine and ro-
have customers all around the world, and by using a
bot builder OEMs to use cellphones for remote access,
remote solution we save time and money by providing
both via browser and apps.
instant support from our headquarters to any of our
“I do design work for several machine builders,”
customers’ locations,” he explains. “No travel time is
says Matt Youney, owner of Youney Instrumentation
needed, and there’s a minimum impact on customer
and Control Systems Engineering (www.youney.com)
uptime, very important
in Lake Worth, Fla. “I have projects deployed all over
in the competitive solar-
the world. This morning, I was making updates to a
panel-producing market.”
semiconductor die-handler machine in Switzerland
Komax produces custom-
while drinking my coffee in Florida. With remote ac-
built machines for the so-
cess, my customers can’t tell if I am in my office, or on
lar industry, specializing
my sailboat in the Florida Keys.”
in thin-film and crystal-
Welcome to the new world of industrial telecommuting. Remote access to machines and robots has
line technologies.
Although everyone we
been available for at least 20 years now. It started
spoke to for this article
with dial-up phone service from an OEM’s home
praised the benefits of re-
office to a customer site. It graduated to hardwired
mote access, there appear to
Ethernet/Internet connections, and now cellular
be some different prefer-
technology and smartphones make it possible to
ences on whether to use the
work from just about anywhere.
hardwired or cellular connec-
“As a contractor without remote access, I wouldn’t
tions. Komax, for example,
be able to do my job efficiently,” Youney reports. “My
prefers the hardwired links
customer base would be limited to local customers,
provided in a Phoenix Contact
most of which moved abroad in the past 10 years. I
(www.phoenixcontact.com)
need these tools to compete in the global economy,
solution. “The remote con-
and hopping on a plane to fight a fire is really a last
nectivity is a hardware VPN,”
resort.” For more on how Youney works remotely, see
McGarry explains. “It doesn’t
the sidebar, “Machine Control From a Sailboat.”
route through an HMI or PLC;
24
CD1111_24_32_CvrStory.indd 24
controldesign.com
10/28/11 2:33 PM
it just goes from router to router via Internet VPN. We
use a web browser interface to interact with machines
from HQ, and use the remote connection to upload
PLC updates, monitor the HMI, and make adjustments
to the programming. In the event that a customer has
an issue, we use the VPN to check machine status and
determine if a technician must be sent out.”
Prism Systems (www.prismsystems.com), a system integrator in Mobile, Ala., builds control systems
for clients around the globe. “Many of our projects
are either very complex or are in locations with
1. Dial-up phone modems over conventional
phone lines
2. Proprietary connections via Internet using
dedicated hardware at both ends
3. Open connections via Internet with web
browser access
4. VPN connections via Internet
5. Cellular connections for web browser access
6. Cellular connections via an app
7. Cellular connections with VPN
limited local support,” says Keith Jones, principal at
Prism. “These systems present support challenges,
especially when your office and the customer’s site
are on different continents.”
Prism uses security modules to connect to PLCs
over Ethernet. “The platform allows us to use one
module at our office, and connect to a maximum of
128 remote devices,” Jones reports. “This definitely
has changed the way we handle support, making
overseas work more manageable.” For more on how
this works, see the sidebar, “Secure Access.”
On the other hand, Joel Froese, owner/operator of
Red Bank Hydro in West Columbia, S.C.,
1.
2.
3.
4.
5.
6.
7.
Security
Obstacles to remote access by customer
Protection of OEM source code
Cost of hardware and software
Cost of cellular or Internet access
Availability of cellular or Internet access
Machine control system’s ability to support
remote access
8. HMI displays might need to be revised for
mobile devices
9. Speed of access
10. Building VPN networks
likes to use his cellphone
for remote access. “A remote
access is free, so why use an app? “We already had
Direct allows me to check
browser access to this information through the built-in
the status of the machinery
web server in the HMI,” Froese explains. “But the iPhone
at our hydroelectric plant
app now allows us to control the plant via the on-screen
from my iPhone even when I
buttons, so we can now start up and shut down the sys-
am away from my computer,”
tem just as if we were standing in front of the HMI.”
he explains. “I feel the future
Froese says remote browser access gives him a
has arrived as I can even start
snapshot of the HMI screens, and is valuable for moni-
up or shut down the plant from
toring the plant from any computer or other Internet-
the road.”
connected device. “The iPhone app, on the other hand,
Although some remote access
gives us a live view of the screens, meaning we can
systems are extremely expensive,
see monitored variable change in nearly real time,” he
the iPhone app is dirt cheap, Fro-
says. “However, the larger difference between browser
ese says. “The HMI screen scales
access and the iPhone app is that browser access is by
perfectly to the iPhone screen in
definition read-only, while the app allows us to push
any orientation, and built-in safety
buttons and spin dials, controlling the plant remotely.”
features ensure that I don’t acciden-
Mark Gentry, an engineer at Samuel Jackson (www.
tally push the wrong button, so it’s
samjackson.com), a builder of moisture control systems
well worth the $4.99 price.”
in Lubbock, Texas, says remote access is very important
controldesign.com
App access is cheap, but smartphone browser-based
HMI app from Automation-
25
10/28/11 2:33 PM
Modlink: Power &
Communication Together
Murrelektronik provides the right contact
source for making brief connections to the
control panel for performing set-up/diagnosis
or carrying out process optimization. Modlink
MSDD makes it easy to connect to laptops,
programming devices, diagnostic equipment,
PCs, printers, network and modems to the
controller.
MSDD avoids additional and improvised
cabling and ensures problem free
operation. The control cabinet stays closed,
and your components are operated using the
prescribed protection.
for his company’s business. “For
remote connectivity, we use an
on-demand VPN connection,” he
says. “Our technical staff can access
customer sites from any Internet
connection, and our customers can
access their own plants using the
same VPN from anywhere, including their iPhone (Figure 1).”
For Samuel Jackson, whose
clients are primarily in agriculture,
such access is vital. “Remote diagnostics and monitoring can be huge
in an industry where our customers literally make all their income
for the year in just a few weeks,”
Gentry explains. “When your entire
year’s income is made in 6-12
weeks, the cost of downtime takes
on a whole new meaning.” For
more on how Samuel Jackson uses
remote access, see the sidebar, “Remote Access Down on the Farm.”
Jordan Wiens, managing
Figure 1: Machine builder Samuel
Jackson and other industrial OEMs
fi nd cellphone app remote access
to be quicker and easier to use
than browser-based smartphone
remote access.
partner at Xenon (www.xenoninc.com), a system integrator in
Irvine, Calif., is another cellular
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“Obviously, the single biggest
believer. “Our remote connec-
challenge to remote access is secu-
tion method uses cellular-based
rity,” says Mark Lochhaas, product
VPN modems,” he explains. “The
manager at Advantech (www.
modems create a dedicated con-
advantech.com). “Any IT person
nection to a main server that
knows that spoofing an Ethernet
performs all the necessary tasks
connection is easy, especially a
and hosts the information on the
public WiFi connection. Tools to ac-
web. Operators and customers
complish this are readily available,
can use any web-enabled device
so even an amateur can sit in a res-
to view the data.”
taurant equipped with WiFi and tap
into almost anyone’s connection.”
What About Security?
Most systems today are vulner-
The recent scandal in England,
able, he adds, and remote access in-
where reporters hacked into the
creases that vulnerability by orders
cellphones of celebrities, raises the
of magnitude. “Cybersecurity has
question of security. How secure
become the biggest perceived threat
are remote connections? Appar-
to remote access. It’s important
ently, it’s quite easy to hack a
that remote access be engineered
cellphone. How-to instructions are
carefully by qualified resources and
on the web, and hackers have been
proper evaluation be used to ensure
getting into Internet sites for years.
there is adequate ROI.”
26
controldesign.com
10/28/11 2:34 PM
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10/26/11 5:14 PM
M
att Youney of Youney Instrumentation and
Control Systems Engineering designs machines and
control systems for machine builders worldwide.
He handled the HMI software and PLC integration for a
Peak Automation semiconductor die handler with seven
vision systems and 20+ motion control axes. The machine is
installed in Switzerland.
“We commissioned and started up the entire machine
remotely, and we support the machine using remote
access,” Youney says. Remote access lets Youney give
immediate support to his customers. “I can do real-time
troubleshooting to reduce their downtime, and make
temporary emergency software workarounds for failed
sensors or other hardware problems,” he explains. “This
higher level of customer service distinguishes us from other
Peak Automation supplied this semiconductor die handler with
seven vision systems and 20+ motion axes to a customer in
Switzerland. It was commissioned and is maintained remotely.
less-connected companies.”
The types of remote access that Youney uses:
1. Third-party OEM software on a PC, Mac, iPhone or
iPad. This, however, only allows remote control of a PC
at the customer’s site, not the actual machine itself.
Programming software has to be installed on the
3. I ndustrial PCs that have built-in web server
visualization. This provides web browser access to
machine settings and visualization from any location
that has Internet access.
4. GSM modems. Machines in remote locations can provide
customer’s PC, and this could allow customer access to the
status via SMS text messaging and email to mobile
source code.
phones. Youney uses this to provide machine status, fault
2. VPN over cellular or Internet. This allows “native” access
to industrial PCs using Codesys software on his computer.
reporting, and cycle-based maintenance for equipment.
5. A custom app on an iPhone/iPad. This option can send/
No software has to be installed on the customer’s PC, and
receive Modbus commands to provide a remote operator
no customer has access to source code.
interface for a machine via wireless LAN or VPN.
Don’t just keep up.
10/28/11 2:34 PM
Greg Garmann, technology leader of software and
Working with corporate IT isn’t easy, Wiens says.
controls at Yaskawa America (www.motoman.com),
“In a world of viruses and zealous IT folks, we’ve had
agrees, saying, “Many customers have a VPN connec-
difficulty proving that our technology is secure and can
tion to their local area network that provides secu-
be integrated into the customer’s existing IT infrastruc-
rity. One also can implement security through cloud
ture,” he laments. “Xenon provides different forms of
computing by giving rights to the application running
security to meet the needs of IT people.”
on the device. This gives access to the data to anyone
using an iPhone, iPad or other computing device with
the proper login and password.”
Security can be a challenge for
Dan Schaffer, network solution engineer at Phoenix
Contact, agrees that implementing security can be
a pain. “While they are very simple
to use, IT technology and network
smaller end users, notes Nathan Eisel,
settings can be a little intimidating to
application engineer at Beckhoff
plant managers and control engi-
Automation (www.beckhoffautoma-
neers,” he notes. “And we all know
tion.com). “Many of the smaller job
that plant and IT departments don’t
shops don’t have a fully staffed IT
always have the greatest relationship,
department, so security might consist
so the plant people don’t always ask
of an Internet router that uses port
for or get IT help.”
address translation (PAT), a firewall
and initializing the connection from
The Rush to Remote
the machine or robot by the opera-
Some machine OEMs take remote ac-
tor,” he explains. “At the other end of
cess a step further and offer preventive
the spectrum, a large corporation has a large IT staff
maintenance options. “Machine builders can remote in
as well as highly engineered and structured network
to the equipment on a fixed interval to review opera-
architecture. In this case, an OEM requires the cus-
tions,” says Michael Miller, supervisor of field appli-
tomer to open up a path from the outside world to the
cations engineering at Yaskawa. “They then use the
machine or robot. As one would expect, many security
collected data to optimize machine performance, and to
policies and considerations must be taken in cases like
advise when and where maintenance is required.”
this, which can become difficult. Some OEMs have even
Another supplier concurs. “Remote configuration
ended up using a cellular modem to avoid corporate IT
and asset-management functions allow machine
security and policies.”
builders to reduce onsite labor costs,” notes Daniel
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10/28/11 2:34 PM
SurvIvAl Of the fItteSt
Proprietary access means that a company establishes
a secure link between its machines in the fi eld and
its home offi ce by using dedicated communications
hardware. System integrator Prism Systems uses security
modules to establish connections to remote systems,
such as a natural gas compressor.
“Over the years we’ve used a number of methods to
support remote sites,” explains Keith Jones of Prism. “If
the end system is primarily software-based—such as an
HMI, web application or database application—then a
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to establish a remote support session to a PC at the
customer’s site. This allows us to take control of the PC
But for remote access to a PLC, Jones says that solution
doesn’t work well. “First, you must have a PC at the
remote site connected to both the Internet and to the
PLC. This never is recommended because it creates
serious security issues. Second, the remote PC must have
the development software installed on it, and this is a
licensing headache we prefer to avoid.”
Instead, Prism uses Siemens industrial security modules
for PLC access. “This is a hardware solution that allows
us to install a special security module at the customer’s
location,” he explains. “This module has two Ethernet
connections—one for the controls network and another
for a network with Internet access. We have a second
module installed at our office. When we configure the
modules, we use a security configuration tool that forms a
permanent VPN tunnel between these two devices.”
Liu, business development manager for data acquisition and control at Moxa Technologies (www.
moxa.com). “Machine builders also can use remotely
collected data to build system performance trends.
With these data, machine builders can optimize their
equipment and improve machine efficiency. As a side
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benefit, this can be sold as an add-on service.”
Greg Philbrook, HMI/communications product manager at AutomationDirect (www.automationdirect.
com), adds some caveats. “Many suppliers now offer
Pepperl+Fuchs, Inc.
Twinsburg, Ohio
330.486.0002
iPhone and other smartphone apps that allow remote
access and control of their devices,” he says. “These
apps make use of virtual networking computing utilicontroldesign.com
10/28/11 2:34 PM
EvEry plant nEEds
a partnEr to kEEp
things buzzing
This confi guration provides a secure connection
from Prism’s offi ce to the remote location with a
minimum of confi guration. “Since this is a hardware
device built specifi cally for secure connections, we can
install it with confi dence that it will provide a high
degree of protection.”
Once the VPN connection is established, Prism can
connect to PLCs as if they were at the site. “The PLC
software is installed on our computers and connects to
the remote PLCs over standard Ethernet. Typically, we
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see no performance issues with the industrial security
modules and find that we truly can support the sites
without having to travel.”
Another advantage to this solution is that Prism
can restrict access on both sides to specific devices.
“We can configure the modules to pass data between
specific MAC addresses to restrict connectivity to only
our modules,” Jones explains. “The device records
all network activity, so the customer has logs of who
connected when and for how long.”
ties, or are custom-designed to communicate with the
manufacturer’s device through supported protocols.”
But it’s not easy, Philbrook says. “Developers have to
increase hardware, software and protocol performance
levels to reduce the latencies that can occur over remote
connections, allowing users to operate with minimum
frustrations,” he cautions. “OEMs must consider remote
connections when designing projects that run on the
Go to www.sensing.net/buzz-i, or give us a buzz at
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devices. Reducing the amount of data transfer that occurs with programs running in PLCs and HMIs should be
a goal if remote connections are a possibility.”
Finally, Philbrook notes, “When designing the application software projects, the OEM must also consider
Pepperl+Fuchs, Inc.
Twinsburg, Ohio
330.486.0001
www.sensing.net/buzz
controldesign.com
10/28/11 2:35 PM
the device that will be used to
connect to the remote controller. If
Samuel Jackson builds moisture control products for drying and moisture
restoration systems. The company uses remote access because many of
its customers are seasonal businesses, such as cotton gins, or are located
in remote areas that are hard for service people to reach. “Saving a few
hours of driving time for a service call to diagnose a problem can be
massive for our customers,” notes Mark Gentry, an engineer with the
OEM. “It allows us to cover customers across a wide area very quickly. As
an example, just today I was able to help customers in Arkansas, Georgia,
Texas and North Carolina that I couldn’t have helped without the ability
to see what they see.”
“Without a doubt the most popular remote access capability we’ve given
our customers is the AutomationDirect MobileMirror iPhone and iPad app
that allows them to watch their operation in real time,” Gentry reports.
Using an app is much better than a web browser, he argues. “With a
browser on a mobile device, you have to load a page with headers, graphics,
and other overhead,” he explains. “With an app, the only thing you need
to pull is the data itself, which, in most cases, doesn’t amount to very many
bytes. Customers don’t really understand this, but they do understand that
the app is very quick to get going and very fast in operation.”
a mobile phone app is to be used,
the screens should contain fewer
objects to offer better operability
on small devices such as iPhones.”
Remote access provides many
benefits to OEMs and their customers, and suppliers are responding by giving many options
for remote connectivity. Local
hardwired connections to the
Internet can be difficult to install
and expensive in terms of monthly
fees, making cellular access a
more attractive option for many
applications. Whatever the means
of access, security is always a
primary issue, followed closely by
cost and performance.
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10/28/11 2:35 PM
Me asurement, Sensing & Vision
Put the Screws to Tough Vision Apps
New Machine Vision Testing Makes Vintage Machines Perform
Better and Satisfy Demanding Customers
by Joe Feeley, editor in chief
The quality requirements for a precision parts
supplier to the automotive and aerospace industries
are a source of both stress and high opportunity for
the parts maker.
Established in 1967, Prime Engineered Components
(www.primeeci.com) has two modern facilities in Connecticut that manufacture precision turned products
Teledyne Dalsa
for industries ranging from aerospace to automotive.
In its Watertown facility, Prime manufactures about
800,000 parts per week, mostly for automotive industry customers. Each part has to be flawless, or Prime
runs the risk of costly and time-consuming returns, as
well as strained relations with its customers.
Using a new, compact, flexible and economical opti-
Complete Vision Works
users alike to implement.
Figure 1: The integrated optical inspection tool chosen
has all the elements of an industrial machine vision
system—including sensor, light control, processing engine,
I/O, factory communications, developer and operator
interfaces, and an IP67 enclosure.
Searching for a Solution
in bar stock form and machined accordingly. “We are
“Our customers don’t require it, but we know that
not doing any in-process inspection,” Dibble explains.
our machines aren’t 100% capable,” says Kathy
“The inspections are done offline by my quality de-
Dibble, director of quality for Prime. “Since our parts
partment on a separate machine.”
cal inspection tool, Prime met its goal of 100% quality
while making inspections easier for programmers and
are produced too quickly for manual inspections, we
had to put vision in place for a multitude of dimen-
Cloudy Vision
sional inspections. We would much rather remedy
Prime was using another vision system in its Wa-
any quality problems in-house before product ships
tertown plant to inspect components, the majority
to our customers.”
of which are knurled. These grooved and patterned
The parts are manufactured on vintage multi-spin-
parts present significant lighting and measurement
dle screw machines. Material is fed into the machine
challenges—challenges that Prime’s previous vision
system wasn’t able to surmount.
“The reason for replacement was due to changes
When It’s time
Prime Engineered Components recognized
its machines weren’t 100% capable and turned
to machine vision to compensate. How does
that conversation go with your customers when
upgrades are needed? Add your expertise at www.
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in critical, high-tolerance dimension requirements
from Prime’s customers,” explains Adam Farley,
product specialist for integrator and solutions
provider Action Automation & Controls. Farley
teamed up with Engineered Solutions—one of
Prime’s machine builders and an Action Automation
customer—to specify and develop the new vision
system. “Before using any inspection equipment, all
controldesign.com CD1111_33_36_Featr2.indd 33
33
10/28/11 2:38 PM
The more
you know…
ME ASUREMENT, SENSING & VISION
C
M
Y
CM
MY
CY
TELEDYNE DALSA
The more you
appreciate
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ESSENTIAL TOOLS
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QC inspections were done by the
The Solution Measures Up
quality department using hand
Farley’s team selected BOA, an
inspection tools,” he adds.
integrated optical inspection tool
CMY
K
Figure 2: The vision system required a simple setup using a laptop PC and
iNspect Express software. Prime says this inspection couldn’t have been done
without the software’s caliper tool to catch any really high points of the critical
dimensions for greater precision.
Farley says Engineered Solutions
from Teledyne Dalsa (Figure 1). “It
uses products and services from
has all the elements of an indus-
Action to support its machine
trial machine vision system—
building operation, and the two
including sensor, light control,
companies have been partners in
processing engine, I/O, factory
many different machine builds
communications, developer and
that required machine-vision
operator interfaces, and a protec-
inspection.
tive IP67 enclosure—in a small,
The existing
system has problematic issues with
accuracy, reliability
and repeatability.
“Kathy’s quality
department was
From 26 to
414 amps
constantly manually
inspecting sample
lots based on these
issues,” Farley says.
smart camera-style
“The reason for
replacement was
due to changes
in critical, hightolerance dimension
requirements
from Prime Screw
customers.”
In this case, speed was not an
CD1111_33_36_Featr2.indd 34
plains. “The system
requires a simple
setup using a laptop
PC and Teledyne
Dalsa’s iNspect Express Software.” The
inspection program
can be set up accordingly and saved
to the camera. The laptop can then
issue to start, but Farley and Dib-
be removed if required when run-
ble expected the system to have
ning the machine.
higher image-processing capabili-
For more information, visit us at
Eaton.com/s611
package,” Dibble ex-
When designing the solution,
ties, able to process any inspection
Farley incorporated new inspec-
speed that might be expected.
tion criteria for gauging the
34
controldesign.com
10/28/11 2:38 PM
g
n
i
d
n
u
n
i
o
b ed
a d
;
e lu
t
c
o
n
N ti
e o
n
is le
x fi
s
i
th
“For the critical knurl dimen-
outside dimensions of the knurled
comes into the field of view. The
parts, he says. Inspections of these
camera takes an image of the part
sions, the part’s orientation to
parts are performed using the cali-
and the caliper tool measures the
the camera was key,” Farley says.
per tool in the iNspect application
outside dimensions of the knurled
“Field of view and lighting became
software. Embedded in the BOA,
part to determine whether it
a factor as well. Speed was not the
iNspect features an easy-to-use
passes or fails.
major concern for Kathy, but ac-
graphical interface and a toolset
for a wide range of applications.
“This inspection couldn’t have
been done without the caliper tool,”
Farley says. He first tried using a
rake tool, but it was only able to
provide an average of the high and
low dimensions. “We needed to
catch any of the really high points
of the critical dimensions for greater precision,” he says. “The iNspect
caliper tool does this (Figure 2).”
The rake tool in BOA computes
the average distance across a
part from the intersection points
between “raked” lines and the part
edges, explains Steve Geraghty,
director of Teledyne Dalsa’s Industrial Products Group. “The caliper
tool uses a similar approach, but
instead computes the maximum
Together, we can eliminate downtime,
reduce development time and get you
to your tee time.
distance between the two outermost points along the edges.”
In addition to its precision, the
iNspect caliper tool is very userfriendly, says Dibble, who does the
verification runs and sets up the
programs for the camera. “Ease of
use and programming, along with
its accuracy, were the primary
reasons I decided to take a chance
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on a new camera,” she states.
Training was not difficult, Farley says. “Kathy did have existing
Sub-Brand
training with other PC-based systems and was able to pick up the
Dalsa iNspect Express software
in no time.”
Basic, but Critical Quality
This current application is pretty
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10/28/11 2:38 PM
Me asurement, Sensing & Vision
OEM PRESSURE TRANSMITTERS
curacy, repeatability and reliability of each inspection
was what would give her peace of mind.”
Parts that pass continue down the production line,
while failed parts are dropped off in the back of the ro-
• 1%, 0.8%, 0.4%, 0.25%, and 0.1% FS TEB accuracies
• 316L SS, Titanium, or Hastelloy C-276 construction
• Internal or external electronics configurations
• Pressure ranges up to 15,000 psi
• Fully temperature compensated
tary table after the inspection is performed, defects are
verified, and the part is taken out of production. “It’s a
simple, streamlined machine vision application that has
worked wonders for our quality control,” Dibble says.
Reaping Prime Benefits
Both Farley and Dibble agree that the quality of the parts
going out the door has increased dramatically since the
BOA solution was implemented during the spring of
2010. “Prime has seen a significant increase in accuracy,
reliability and repeatability,” Farley reports. “Machine
downtime stemming from frequent issues with the old
vision system has been greatly reduced, and we can
expect zero defects to our customers,” Dibble adds.
“Ease of use and programming, along
with its accuracy, were the primary
reasons I decided to take a chance
on a new camera.”
In addition, Dibble and her team are very pleased
with the ease of use of the BOA, in particular with the
embedded iNspect Express interface. “iNspect Express
allows users to build solutions using a comprehensive toolset that is accessed via a web browser from
a standard PC or laptop, and it connects directly to a
variety of Ethernet-ready factory devices,” she says.
“We haven’t had a single glitch with the system in the
six months that it’s been up and running.”
Keller OEM pressure transmitters provide
low cost solutions for reliable pressure
measurement.
Each transmitter is fully temperature
compensated and designed for simplified
integration and compatibility with process
controls and automated systems.
Prime says it’s installing two more Teledyne Dalsa
cameras for inspections on high-volume automotive
inspection machines at its Watertown plant for 2011
operation. “The technology has proven itself, and we
feel confident that Prime and our customers will continue to benefit as a result,” Dibble concludes.
Farley says that extensive data acquisition and
networking are planned for the future. “Data acquisition would result in the ability to count parts
accurately, better tracking those parts, and monitor
machine ware,” he says. “It also will let Prime create
reports for customers based on the particulars of
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the inspection criteria, and internally the data can
supply design engineers and the quality team with
failed-part images.”
controldesign.com
10/28/11 2:39 PM
Control the Air
system can incorporate up to 13 modules with a
maximum of 64 valves accepted.”
detect leaks and lower operating and mainte-
Machine builders know that the only constant
nance costs with some recent advancements.
in machine design is change, so they prefer to use
Studies conducted over the years by SMC
components that accommodate field modifications. “Valve manifolds offer OEMs the benefits
consumed by a typical factory, 20% goes to the
of simpler installation and reduced leakage in
production of compressed air. Of that 20%, up to
pneumatic systems, but they create a challenge
30% is wasted by leaks.
when an end user changes a design or wants to
“Historically, leak detection has been costly and
add features,” notes Bradlee Dittmer, product
usa.norgren.com). “Our VS manifolding valve
most of them manual and all of them cumbersome
product range solves this problem by building
and/or expensive. Our automatic leakage detection
in capability to expand the manifold in the field
system (ALDS) solves the leak detection problem.
without tearing it apart or replacing it. Modular
By quantifying daily the amount of leakage on a
design allows for expanding in single stations to
machine, the ALDS provides companies with clear
as many as 16 valves.”
Many industrial machine OEMs combine pneu-
tion of each leak.”
performance. “In many cases, electric and pneu-
Remote diagnostics isn’t limited to leak detec-
[email protected]
matic and electric actuation to achieve optimum
•
per minute with a detailed report listing the loca-
matic components are complementary, which is
tion. “Fieldbus-enabled valve manifolds with
why this design decision is largely dependent on
integrated communication and I/O are replacing
application requirements,” explains Tom Wood,
conventional hardwired pneumatic manifold
solutions,” reports Enrico De Carolis, director
of technology development at Numatics (www.
numatics.com/g3).
Gone are the dreaded DIP switches and the
senior technical editor
marketing manager for valves at Norgren (www.
manager at SMC. “Many methods have been used,
•
time-consuming,” says Pam Ohlemiller, product
data containing the exact value of the leak in liters
Dan Hebert, PE
(www.smcusa.com) revealed that of the energy
techflash
If your machine uses pneumatics—or has the
potential to do so—you can simplify installation,
uppliers are adding connectivity
S
options to their pneumatic products,
including tight integration with PLCs.
often confusing status LEDs. “Our G3 platform
integrates a graphic display on every module,
marketing manager at Bimba Manufacturing
with accessible pushbuttons and intuitive menus
(www.bimba.com). “Our Original Line Electric
for easy configuration, status checking and point-
actuators and pneumatic cylinders handle a wide
of-use diagnostics,” De Carolis explains. “The
range of applications as a complete motion control
platform even enables configuration and online
solution or as an actuator only, ready to accept any
diagnostic monitoring via standard web browsers
user’s motor.” Wood says you can read more in the
via Ethernet-based protocols.”
whitepaper, “Debunking ‘Conventional Wisdom’
Other suppliers are adding connectivity options to their pneumatic products, including
tight integration with PLCs. “Our AirLine remote
in Actuator Selection and Deployment,” at www.
bimba.com/pdf/Bimba-OLE-Whitepaper-0411.pdf.
Festo takes flexibility a step further with its con-
process actuation and control system is com-
trollers. “Our CPX controller family can act as a host
patible with the Rockwell Automation Point I/O
for most of our valve terminals,” notes Sachin Kam-
System,” notes Andrew Pierro, the field sales
bli, product manager at Festo (www.festo.com/us).
manager for pneumatics at Bürkert Fluid Control
“The CPX forms a unique system that can combine
Systems (www.burkert.com). “AirLine is the only
pneumatics, servo-pneumatics, electric drives and
system that allows Point I/O modules and our
I/O on the same platform—ideal for control of an
solenoid pilot valves to be mounted in a single,
industrial machine or robot. The other advantage
compact, rail-mount assembly. This assembly
of the CPX platform is that it can communicate over
supports virtually any field device, pneumatic
most industrial communication platforms, thus
or electronic. Depending on the application, the
enhancing connectivity.”
controldesign.com CD1111_37_TechFlash.indd 37
37
10/28/11 2:47 PM
[email protected]
PRODUCT ROUNDUP
All-Inclusive or Else
Pace Quickens for Integrated Machine Automation Software
Development Platforms
With few exceptions, the
All in One
year-to-year enhancement of
CX-One V. 4.0 integrates PLC
machine automation and control
programming software with
software from the supplier com-
support software for setting up
munity grows and improves the
networks, operator interface
width and breadth of functions
HMIs, servo systems, invert-
included in integrated develop-
ers and temperature control-
ment platform software suites.
lers. Users can manage entire
One of our recent Control
projects from sequencing and
Design audience surveys re-
and WindO/I-NV2 OI software
vealed that about 58% of respon-
with WindCFG system con-
dents now say they use an inte-
figuration software. WindLDR
grated controller platform with
and WindO/I-NV2 have new
one programming development
graphical user interfaces and
environment to handle all re-
a redesign of the menu icons.
quired functions. The functions
Users can create a common tag
they identified include machine
name database for IDEC PLCs
control, HMI, I/O and motion,
and OI touchscreens.
configuration of field network
among others. We also note that
IDEC; 800/262-idec; devices without leaving the
an integrated simulation capa-
www.idec.com/upgrades
operating environment, and
bility is a growing expectation
motion control programs to
support for all IEC 61131-3
for these platforms.
programming languages is
Extends to Robots
provided in each license.
Calif., builds robot-enabled ma-
TwinCat Kinematic Transfor-
Omron Industrial Automation;
terial handling workcells. In a
mation software extends its
866/88-omron; www.omron247.com
recent Control Design article,
standard machine sequencing
Bob Sullivan, vice president of
and motion control capability
Saber Engineering in Auburn,
Saber Engineering, said “With a
Scalable
reduced time to build, select-
RSLogix 5000 v20 software
ing a common platform that
provides a single development
is well-understood is the best
environment for CompactLogix,
choice. We try to use more all-
ControlLogix and GuardLogix
inclusive automation packages
programmable automation
that have many of the func-
controllers; Kinetix 350 servo
tions and features required by
drives on EtherNet/IP; and
our customers. This cuts devel-
to Delta- and SCARA-type robot
PanelView HMIs. In combina-
opment time, and ultimately
mechanisms and eliminates
tion with scalable, right-sized
our time to market.”
the need for a dedicated robot
control system components,
You’ll see evidence in the
controller, the associated soft-
pages that follow of suppliers
ware and handshaking routines
trying to fulfill those needs.
in applications that require a
robot to handle part loading/
One for All
unloading tasks.
Automation Organizer (AO)
Beckhoff Automation;
software suite combines the
952/890-0000;
latest versions of WindLDR PLC
www.beckhoffautomation.com
38
CD1111_38_43_Roundup.indd 38
Control Design November 2011 controldesign.com
10/28/11 2:48 PM
users can scale from 48 to 10,000
bases, plus support for redundant
I/O using a single control platform
controllers, complex network
and common user experience.
architectures, and legacy I/O.
Rockwell Automation; 414/382-2000;
Opto 22; 951/695-3010;
www.rockwellautomation.com
www.opto22.com
OOPS, I DID IT
A PRO’S TOOL
Automation Studio object-oriented
Wago-I/O-Pro CAA 3.0 streamlines
programming provides an inte-
control programming and visualiza-
grated simulation environment,
tion for PLC application develop-
open interfaces and seamless
integration of C++ for design and
simulation of the machine all the
ment, conforming to IEC 61131-3. For
way to commissioning, while re-
additional support during develop-
ducing overall development times.
ment, the software user-defined
B&R Industrial Automation;
data types, and a visualization tool
770/772-0400;
permit direct access and visualiza-
www.br-automation.com
tion of data within a Wago PFC.
Wago; 800/346-7245; www.wago.us
PICK A PAC SUITE
PAC Project software suite for
SMALL APP CONTROL
the company’s programmable
Web control software with Ajax
automation controllers has a
technology can remotely monitor
free, basic version that includes
and control a few points in a PLC-
a flowchart-based programming
managed environment or machine
tool, and an HMI development
and runtime application. PAC
Project Professional adds an OPC
server for communication with
OPC clients, the ability to share
system data with common data-
using Nano-10 and FMD PLCs. Users
can create and configure a custom
web page that will open in a standard web browser on any PC, iPhone,
iPad and most Android devices.
Triangle Research Intl;
877/874-7527; www.tri-plc.com
controldesign.com
39
10/28/11 2:49 PM
PRODUCT ROUNDUP
OPC Connects
protocols, APIs and other auto-
standardized interfaces such
KEPDirect OPC Server connects
mation system interfaces.
as FDT/DTM. It supports real-
your Windows client software
AutomationDirect; 770/889-2858;
time Ethernet communication,
with a scalable OPC server
www.automationdirect.com
including SERCOS III, EtherNet/IP and Profinet. It offers
for connecting, managing,
standard HMI screens and
All Access
the ability to develop custom-
IndraWorks Engineering 12
ized screens and implement
software provides access to all
ActiveX controls.
system components, uniform
Bosch Rexroth; 847/645-3600;
programming according to IEC
www.boschrexroth-us.com
61131-3, and open support of
ELC Programmer
ELCSoft programming software runs on a PC to configure
monitoring and controlling the
ELC controllers. Programs can
company’s Ethernet remote
be created, edited, download-
I/O, PLCs and PACs. Communi-
ed, uploaded, monitored and
cations is managed through a
forced. The software supports
robust platform that supports
copying programs from one
an array of open standards,
controller to another, and it
proprietary communication
supports copying programs to
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and from the handheld programmer accessory. ELCSoft also
encoder). It simulates possible
provides a powerful instruction
control solutions and synthesizes
set usually found only in more
the two for Bode analysis of the
expensive PLCs.
closed-loop system.
Omega Engineering; 888/55-omega;
Galil Motion Control;
www.omega.com
800/377-6329; www.galilmc.com
COMPILE FASTER
IT’S GOOD TO SHARE
LabView has an off-the-shelf
Totally Integrated Automation
compiler, which abstracts tasks
Portal (TIA Portal) software
such as memory allocation and
engineering framework enables
users to develop and commission
automation systems, and eliminates time-consuming integration
of separate software packages.
The software provides advanced
shared services across all the
configuration interfaces so devices and networks in any system
can be configured in one shared
device and network editor.
Siemens Industry; 800/241-4453;
thread management to execute
www.siemens.com/tia-portal
code an average of 20% faster. For
field-programmable gate array
(FPGA) users, it provides a new IP
UPGRADE MANAGER
Integration Node to integrate any
SoftPLC v. 4.6 has a major up-
third-party FPGA IP into LabView
grade to Gatecraft Linux, the op-
applications, and it is compatible
erating system on SoftPLC PACs,
with the Xilinx Core Generator.
with addition of Package Manager
National Instruments;
capability and provides an easy
800/258-7022; www.ni.com/labview
remote upgrade capability for the
runtime software in a SoftPLC. A
Package Manager is a collection
FAS TUNING
of software tools to automate
Frequency analysis software
installion, upgrade, configura-
(FAS) tunes servo systems in
tion and removal of software
the frequency domain and with
packages for a computer’s OS in a
a motion controller measures
consistent manner.
the frequency response of the
SoftPLC; 512/264-8390;
plant (amplifier, motor, load and
www.softplc.com
controldesign.com
41
10/28/11 3:54 PM
PRODUCT ROUNDUP
Does the Math
OPEN INTEGRATION
opment environment, unify-
nanoNavigator 3.0 for the
IsaGraf IEC 61131-3/IEC
ing them under IEC 61131.
nLC-055 controller supports
61499-compliant environment
IsaGraf; 450/445-3353;
new math capability, counter
programs a variety of auto-
www.isagraf.com
functions and larger data sets.
mation products, including
It requires no programming
PACs, PLCs, DCSs, RTUs, CNCs,
experience, and is ideal for
embedded microcontrollers
Reusable Structures
small to mid-sized machines
and motion controllers. Based
MachineStruxure automation
on a scalable and modular
solution for industrial machines
platform, IsaGraf 6 provides a
is based on flexible hardware
managed open plug-in envi-
platforms and SoMachine soft-
ronment that enables inte-
ware, a modular and reusable
gration of components. The
software suite developed to en-
infrastructure allows IsaGraf
Runtime to coexist with any
other PLC in the same develwith limited I/O. It can be
programmed via flow charts or
Relay Ladder Logic (RLL), and
is free to download from www.
nanonavigator.com.
Phoenix Contact; 717/944-1300;
www.phoenixcontact.com
able the design, commissioning
and maintenance of logic, drive,
motion and HMI controllers in a
For An Angle Sensor That Works
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controldesign.com
10/28/11 2:49 PM
READY, STEADY, DRIVE
SIZE THEN SELECT
full version can be download-
MotionSet proprietary com-
Motioneering 6.1.0 motion
ed at www.codesys.com after
missioning software can
system sizing and selection
registration.
speed conventional indexer
software uses a mechanism
3S-Smart Software;
setup with pre-defined load-
project concept to collect and
+49-831/5 40 31-17;
and-go application templates.
save axis load information,
www.3s-software.com
It also allows programming of
automatically calculate ap-
32 individual motion profiles
plication results, and compare
from a single screen via a
those results against a robust
FULL SUPPORT
tree configuration, which
database catalog of products
Scalable Proficy View machine-
can be mapped to I/O points,
to identify the optimized lin-
level HMI supports company’s
initiated via Modbus TCP, and
ear or rotary motion system
solutions to meet specific
operator interface products
from a single graphics editor
with functions for data collec-
PRODUCT ROUNDUP
ality in CoDeSys SoftMotion. A
tion, visualization, animation,
alarming and trending, and
supports PLCs, CNCs, motion
chained or looped together.
controllers and serial devices.
Input functions can be used
It supports OPC for data con-
to trigger motions, change
nectivity and the exchange of
operating mode, clear fault
machine builder application
alarm and event information,
conditions and synchronize
requirements. In rotary appli-
HTML for publishing apps
motions; and output functions
cations, it can sum the effects
as web pages, XML for data
include drive status, motion
of multiple axes of motion to
exchange, SQL for database ac-
status, motor position and
rightly size the power supply
cess, and VBScript.
timed pulses.
and shunt regeneration.
GE Intelligent Platforms;
Ormec Systems; 585/358-3520;
Kollmorgen; 540/633-3545;
800/433-2682; www.ge-ip.com
www.ormec.com
www.kollmorgen.com
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real answers
Take E-CAD to the Cloud?
E-CAD seems like a perfect application for the
a technical platform would be mature enough to
concept of ‘software as a service.’ There’s tons of
use as an enterprise solution.
data to be stored, the data needs to be accessed
Hendrik Stoltz, director, Elopak Equipment Supply,
by multiple users, there has to be tight version
Elopak, www.elopak.com
control, and nothing has to happen in real time.
The software itself is very complex and requires
It’s a Game Changer
frequent updates, so this also seems to fit the
Is E-CAD a perfect application for the concept of
software-as-a-service model. Does anyone have
software as a service? Well, it depends.
experiences they can share about E-CAD software as a service?
—From September ’11 Control Design
Answers
Software as a service (SaaS) is one of the three
main application fields related to the highly topical paradigm of cloud computing. The other two
application fields are infrastructure as a service
and platform as a service. Simply put, cloud
computing might be considered a fancy term for
Cloud Control
networked computers that provide services (or
Cloud thinking is cool, but does not necessar-
resources) through the Internet to a network of
ily reduce cost of ownership in the long run. It
clients who use them. The now demystified cloud
allows a lower barrier of entry by potentially
can be public, private or a hybrid. In other words,
reducing investment cost and replacing that
companies can choose to implement their own
with a monthly fee.
internal cloud as a LAN (private cloud), use the
In general, when looking at the cost of own-
cloud-infrastructure from a third-party provider
ership of a system and comparing the invest-
(public cloud), or opt for a hybrid—to rent and
ment route with the associated depreciation and
run SaaS in the public cloud and store application
maintenance costs as a cash flow effect vs. cloud
data in a local, private cloud, for example.
hosting and its monthly fee, the cloud is a more
expensive way to go.
In addition to that, most serious design orga-
We should take a look at some of the pros
and cons of cloud-based E-CAD (or E-CAD SaaS).
Running the software on somebody else’s server
nizations have a requirement for some level of
through the cloud and paying a small fraction of
integration with other systems. Those systems
the original license fee on a pay-as-you-go usage
all need to work in harmony with regards to
base certainly is appealing. Time- and cost-inten-
release levels, both with integrations as well as
sive software updates and maintenance issues
operating systems.
are out of the picture as well.
In our experience, this mix creates an eco-
On the downside, an internal LAN connection
system of software that needs to be carefully
allows significantly faster data transfer rates than
managed with update and revision control, and
an Internet connection. Rendering CAD data can
I do not see how this could easily be maintained
demand a lot of computing power, and running
if some of the core operating systems as well
it over the Internet could cause a slight lag in
as database environments are sitting in a cloud
response time. Whether that lag is tolerable or not
somewhere. There would be limited access and
depends. Although it might be perfectly accept-
control to the core, which could potentially be
able in an E-CAD training environment, it could
updated without consultation with the user/
be annoying (and costly) in day-to-day full-scale
subscriber. This could create all sorts of sync and
design operation. In practice, most companies
compatibility issues for projects.
choose speed over cost and prefer to run their
If you therefore consider the use of design
software locally. One way of minimizing the re-
software in isolation from other sets of software
sponse lag is to store E-CAD data and software on
like mechanical CAD, PLM or even ERP, with
the same server. The less data we need to transfer
a low barrier to entry but slightly higher cash
through the cloud, the better (and faster/cheaper).
flow impact, I guess cloud services could be a
scenario to look at. I am not convinced that such
44
CD1111_44_45_RealAnswrs.indd 44
Control Design November 2011 In light of this, it becomes apparent that providing/renting storage space as a service through
controldesign.com
10/28/11 2:52 PM
the client to send and retrieve digital information
model to consider. Pay-as-you-go rates for data
that is stored outside of the client’s IT environment.
storage might be significantly cheaper than pur-
Data that lends itself well to SaaS would be similar
chasing your own hard disk drives and, similar
to what Salesforce has created for CRM manage-
to the SaaS case, hardware maintenance and
ment, where users can get access to data without
replacement are no longer an issue.
bogging down their computers or smartphones
What I haven’t talked about yet is the issue of
data security. Not knowing exactly where in the
cloud sensitive data is stored and what is going to
with large applications and even larger data sets.
That works great with CRM and even MRP/ERP data.
The drawback to SaaS is that it requires a
happen to it in case of a blackout or server crash
constant and consistent Internet connection to
is a major concern for any company. Overall, the
fetch and restore data. Some SaaS providers offer
risk of losing data is relatively small. Major, well-
offline data services. The main intent is to be on-
established providers of cloud-based services
line all the time and access the data in real time.
usually clarify all data security and IP-related as-
If your Internet service provider goes out, then
pects in their terms and also provide testimonies
backup or interruptive services need to be created
of high-caliber clients with highly confidential
and used until the connection is restored.
data. If such information is not provided voluntarily, it should raise a red flag.
Whether E-CAD software and/or data storage as
The creation of E-CAD data or drawings relies
on sophisticated models or data structures to assemble and manage the documentation creation.
a service makes sense for your company—at this
Much of the creation process is graphical and
very moment—needs to be determined on a case-
requires a graphical interface to aid in the docu-
by-case basis and with a thorough ROI analysis.
ments’ compilation. E-CAD data can exist in many
Technically, it sure works. The technology is there
places both within and outside an origination. For
and new “everything-as-a-service” business mod-
instance, with our product, a basic component
els mushroom daily.
library is installed with the initial installation of
Overall, the paradigm of cloud computing is
expected to be a major game changer and long
term there is no way around it if you want to stay
competitive. Another strong point for moving
real answers
the cloud is yet another interesting business
the software, but users can access components
through an Internet-based data portal.
Michael Cranmer, area sales executive,
Eplan, www.eplanusa.com
E-CAD software and data into the cloud is that of
collaboration. Cloud-based E-CAD significantly
increases the feasibility of globally distributed
E-CAD and sharing of project data, including
backups and revision management.
Long-term, computer-aided product development
in general (including design, analysis and simulation, as well as manufacturing) is expected to become predominantly cloud-based. At Georgia Tech,
we work on integrating digital resources, such as MCAD and E-CAD systems, with physical resources,
such as 3D printers for rapid prototyping as well as
micro mills through the cloud to allow for globally
distributed design and manufacture activities.
Dirk Schaefer, assistant professor,
School of Mechanical Engineering,
Georgia Institute of Technology, www.me.gatech.edu
Constant Connection
Software as a service (SaaS) is defined by the ability
of a service provider to streamline a client’s digital
January’S PROBLEM
More of the automation we install on our
machines has Ethernet and web-based connections.
This helps with remote troubleshooting and
enterprise reporting, but some customers worry
that their connected factory floor is vulnerable to
internal input mistakes that can cascade through an
entire process. What kind of prioritized operator and
technician HMI access can protect the process, but
still give us the links needed to the outside?
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include it in
the January ’12 issue, and post it on ControlDesign.
com. Send visuals if you’d like—a sketch is fine. Email
us at [email protected]. Please include your
company, location and title in the response.
HAVE A PROBLEM YOU’D LIKE TO POSE to the
readers? Send it along, too.
data in a cloud computing environment, enabling
controldesign.com CD1111_44_45_RealAnswrs.indd 45
45
10/28/11 2:52 PM
EXCLUSIVE
Co-Simulation Sparks Motion Software
IT’S EASY TO SAY that true mechatronics
should bring mechanical engineers and their CAD
software together with electrical and controls engineers and their ladder and sequential function
chart software for machines. It’s more difficult to
make this collaboration happen in reality.
To help with this, Rockwell Automation spent
the past four years working with partner Dassault
Systèmes to combine their softwares to enable
dynamic simulations that include physical forces
and other closer-to-real-time data inputs.
They’d already joined Rockwell Automation’s
Motion Analyzer software with the Motion
Analysis simulation feature in Dassault’s Solid-
FOR MORE INFORMATION
Works software. This link allows the programs
Browse to http://ab.rockwellautomation.com/MotionControl/Motion-Analyzer-Software.
to converse in the background, use performance
specifications and operations data, and create
a “move profi le.” This gives users a detailed
between Motion Analyzer and SolidWorks. Next,
animation—with up to eight axes running at
the tuning simulation environment will display
once—to see if their design will move correctly.
the interaction between the mechanical system
SolidWorks reports on the torque those axes
(in SolidWorks) and Rockwell Automation’s servo
will need, and this guides users to the motor
motors, drives, network and controller based on
and drive they’ll need. This search can be re-
the motion profiles and tuning gains chosen. For
fi ned further based on 27 other criteria.
example, the co-simulation feature could provide
“However, there was one question that wasn’t
if a machine or system design is stable, and so
Pritchard, global product marketing manager for
provide needed throughput at required accuracy.
Rockwell Automation’s Kinetix business. “Engi-
Besides connecting designs, profiles and controls,
neers tuning a servo drive, for example, also want
the tuning simulation can be used to slow down
to know, ‘What kind of dynamic performance can
mechanisms to “human time,” and let users see
I achieve, and will my system be stable?’ So the
what’s happening as they operate. “For example, us-
next step was to develop a co-simulation feature to
ers will be able to see if system tuning gains are too
show what the real world looks like, and how it’s
high, leading to high-frequency oscillation, which
going to affect their design. Many simulations are
is something they might not even be able to see in a
developed around ideal profiles, but the real world
real, functioning machine,” Pritchard adds.
isn’t a perfect place, so users need simulations that
In addition, the new tuning simulation environ-
can handle all the unexpected starts, stops, slow-
ment will help develop and deliver machines
downs and reverses in real applications.”
faster. “This co-simulation doesn’t replace the
Consequently, Rockwell Automation plans to
skills of the controls engineers,” Pritchard ex-
launch its tuning simulation co-simulation feature
plains. “The difference is that, instead of waiting
as part of its latest Motion Analyzer 6.0 software. It
for a physical machine to be built before it can
will be demonstrated Nov. 16-17 at Rockwell Auto-
be tested, many machine builders will now be
mation Fair 2011 in Chicago, and it’s scheduled for
able to test machines months ahead of time in
release in Spring 2012.
the comfort of their offices. Earlier testing also
Co-simulation will let users initiate a dialog
means users will be able to adjust tuning, and get
between the Motion Analyzer tuning simulation
to a stable solution sooner. In the past, this kind
engine and SolidWorks by clicking an onscreen
of dynamic simulation took much longer—to the
setup bar. The dialog is accomplished using
point that a builder might decide it was quicker to
application programming interface (API) calls
just construct a physical prototype.”
46
CD1111_46_Exclusive.indd 46
dynamic performance indicators that will show
answered by our joint solution,” says John
controldesign.com
10/28/11 2:55 PM
and monitoring applications
NEC UPDATE
AG200 media-isolated, digital
are powered by reconfigurable
Analysis of NEC Code Changes
pressure gauge has 4–20 mA
I/O (RIO) and LabView FPGA
2011 highlights changes to the
output signal and large LCD
technologies. They combine an
National Electrical Code (NEC)
that can display psi, bar, kg/cm,
industrial 400 MHz Freescale
for the 2011 code cycle that re-
real-time processor and four-
late to the company’s products.
slot chassis with an embedded,
The 156-page handbook is orga-
reconfigurable Xilinx Spartan-6
nized by NEC article numbers
FPGA for custom timing, con-
with a table of contents and in-
trol and signal processing.
cludes illustrations of products
National Instruments;
and applications that pertain to
800/258-7022; www.ni.com
ATM, inches H20 and Hg mea-
ARRAY OF CONTROL
users can evaluate loop current
Array controllers have 12 or 22
to ensure the system is set up
I/O and are expandable to 122
correctly and adjust the current
I/O (74 inputs and 48 outputs).
in 2 mA increments. Loop cur-
Function block programming
rent update rate is 32 times/s;
software is free. Expandable
the display updates 3 times/s.
modules include remote control
code changes. It is available in
American Sensor Technologies;
receivers and handheld trans-
print, downloaded as a PDF, or
973/448-1901; www.astsensors.com
mitters with 70 m range and
as an eBook.
[email protected]
suring units. With a test button,
PRODUCT SHOWCASE
DISPLAY OF PRESSURE
Thomas & Betts; 800/816-7809;
www.tnb.com
VALVE DRIVER
D1 PWM Valve Driver is designed to drive and manage
REAL-TIME VISION
proportional valves. It converts
VC nano 3D compact machine
proportional command voltage
vision system for 3D and 2D
to a -1.1…1.1 A signal to drive
Modbus RTU extended protocol.
inspection tasks has an intel-
the valve’s linear force motor. It
Electrotech; 215/997-8855;
ligent camera and a 5 mW line
works with 12 or 24 Vdc power
www.esgllc-usa.com
supply and valve deadband;
SERVO AND MORE
SM23165MT-IP SmartMotor with
mil-style connectors and IP65
rating has 10 points of 24 V I/O,
laser for real-time recording of
images at a scan rate to 400 Hz
dither amplitude and maximum
via triangulation. Programma-
current are adjustable.
ble 100 Mbps Ethernet interface
Enfield Technologies; 800/504-
provides live video output on a
3334; www.enfieldtech.com
PC. Two digital inputs and four
outputs are available for inteRS-485 port, DeviceNet or CANo-
gration into existing automa-
MONITOR AND CONTROL
pen support, optional brake, and
tion environments.
cRIO-9075 and cRIO-9076
programmable limits.
Vision Components;
integrated chassis and con-
Animatics; 408/748-8721;
+49-7243/216-716;
trollers for embedded control
www.animatics.com
www.vision-components.com
controldesign.com
CD1111_47_48_Showcase.indd 47
47
10/28/11 2:57 PM
Torque Tamer
pivots out of an engagement
Torq-Tender overload safety
slot, disengaging the prime
couplings protect critical rotat-
mover from the load. Avail-
ing power transmission com-
able in torque ranges of 2–3,000
ponents from torque overload.
in-lb with tamper-proof preset
When a system’s load exceeds
torque settings.
the preset torque-spring rating,
Zero-Max; 800/533-1731; the device’s drive mechanism
www.zero-max.com
Does a Lot
United States Postal Service
Vision350 and Vision130 all-in-
Statement of Ownership, Management, and Circulation
1.
2.
3.
4.
5.
6.
7.
Publication Title: Control Design
Publication Number: 1094-3366
Filing Date: 9/30/11
Issue Frequency: Monthly
Number of Issues Published Annually: 12
Annual Subscription Price: $96.00
Complete Mailing Address of Known Office of
Publication:
555 West Pierce Road, Itasca, IL 60143
8. Complete Mailing Address of Headquarters or
General Business Office of Publisher:
555 West Pierce Road, Itasca, IL 60143
9. Full Name and Complete Mailing Address of
Publisher, Editor,
and Managing Editor:
Publisher: Keith Larson, 555 West Pierce Road,
Itasca, IL 60143
Editor: Joe Feeley, 555 West Pierce Road,
Itasca, IL 60143
Managing Editor: Aaron Hand, 555 West Pierce
Road, Itasca, IL 60143
10. Owner:
Putman Media, Inc., 555 West Pierce Road,
Itasca, IL 60143
John M. Cappelletti, 555 West Pierce Road,
Itasca, IL 60143
Julie A. Cappelletti-Lange, 555 West Pierce Road,
Itasca, IL 60143
Jenny G. Cappelletti, 555 West Pierce Road,
Itasca, IL 60143
Nicholas G. Cappelletti, 555 West Pierce Road,
Itasca, IL 60143
Melody L. Cappelletti, 555 West Pierce Road,
Itasca, IL 60143
11. K nown bondholders, mortgagees, and other
security holders owning or holding 1 percent or
more of total amount of bonds, mortgagees, or
other securities. If none, check box X None
12. Tax Status (For completion by nonprofit
organizations authorized to mail at nonprofit
rates.) The purpose, function, and nonprofit status
of this organization and the exempt status for
federal income tax purposes:
• Has Not Changed During Preceding 12 Months
13. Publication Title: Control Design
14. Issue Date for Circulation Data Below:
September 2011 .
CD1111_47_48_Showcase.indd 48
15. Extent and Nature of Circulation:
one controllers support inputs
a. Total number of copies (net press run)
36,471
35,667
b. P aid and/or
requested
circulation
33,449
33,025
34
34
(1) Paid/requested
outside-county mail
subscriptions stated
on form 3541.
to 200 kHz, and 5 Hz to 200 kHz
No.copies No.copies
12 months single issue
outputs. Users can implement 3
independent Pulse Train Output
(2) Paid in-county
subscriptions
stated on form 3541
(3) Sales through
dealers and carriers,
street vendors,
counter sales, and
other non-usps
paid distribution
instruction sets and create and
(4) Other classes mailed
through the usps
c. Total paid and/or requested circulation
d. Free distribution
by mail (samples,
complimentary,
and other free)
(1) Outside-county as
stated on form 3541
save multiple speed profiles for
33,483
33,059
852
1,615
step-motor control. Capabilities
include auto-tuned PID loops.
Unitronics; 866/666-6033;
www.unitronics.com
(2) In-county as stated
on form 3541
(3) O ther classes mailed
through the usps
(4) C opies Distributed
Outside the Mail
(Include Pickup
stands, Trade shows,
Showrooms and
Other Sources)
Safe on, Safe off
8537 series safety switches
256
have a rotary handle to discon-
500
nect frequency-controlled
motors from the mains without
e. Total Non-requested Distribution
1,108
2,115
f. Total Distribution
34,591
35,174
1880
493
h. Total
36,471
35,667
have switching contacts with
i. Percent Paid and/or Requested Circulation
96.80%
93.99%
individual flameproof encapsu-
g. Copies Not Distributed
an electrician. Rated operational currents are 12/16 A,
25 A, 40 A or 63/80 A. The units
lation, are available as 3-pole
16. P ublication of Statement of Ownership.
Publication required. Will be printed in the
November 2011 issue of this publication.
17. Signature and Title of Editor, Publisher,
Business Manager, or Owner
Jeremy L. Clark, V.P. Circulation, Date: 9/30/11
I certify that all information furnished on this form
is true and complete. I understand that anyone who
furnishes false or misleading information on this form
or who omits material or information requested on the
form may be subject to criminal sanctions (including
fines and imprisonment) and/or civil sanctions
(including civil penalties).
and 6-pole models, and are
qualified for international use
through ATEX/IECEx certifications and further explosionprotection classifications for
various regions.
R. Stahl; +49-7942-943-0;
www.stahl.de
controldesign.com
10/28/11 2:57 PM
CLASSIFIED
is the only magazine exclusively
dedicated to the original equipment
manufacturing (OEM) market for
instrumentation and controls—the
largest market for industrial controls.
630/467-1300
Fax: 630/467-1124
equipment
INTEGRATED
PLCs with Integrated Ethernet
publishing team
group publisher & vp, content
Keith Larson [email protected]
director of circulation
From
$129
Jack Jones [email protected]
sales team
northeastern and mid-atlantic regional manager
Dave Fisher [email protected]
TRIANGLE
RESEARCH
508/543-5172 Fax: 508/543-3061
24 Cannon Forge Dr.
Foxboro, Massachusetts 02035
midwestern and southern regional manager
Greg Zamin [email protected]
INTERNATIONAL
Reprints are available on a custom basis from
FosteReprints
Call toll-free : 1 877 TRI-PLCS
www.tri-plc.com/cm.htm
Contact Jill Kaletha at [email protected]
630/551-2500 Fax: 630/467-1124
western regional manager
Laura Martinez [email protected]
310/607-0125 Fax: 310/607-0168
LOOKING to
ADVERTISE?
218 Virginia, Suite 4, El Segundo,
California 90245
digital sales specialist
Jeanne Freedland
Contact: Polly Dickson • [email protected] • 630-625-1176
[email protected]
805/773-4299 Fax: 805/773-0451
inside sales specialist
Polly Dickson [email protected]
ad index
Allied Electronics . . . . . . . . . . . . . . . 12
Measurement Computing . . . . . . . . . . 40
ASCO . . . . . . . . . . . . . . . . . . . . . . . 22
Molex . . . . . . . . . . . . . . . . . . . . . . . 27
executive staff
AutomationDirect . . . . . . . . . . . . . . . 52
Murrelektronik . . . . . . . . . . . . . . . . . 26
president & ceo
B&R Industrial Automation . . . . . . . . . 8
National Instruments . . . . . . . . . . . . . 4
630/467-1300 Fax: 630/467-1124
John M. Cappelletti
vice president
Julie Cappelletti-Lange
vp, circulation
Baldor Electric . . . . . . . . . . . . . . . . . 10
Balluff . . . . . . . . . . . . . . . . . . . . . . . 39
Beckhoff Automation . . . . . . . . . . . . . 6
Jerry Clark
c3controls . . . . . . . . . . . . . . . . . . . . 21
vp, creative services
Eaton . . . . . . . . . . . . . . . . . . . . . . . 34
Steve herner
Electrochem Solutions . . . . . . . . . . . 32
vp, technology
Eplan Software & Services . . . . . . 28-29
Rose Southard
Novotechnik . . . . . . . . . . . . . . . . . . . 42
Omega Engineering . . . . . . . . . . . . . . . 3
Panduit . . . . . . . . . . . . . . . . . . . . . . 14
Parker Hannifin . . . . . . . . . . . . . . . . 35
Pepperl+Fuchs . . . . . . . . . . . . . . 30, 31
Sealevel Systems . . . . . . . . . . . . . . . 20
eWon . . . . . . . . . . . . . . . . . . . . . . . . 43
Siemens Industry . . . . . . . . . . . . . . . 17
REPRINTS
EZAutomation . . . . . . . . . . . . . . . . . . 2
VIPA . . . . . . . . . . . . . . . . . . . . . . . . 18
Foster Reprints www.fosterprinting.com
Keller America . . . . . . . . . . . . . . . . . 36
Wago . . . . . . . . . . . . . . . . . . . . . . . . 19
Jill Kaletha
Maple Systems . . . . . . . . . . . . . . . . . 41
Yaskawa Electric . . . . . . . . . . . . . . . . 51
[email protected]
866-879-9144 ext. 168
CD1111_49_ClassIndex.indd 49
49
10/26/11 5:19 PM
oem insight
Think Small. Get Big Results
Bigger isn’t better when it comes to machine
enough time and space to avoid interfering with
footprints in packaging facilities. As budgets
the next task. Simulation packages built into these
tighten, manufacturers look for ways to get more
CAD programs allow a designer to see and elimi-
production capacity from every inch of factory-
nate interferences before the machine is built. The
floor space. The result is an increasing demand for
real challenge then becomes going beyond that
packaging machinery that maximizes productivity
and planning for additional spaces and assemblies
while minimizing footprint. For design engineers,
that meet the customer’s special requirements.
the challenge to think small can lead to big results.
A great example of this is the work we did to
Fast, simple changeovers are a common customer requirement. Changeover time is produc-
develop a very compact automatic cartoning sys-
tion uptime lost, and changeovers should be
tem. It is time-consuming and costly to miniatur-
tool-less and fast with easily readable indicators
ize a large machine. With complex machinery, all
for change points. Although space constraints on
parts are interconnected, and the modification of
a small machine sometimes limit the choices for
one part generally requires modifications of all
locating change points, the majority of change
related parts. Both the performance and size con-
locations can use the same mechanism as those
siderations will be subject to change as the design
used on larger equipment if considered from
progresses. These two constraints will conflict
the beginning. The design resulted in a machine
with one another as they jockey for importance.
with simple and reliable changeovers that uses
Designing small means looking at market
trends, determining where to set the performance
change-parts only where absolutely necessary.
Ease of maintenance is important, but mainte-
goals on size and rate, and designing around the
nance on small equipment can be more cumber-
majority of what the target industry runs. The
some. Proper machine design tries to maximize
enerally speaking, the larger
G
the machine, the more time
available to each process
performed by the system.
access to critical components and locations where
daily operations could need access for cleaning,
clearing or inspection. Proper component selection can minimize maintenance headaches. Although often more costly, high-end components
usually last longer and require less maintenance.
prevailing trend in manufacturing maximizes ef-
Some strategies for minimizing required main-
ficiency within the available space. Smaller equip-
tenance include using “lubed for life” bearings,
ment means more production with less floor space.
replacing chain drives with belt drives, and add-
Compact size impacts decisions along the way.
Generally, the larger the machine, the more time
ing seals and wipers to linear bushings.
Thinking small resulted in a robust, reliable
available to each process performed by the system.
cartoning system that handles up to 60 cartons
To maintain production rates with small equip-
per minute while occupying considerably less
ment, the machine must complete each operation
floor space than most commercially available
precisely on time at high speed. Material selec-
cartoning systems. The use of 3D and simula-
tion, therefore, is based on rigidity and vibration
tion software allowed the designer to specify the
dampening. Precision equipment can move so fast
correct components the first time. By selecting
that even minute variations in position can cause
components that balance cost and performance,
product rejections. Components and materials
the design team was able to create a machine that
that counteract these possibilities must be chosen
is easy to use, easy to maintain, and easy to fit
carefully. We are always on the lookout for products
into existing factory floor space.
from our core suppliers to better our machines.
Small equipment design takes longer, but
Neil Elko is a mechanical engineer and project manager for
today’s 3D CAD packages can greatly shorten
ESS Technologies (www.esstechnologies.com) in Blacksburg,
design time. The designer’s greatest challenge in
Va. Reach him at [email protected]. Paul
small equipment manufacturing is to ensure that
Landers is the mechanical engineering manager at ESS
all moving components complete their task with
Technologies. Reach him at [email protected].
50
CD1111_50_Insight.indd 50
Control Design November 2011 controldesign.com
10/28/11 3:03 PM
Follow us:
View video:
YA S K A W A A M E R I C A , I N C . - D R I V E S & M O T I O N D I V I S I O N
http://Ez.com/yai235
CD1111_FPA.indd 51
10/26/11 5:14 PM
4.99
$
Automationdirect has released its first mobile
application for the iPhone and iPad! The Remote
HMI app is just one of the many advanced
features you will find in the C-more product line.
The Remote HMI App lets you remotely monitor
or control the machine process from an iPhone
or iPad as though you’re standing at the C-more
panel.
Do all this from the palm of your hand!
• Monitor and control screen operations of the C-more panel
as if touching the panel itself
• Save JPG screen captures to review, email and print if needed
• Zoom in on specific objects on the screen and then save a screen
capture if needed (using iPhone or apple Zoom feature)
• Multilevel Logon Security supports three Remote Access user accounts
• Multilevel Access Control allows each account to be configured in one
of the following levels of access: Full control, View only, View and
Screen Change only.
• Screen Lock/Unlock button reduces unintentional activation of the
remote C-more panel inputs
• Remote HMI app requires software and firmware Version 2.73 or later*,
and an Ethernet-enabled C-more panel to function.)
Remote HMI works with iPad 2, iPad, iPhone 4,
iPhone 3GS, iPhone 3G, and iPod touch®.
Apple, iPad, iPhone, and iPod touch are trademarks of
Apple Inc., registered in the U.S. and other countries.
App Store is a service mark of Apple Inc.
• Activation or Notification Tags allow each account to have associated
user configurable TAGS so the Panel project or PLC project can indicate
that a remote user is connected, or to enable or disable the remote
access feature. These tags can activate alarms, events or notifications
to alert local operators that a remote user is connected.
For complete details on Remote HMI or to order, visit:
http://www.c-moreHMI.com/app
C-more touch panel line-up:
* Software and firmware are downloadable for
authorized customers from:
CD1111_FPA.indd 52
Go online or call to get complete information,
request your free catalog, or place an order.
1-800-633-0405
10/26/11 5:14 PM

connect four... - Control Design

Transcription

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