Steps Above the Rest

Transcription

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Is It Real, or Is It
Simulation?
Three Technologies That
Improved Alarm Systems
Steps Above
the Rest
Safety at the Speed of
Light Curtains
SEPTEMBER 2010
This Year’s Readers’ Choice
Awards Winners Have What
It Takes to Climb to the Top
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CONTRLDES_0810:Control Design 7/23/10 2:18 PM Page 1
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22 Cover Story
Steps Above the Rest
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This Year’s Readers’ Choice Awards Winners
Have What It Takes to Climb to the Top
Joe Feeley, editor in chief
Models and Simulations are Spreading Beyond Former Boundaries
Into Machine and Production-Line Optimization and Can Even Aid
Real-Time Operations
22
Volume 14, No. 9
35 Machine Control
Simulations Branch Out
contents
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U.S. TRADE
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Jim Montague, executive editor
42 Product Roundup
Drives and Motors Accelerate Growth
Advances in Microprocessors Fuel Motion Networks and Capabilities
Columns
13
7 ControlDesign.com
21 Embedded Intelligence
Unconventional Learning
Find the Bottlenecks
9 Editor’s Page
Key Points Shared
15 Live Wire
Safety Relays or Better
Diagnostics?
41 TechFlash
Alarms Simplified
50 OEM Insight
Design, Build With Trouble
in Mind
Hot Buttons
35
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by
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(Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at
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CD1009_05_TOC.indd 5
13 OEM Spotlight
49 Real Answers
Welding Machine Builder
Keeps It Simple
Programmable Safety
Help
16 InDiscrete
China Leads Machinery
Production Growth
September 2010 Control Design
5
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New White Papers
Boost Your PLC Systems
Find out why advanced control
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Special to the Web
the video, Market Intelligence
front of a blackboard and listen
Report: Design & Simulation
to an instructor go over the
Software, a CIA Virtual Brigade
day’s lessons. In recent years,
Briefing. Watch this online
learning via virtual approaches
video report at www.Contr-
has infiltrated schools, and
olDesign.com/simulation, and
students today demand online
see if you agree.
lessons, if not virtual teachers,
When it comes to designing
or devices to replace the con-
embedded machine control
ventional human educator.
systems, traditional meth-
Today, simulation software,
ods typically involve multiple
virtual reality and online
stages of development that
tools are all part of unconven-
require specialized electronic
tional teaching methods. These
design automation (EDA) tools.
techniques have proven to be
Getting all the specifics correct
convenient and effective. In
can take a few tries. Different
the past, simulation tools were
system integrators offer hard-
used to teach students how to
ware and software equipment
drive automobiles, fly planes
that can facilitate the system
and even space ships, but how
designing process. Visit www.
is simulation used in industrial
ControlDesign.com/graphical
automation? How are our ma-
to read “Graphical System
chine builders and integrators
Design for Machine Control,”
using this technology to their
and learn how National Instru-
and the industry’s advantage?
ments’ hardware and software
One of our contributors, Don
Talend, who specializes in
can help.
A few decades ago, simula-
technical trade media, wrote
tion seemed like a futuristic
the article, “Prototyping of the
technology, far from ever being
Virtual Type.” In this piece,
useful, but now simulation is
Talend covered digital simula-
more accessible to everyone
tion tools and how these can
and to different processes.
be used to integrate functional
Executive Editor Jim Montague
areas of design, improving
talked about the changes in
product quality, maximizing
system design tools that are
throughput and reducing time
pushing CAD and CAE draw-
to market. Visit www.Contr-
ings into the real world in his
olDesign.com/digitalsimula-
article, “System Design Tools
tion to read this article and
Make Simulation Real.” Read
learn more.
this article at www.ControlDe-
We also surveyed our read-
[email protected]
CD1009_07_WebTOC.indd 7
analyzed and interpreted in
centrally located school, sit in
•
controldesign.com findings of this survey were
students physically attend a
managing editor, digital media
Market Intelligence
Report: Electromechanical
Components Control Design
surveyed its audience members
to get a look at the types of
electromechanical technologies
now being used in their
machines and applications.
Watch this video report with
expert comentary from Chris
Lovendahl, and learn more at
www.ControlDesign.
com/multimedia/2009/
MIR1008ElectroComponents.
and simulation software. The
learning has been one where
•
get your design right the
first time with virtual
Prototyping Engineers
use virtual prototyping to
design, optimize, validate
and visualize their products
digitally and evaluate different
design concepts before
incurring the cost of physical
prototypes. Join the virtual
prototyping community at
www.ControlDesign.com/
virtualprototyping to share
code and learn best practices.
ence finds useful about E-CAD
Katherine Bonfante
To download PDF papers,
go to ControlDesign.com/
whitepapers.
For centuries, the preferred
and widely accepted method of
CONTROLDESIGN.COM
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sign.com/realsimulation, and
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see how Web-based diagnostics
using design and simulation
tools can pre-operate individu-
software. We wanted to know
al machines even before they
what our machine builder audi-
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Key Points Shared
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
When I attend an event spon-
KPI to reduce purchased compo-
sored by one of our machine build-
nent cost at some meaningful per-
er or system integrator audience
centage over some fixed period.
members, it’s usually worth it.
I sat in on a worthwhile presen-
Next door sits the assembly
team pursuing a KPI that can
changing to a couple of slightly
ing & Manufacturing Assn. DMC
more expensive components with
President Frank Riordan and some
superior tolerances that all but
of his engineers have contributed
eliminate chronic, vexing assem-
to Control Design over the years in
bly problems. You can almost hear
managing editor
activities ranging from authoring
the collision, can’t you?
mike bacidore
[email protected]
the OEM Insight column to partici-
Another favorite is the pro-
pating in webinars and speaking at
duction team that has to raise
Katherine Bonfante
[email protected]
our AutomationXchange event.
machine utilization by x% and, as
senior technical editor
look at Microsoft’s Sharepoint Col-
engineering and maintenance crew
laboration Portal and how DMC be-
can spend keeping the machines in
lieves it can help companies more
optimal operating shape—although
easily handle their critical key
those guys have a KPI to improve
columnist
performance indicators (KPIs), as
machine availability and require
Jeremy Pollard
[email protected]
well as benefit from Sharepoint’s
some non-productive time.
editor in chief
Joseph Feeley
[email protected]
executive editor
Jim Montague
[email protected]
Lori Goldberg
[email protected]
Design/Production
art director
Derek Chamberlain
Subscriptions
customer service
888/644-1803
circulation
audited December 2009
Air & Gas Compressors
738
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Integration Services
8,959
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collaborative document creation
and management, search functions and dashboard features.
While DMC is delighted to quote
its Sharepoint consulting services
to needful companies, they made
it clear that the free entry-level
onflicting KPIs mean the
C
thrill of long production
runs, followed by long,
costly breakdowns.
Conflicting KPIs mean the thrill
versions of Sharepoint are powerful
of long production runs, followed
tools, even if you do need a bit of
by long, costly breakdowns due
third-party startup help.
to the lack of available time for
DMC’s Rick Rietz discussed creating, monitoring and making the
maintenance.
So it’s no secret that the under-
actionable most out of KPIs. He had
lying basis to all successful manu-
a nice reminder about the value
facturing companies is a culture
of the 1% improvement. Do the
that eliminates company depart-
math with a customer on what a
ment information silos and that
measly 1% yield improvement or 1%
develops cross-discipline operat-
machine-utilization improvement
ing objectives that make sense to
could mean to its bottom line.
everyone involved for the overall
This reminded me of the avoidable pitfalls in constructing KPIs.
[email protected]
editorial assistant
a consequence, limits the time the
•
Dan Hebert
[email protected]
The session gave the audience a
editor in chief
managing editor, digital media
•
reduce assembly time by 30% by
at the headquarters of the Tool-
Joe Feeley
tation by DMC, a Chicago-based SI,
Editorial team
editor’s page
controldesign.com
improvement of the bottom line.
Those are KPIs that DMC and
The companies that offered up
Sharepoint probably can help your
examples at the session seemed to
customers improve.
have a good handle on KPIs, but a
lot of companies don’t.
Many of us have known the purchasing department with a crucial
CD1009_09_Edit.indd 9
9
8/30/10 5:07 PM
©2010 Kollmorgen. All rights reserved.
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8/30/10 10:59 AM
Welding Machine Builder Keeps It Simple
OEM SPOTLIGHT
Janda Thinks Like Its Users: Good Enginering Is Simple Engineering
MANY MACHINE BUILDERS
talk about seeing what their
customers see. However, fewer
were founded by an end user
who built his entire business
around knowing other users’
points of view.
Before he founded Janda Co.
(www.jandawelders.com) in
1960, Bob White, Sr., served
JANDA
in the U.S. Navy and worked
for Chrysler Motors, where he
maintained and supervised
welding machines. So, when he
started his resistance welding
machine company, he knew
FOUR HEADS = WELDING WISDOM
This quad-head seam welder with ac frequency drive, HMI station and PLC is
fully automated and can weld both sides of a truck bumper at the same time.
what his customers were going
which users add stucco or foam
controls requires a lot less wire,
to create wall sections or other
and this helps us keep our
chines, and so he always kept
construction components. “The
machines simple, which follows
the user’s perspective,” says
3-D panels were invented when
my dad’s machine building phi-
Bob White, Jr. “He designed
a customer came to us with
losophy,” adds White. “My dad
and built machines that were
the idea, and my dad designed
was old-school and still liked to
simple, easy to use and always
the form and machine to do it,”
design on the board, but he was
at a good price. He also didn’t
explains White.
also fascinated by new technol-
to want and need.
“My dad repaired a lot of ma-
want our machines to be com-
Some of the panel welders
ogy. We actually put in some
plicated and believed this was
can be 120–130 ft long, and
smaller PLCs before he passed
good engineering.”
naturally their controls have
away, and he liked them and
evolved over time, too. They
thought they were pretty cool.”
fornia, Janda started out
started out hardwired and then
The company founder died in
developing standard welders,
gained Ethernet ports four or
June 2008.
which now include 42 types
five years ago. Now, they have
of resistance welders. Much of
20 Ethernet ports, Rockwell Au-
Janda’s latest welders are even
Janda’s growth has been fueled
tomation’s CompactLogix PLCs,
more automated and are avail-
by creating special welders for
six or seven ac inverter drives,
able with built-in weld checkers
specific applications such as
one servo drive and PanelView
capable of stopping a machine
constructing tail-cones for Boe-
HMIs to help supervise 12 weld-
if it’s unable to achieve a good
ing’s airplanes. Most of these
ing controls and I/O points.
weld, which reduces scrap
Located in Corona, Cali-
specials were firsts in their
Besides moving to Ethernet-
Today, White adds that
parts. The new welders’ controls
based controls and saving wire,
also have Internet access that
Over the years, Janda also
White reports that Janda ben-
can transmit machine per-
began to design and build weld
efited as PLCs shrank over the
formance anywhere and even
forming machines and zig-zag
years. “A PLC with 20 I/O used
allow remote repairs. All these
wire equipment. One of its cus-
to be 18 x 18 in., but now it can
new technologies further sim-
tomized welding machine lines
fit in your hand, and that saves
plify the machines and keep on
forms, assembles and welds
us a lot of space,” he says.
following White’s father’s phi-
respective industries.
wire into 8-ft, 3-D panels to
controldesign.com
CD1009_13_Spotlight.indd 13
“Using Ethernet and smaller
losophy of keeping it simple.
13
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CD1009_FPA.indd 14
8/30/10 11:00 AM
Safety Relays or Better Diagnostics?
could be delayed, which might result in an unacceptably hazardous condition, says Hammond.
stops, you still have to go out and do some
“My first safety relay system had more than
30 relays in a cabinet,” recalls Wade Peterson,
and then restart the machine. But where do ma-
electrical engineer, CMD (www.cmd-corp.com),
chine builders draw the line between diagnostic
in Appleton, Wisconsin. “It took two days to
needs and safety?
fully commission that system. But we became
“We use a lot of safety relays,” says Jim Braun,
a lot more proficient at it and got to the point
where the same job would take only four hours.
dardization for MAG Americas (www.mag-ias.
Better diagnostics would have helped in the
com), Hebron, Kentucky. “We also have safety
first situation but would have been of less use
integrated on our machines, which you’re doing
toward the end after the initial learning curve
through safe PLCs and specific logic. It adapts well
was overcome. Diagnostics should be a concern
on some machines and not on others. You see a
when there are a variety of devices or if main-
lot of safety integrated on European machines.”
tenance resources are scare. Product longevity
•
vice president, product development and stan-
Mike Bacidore
troubleshooting, find and repair the problem,
LIVE WIRE
A downside of safety relays can be the lack
of diagnostics they provide. When the machine
good training are in place.”
is that the relays are pretty reliable. If there’s a
Traditional safety relays can be problematic,
problem, they’re a little more difficult to trouble-
says Helge Hornis, PhD, manager, Intelligent
shoot. The trend in the industry is going more to
Systems Group, Pepperl+Fuchs (www.pepperl-
safe PLCs and safe drives. You have this whole
fuchs.com). “AS-Interface offers a safety
regimen of software you go through. Over time
solution—Safety at Work—that enables very
that will tend to eliminate the safety relays. Safe
PLCs and safe drives can be more cost-effective.”
Jack Chopper, chief electrical engineer, Filamatic (www.filamatic.com), Baltimore, believes
the lack of diagnostic information will be a shortlived problem. “Diagnostic capability is always a
“Diagnostic capability is always a time-saver, but the safety integrity and reliability must override the other information-related features.”
time-saver, but the safety integrity and reliability
detailed diagnostics down to the contact level,”
must override the other information-related fea-
he offers. “Using this solution for safety applica-
tures,” he says. “The safety-rated PLC is relatively
tions, it is easy to find sticky contacts. All it
young and still very pricey, but as those types of
takes is a few rungs of PLC logic.”
products mature, they will settle down in price.”
Diagnosing a problem determines the root
There are more downsides to safety relays
than just the lack of diagnostics from the relay,
cause of a potential or pending failure, explains
warns Kurt Wadowick, I/O systems specialist
Hilton Hammond, product manager—ScopeMeter,
at Beckhoff Automation (www.beckhoff.com).
Fluke (www.fluke.com). “Safety components, by
“With outdated relay technology, safety system
design, are built into a system to ensure, in the
designers also need accurate electrical draw-
event of a failure, something catastrophic does
ings, a trained electrician who can read those
not occur that could present a hazardous condi-
drawings and at least a digital multimeter to test
tion to the operator or the surrounding environ-
the circuits that are in doubt,” he explains. “In
ment,” he explains. “Sensing and measuring criti-
contrast, distributed and automated safety com-
cal variables, like voltage or current, and applying
ponents with proper configuration can point out
them to some form of a diagnostic algorithm, can
faults automatically. This enables the electrician
provide the user feedback about the operating
to immediately understand which component
state of the machine or process.”
has failed and focus attention on repairing the
Without a relay, interlock or other protective
device built into the active circuit, a shutdown
controldesign.com CD1009_15_LiveWire.indd 15
[email protected]
circuits when component standardization and
lot of safety relays,” says Braun. “Our experience
•
and reliability are more important in safety
chines in and for Europe. “In the U.S., we still do a
managing editor
Being a global company, MAG builds a lot of ma-
actual failure point instead of spending excessive time trying to find that failure.”
15
8/27/10 9:35 AM
DESPITE THE WORLD re-
40%
cession, China still grew its
30%
machinery production in 2009,
20%
IMS Research (www.imsresearch.com). Although it dipped
from the incredible growth
rates of the preceding years,
10%
0%
-10%
2007
2008
2009
2010
2011
2012
2013
U.S.
China
Japan
Germany
2014
-20%
Chinese output still grew, while
-30%
almost every other country
-40%
experienced steep declines.
-50%
IMS RESEARCH
according to a new report from
Growth Rate
INDISCRETE
China Leads Machinery Production Growth
Growth in China is predicted
to increase in 2010 from the
2009 level, but not at the 20%
growth seen the previous year.
MACHINERY REVENUE GROWTH
Because the U.S. was one of the first countries to enter the downturn, it
should be one of the earlier nations to return to growth.
Continued growing domestic
demand, with higher levels of
stimulus packages, is helping
driven by and depending on a
disposable income and large
drive growth in machinery
recovery in exports, which are
government investment, un-
production revenues in 2010,
benefiting from a weak euro.
derpins this return to stronger
according to the report.
growth in machinery produc-
Germany, the leading Euro-
Likewise, Japan’s machinery
production also relies heav-
tion, explained Andrew Robert-
pean producer of machinery,
ily on exports and suffered
son, research analyst at IMS.
suffered badly as its exports
badly from the trade drop-off
Of the major industrial na-
declined throughout the eco-
in 2009. As with the other coun-
tions, the U.S. is expected to be
nomic downturn. Recovery in
tries considered, only limited
among the strongest in terms
Europe started slightly later
growth in 2010 is predicted,
of growth in 2010. The U.S. was
than in the U.S. and is tem-
according to IMS. The Japanese
one of the first into the down-
pered by concerns in several
machinery sector benefited
turn and subsequently one of
countries about vast sovereign
from government incentives;
the earlier nations to return to
debt and the effects of auster-
however, these recently ended.
growth. The recovery in the au-
ity programs to address it,
In addition, a strong yen is ad-
tomobile industry, which ben-
explained Robertson. Growth
versely affecting the competi-
efited from large government
in Germany is being primarily
tiveness of Japan’s exports.
June Manufacturing Technology
Consumption Up 36%
U.S. MANUFACTURING tech-
facturing Technology Consump-
struction equipment through
nology consumption in June
tion (USMTC) program, was up
the fi rst half 2010 resulted
totaled $241 million, according
36% from May and up 71% from
in an acceleration of USMTC
to AMT—The Assn. for Manu-
the $141 million reported for
orders,” said Douglas Woods,
facturing Technology (www.
June 2009. With a year-to-date
president of AMT.
amtonline.org) and the Ameri-
total of $1.2 billion, 2010 is up
can Machine Tool Distributors’
56% compared with 2009.
Assn. (www.amtda.org). This
“Increased foreign direct
The report provides U.S.
consumption data of manufacturing technology and domestic
total, as reported by companies
investment and a doubling of
and imported machine tools
participating in the U.S. Manu-
orders in aerospace and con-
and related equipment.
16
CD1009_16_19_Indiscrete.indd 16
Control Design September 2010
controldesign.com
8/27/10 11:29 AM
SEPT10-NC2Safety (CD).qxd:CONTROL DESIGN
8/6/10
3:16 PM
Page 1
When safety is key to
your operation…
Allied offers product solutions that
reduce risk and protect personal
equipment.
Honeywell
Cable-Pull Safety Switches
Allied Stock Number
642-0013
Amphenol PCD
Explosion Proof
ATEX Connectors
Allied Stock Number
308-0246
Find more safety and compliance
solutions at:
www.
/safety
THINK ALLIED
SM
Manufacturer
Description
Allied Stock Number
Fluke
233 Remote Display
Digital Multimeter
730-0531
© Allied Electronics, Inc 2010. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
CD1009_FPA.indd 17
1.800.433.5700
An Electrocomponents Company.
8/30/10 11:01 AM
Don’t let its size fool you.
The mighty Micro 10 turns over a new leaf in outsize performance.
This new line of rocker isolation valves combines small size and extraordinary
functionality in clinical, life science, analytical, and fluid handling applications.
With its 10 mm width, the Micro 10 is almost 40% smaller than comparable
16 mm designs, but with orifice diameters reduced by only 10%. So instrument
manufacturers can pack in more Micro 10s for powerful teamwork and greater functionality in the
same space, or help reduce costs by shrinking the size of the equipment or instrument. Unique internal
geometry provides exceptional flushability. Small internal volume reduces waste of expensive
reagents. Plus robust mounting hardware withstands assembly stress. Small, but strong — another big
idea from ASCO, the world’s leading manufacturer of solenoid valves.
4
800-972-ASCO (2726)
CD1009_FPA.indd 18
www.ascovalve.com/micro10
e-mail: [email protected]
8/30/10 11:01 AM
NOTEWORTHY
The Safety-over-EtherCat
protocol has been accepted
by the IEC (www.iec.ch) as an
international standard.
were among the “world’s most
ethical companies,” named by
the Ethisphere Institute (www.
ethisphere.com).
Rockwell Automation (www.
rockwellautomation.com)
and Eaton (www.eaton.com)
Portwell (www.portwell.com)
won the Intel 2009 Award of
Excellence for Participation
in ECG Product Launches for
providing Intel architecture in
the embedded market.
Allied Electronics (www.
alliedelec.com) was recognized as
Distributor of the Year by Cooper
Tools (www.coopertools.com).
June’s Northeast Region manufacturing technology consumption was up 52% when compared
with May’s $34 million, and up
91% when compared with June a
year ago. At $211 million, 2010’s
year-to-date was 33% higher
than the figure a year ago.
Southern Region manufacturing technology consumption in
June stood at $35 million, 19%
higher than May and 37% higher
than the June 2009 total. With a
YTD total of $189 million, 2010
was up 75% compared with the
same 2009 period.
At $73 million, Midwest Region manufacturing technology
consumption in June rose 70%
compared with May and 83%
higher than last June’s total. The
YTD total of $335 million was
51% more than the 2009 figure.
June manufacturing technology consumption in the Central
Region totaled $57 million, up
7% when compared with the
$53 million total for May and up
97% when compared with June
a year ago. The $329 million
year-to-date total for 2010 was
85% higher than the total for
the same period last year.
At $26 million, June manufacturing technology consumption in the Western Region was
up 38% from May’s $19 million
and up 28% when compared
with last June. The $144 million year-to-date total was 33%
more than the 2009 total at the
same time.
controldesign.com
CD1009_16_19_Indiscrete.indd 19
8/27/10 11:30 AM
Red or Green?
What if you couldn’t tell?
Just like a driver approaching a busy intersection, a machine operator must make
split-second decisions based on the color of a signal. The wrong choice could have
serious consequences.
The 125XBRi Chameleon™ Xtra-Brite™ Multi-Status Indicator, with Xtra-Safe™
Technology makes it easier for operators to differentiate machine status with
a greater degree of confidence than with “color-based” indication alone.
And if an operator has some degree of color vision deficiency, this is a
critical distinction.
Plus, the ultra-high output LUXEON Rebel LEDs that power the 125XBRi
light engine are extra-bright, more efficient, reliable, and longer lasting than
other LEDs. In fact, they’re as eye-catching as xenon strobes while lowering
high current draw and high operational costs of frequent strobe tube replacement.
The Future is Bright!
Three colors in one.
www.edwardssignaling.com/125XBRi
CD1009_FPA.indd 20
The 125XBRi Chameleon multi-status
LED indicator is available in your choice of
Red/Amber/Green or Red/Amber/Blue.
A quick and easy change to the 125XBRi
dip switch settings instantly converts these
flexible indicators for use with or without
control from an external PLC, PAC,
or control relay.
8/30/10 11:02 AM
Find the Bottlenecks
help. Likewise, packet monitoring software such
as Wireshark also can be very helpful.
other issues that can make projects more efficient,
usable, cost-effective and innovative.
That’s all good. But what about the bad stuff? It’s
Software stability is very key. A rogue application
can take down a server in a heartbeat. If it is a COTS
package, you don’t have much control over the solu-
time to do a session on what to think about when
tion, and maybe a reboot is in order. Maybe worse,
deciding what the system should do.
there’s the blue screen of death. Once this happens,
If you’re going to be creating a server-based
system with some clients on the floor and using
any connection method, then you’ll need to find
the bottlenecks.
A server is a central computer that is the
the server cannot serve the clients, and they all are
dead—the worst situation you can have.
This is why a solid strategy is so very important. Contingency also is very important.
Vendors sometimes forget that just because it’s
a Windows application and runs on Ethernet, this
ware such as Windows Server 2008 R2. It could
doesn’t mean full access to all of the bandwidth.
be running Windows XP, Apache, Linux or HP
A common HMI uses multicast messages for all
UX, but we’ll keep this in the Microsoft world
communications. A network hog like that will kill
for pretty obvious reasons.
response time due to data collisions.
There is a patch to Windows XP that permits
Remember that, when you make changes to
four users. If your server has it, then three remote
the software application, you might have to re-
users can log in using RDP protocol, and you have
start the application on the server, and that will
a small, unlimited client-server environment.
take down the client side for that application.
Windows XP can be a file server, so clients can
sees a number of connections larger than that as
being an environment for a true server-based OS.
ystem reliability and availability is
S
the most important measure of client
and server-side applications.
The Elusiva Terminal Server is unlimited
(per license), and a true server-based OS can
Typically, you would want to do the upgrade dur-
handle many users. Application servers such
ing a soft time, but that might not be possible.
as 2X also permit multiple users to run apps
from any server.
So, where are the bottlenecks and the big is-
System reliability/availability is the most important measure of client and server-side applications. They might work great for five years, and
sues? Server hardware, network reliability and
then “pow”—a disruption arises and the system
software stability are the show stoppers. Server
is whacked like a stiff Tony Soprano backhand.
hardware must be able to shift execution eas-
This is where the strategy and documenta-
ily. This could be as simple as a network cable
tion of that process come in. It’s likely that the
switchover, moving the RAID drives to the backup
people who put the system in place have moved
server. A server farm could solve this, but it prob-
on, hardware is no longer available, the software
ably takes control of the server away from the
platform has changed, and there is no budget for
control domain and into the IT domain.
replacement—only repair.
Networking is key. All clients communicate
[email protected]
10-user connection limit. Go figure that Microsoft
Can your strategy stand that interruption?
•
log into an SQL database, for instance, but with a
Jeremy Pollard, CET
boss. It does not have to run server-based soft-
embedded intelligence
We have talked about thin-client/server-based
applications, VB vs. COTS software, databases and
So, remember, while all of these really great
over this network. Typically, it is one cable from
tools for development and implementation of very
the client to a switch or router. One client down?
cool applications and platforms allow us to shine,
That’s no problem.
the lurking issues also must be acknowledged.
Trouble with the main switch/router that connects the server? Big problem. Have the tools
jeremy Pollard has been writing about technology and
in place to be sure you can track down an issue
software issues for many years. Publisher of The Software
should one arise. Network monitoring software
User Online, he has been involved in control system
tools such as IntraVue from Network Vision will
programming and training for more than 25 years.
controldesign.com CD1009_21_EmbedIntel.indd 21
21
8/26/10 10:30 AM
by Joe Feeley, Editor-in-Chief
ow does that go, again? Is it tougher to get to the
a one-year or more absence. Reflecting a somewhat
top, or tougher to stay there once you get there?
traditional annual churn, the results jettisoned 20
It’s clear that the answer is “yes.”
companies that had been in the rankings in 2008.
The journey to market acceptance, and in some
Nine companies, two fewer than in 2009, won in
cases dominance, requires immense work and excel-
multiple categories. Perennial heavyweight Rockwell
lent listening skills. Staying there requires that these
Automation won or tied for first place in 19 hard-
same companies never rest on their laurels. There are
ware and software categories. Emerson received five
plenty of worthy competitors working hard to knock
category wins. Advantech, Cisco, Fanuc CNC, National
them off the platform.
Instruments, Parker-Hannifin, Pepperl+Fuchs and
Our annual Readers’ Choice Awards balloting is one
Thomson each won twice.
venue where automation supplier companies get put
Similar to prior results, many of companies had
in their places by our audience, and that has clear re-
clear wins in their categories. This year, 34 of the 51
flection on their market standing. It’s our automation
(35 last year) categories had winners with margins of
users who anoint the most worthy.
greater than 10 percentage points. Close races decided
Our model for this award is the same as when we
by a margin of five percentage points or less
first presented Readers’ Choice Awards results 10
dropped slightly to nine, compared with 11
years ago. We sent questionnaires to about 15,000
in 2009. Four of those tight races ended
subscribers, who tell us they specify, recommend or
in statistical dead heats between
buy industrial automation and control products. Ven-
two or more companies.
dors are not eligible, so we didn’t knowingly let any
supplier vote. If we did find a vendor in the mix, we
deleted it. The voting is only for our machine-builder
and system-integrator readers. We use an unaided
ballot, meaning we don’t provide a list of vendors or
product brands to choose from. We include 50-odd
hardware and software categories and ask participants to name the companies that provide them the
best technology value for the products with which
they have experience. We tallied nearly 400 ballots
this year. Once they chose the best providers, participants rate service and support they receive from
them. Only companies that received at least 5% of
their category vote are recognized.
Those Usual Suspects and the Up and Coming
In 51 product categories, 87 individual companies
made the cut this year, compared with 92 in 2009 and
107 (in 54 categories) in ’08. Eleven companies made
this elite list in 2010 either for the first time or after
22
CD1009_24_32_CvrStory2.indd 22
8/30/10 1:10 PM
Service Scores Better
Every company making the service and support
Of those 87 individual companies in the product cat-
list should be pleased. Some achieved great service
egory results, you awarded service and support scores
marks more than once. The table on p. 32 lists those
of 4.0 or better (very good-to-excellent performance
companies that voters say have terrific service/
on a 1 = poor to 5 = excellent scale) to 62 (71%) of them.
support in specific product categories. Voters again
This is noticeably up from the 63% rate last year, and
recognized Rockwell Automation service and support in 26 product categories, followed by Emerson
more in line with the 70% in ’07, and 80% in ’06.
Process Management and Siemens Industry in eight
Reversing last year’s result, service recognition
categories. Yokogawa made the service rankings in
scores generally rose. You assigned 20% of the
service recognitions to the 4.3+ columns, compared
with 15% last year, and 17% in 2008. Awards in the
seven categories while Banner Engineering, Invensys,
National Instruments and Schneider Electric each
received six service accolades.
4.0 to 4.1 ranges dropped to half the total service
Endress+Hauser, General Electric, Phoenix Contact
recognitions, compared with 59% last year.
You awarded the highest service praise this
and Turck were recognized four times; ABB, Auto-
year—at 4.4—to AutomationDirect in the
mationDirect, Cisco/Linksys, Honeywell, Mitsubishi
Operator Terminal category and to Precsion Digital in the Panel Meter category.
Electric, and Pepperl + Fuchs each received service
plaudits in three categories.
Belden, Cooper Bussmann, Hoffman, Moxa, Omega
Engineering, Omron and SMC made the list twice.
So, with product categories listed alphabetically,
here are 2010’s choice companies.
Ball Screw/Lead Screw
1. Thomson . . . . . . . . . . . . . . . 22%
2. Nook . . . . . . . . . . . . . . . . . . . 9%
SKF . . . . . . . . . . . . . . . . . . . . 9%
4. THK . . . . . . . . . . . . . . . . . . . . 6%
Thomson
Ballscrews and Leadscrews
Controller, CNC
1. Fanuc CNC America . . . . . . . 27%
2. Siemens Industry . . . . . . . . . 14%
3 Rockwell Automation . . . . . . . 6%
Mitsubishi . . . . . . . . . . . . . . . 5%
Fanuc CNC America
30i-B Series CNC Control
Controller, Loop
Honeywell HC900 Control System
1. Honeywell . . . . . . . . . . . . . . 17%
2. Yokogawa . . . . . . . . . . . . . . . 14%
3. Siemens Industry . . . . . . . . . . 9%
Invensys. . . . . . . . . . . . . . . . . 8%
Emerson Process . . . . . . . . . . 7%
6. ABB . . . . . . . . . . . . . . . . . . . . 5%
Differences less than 3% are not statistically significant.
23
8/30/10 1:16 PM
Controller, Motion
Rockwell Automation
ControlLogix Programmable
Automation Controller
1.Rockwell Automation
2.Siemens Industry
GE Intelligent Platforms
Industrial Computer
32%
7%
6%
Advantech Trek-550
Rockwell Automation 6180 Series
Controller, PLC
Rockwell Automation ControlLogix L73 and L75 Programmable
Automation Controllers
2.Siemens Industry
3.GE Intelligent Platforms
Schneider Electric
AutomationDirect
1.Turck
2.Molex/Woodhead
Phoenix Contact
Industrial Electric Motor Drive
25%
14%
9%
6%
5%
Rockwell Automation PowerFlex
755 AC Drives
NI LabView 2010
Data Recorder
1.Yokogawa
2.Honeywell
National Instruments
4.Invensys
2.ABB
3.Siemens Industry
4.Baldor
Yaskawa
Mitsubishi
27%
13%
10%
6%
6%
5%
Industrial Enclosure
19%
12%
11%
8%
Yokogawa DXAdvanced Data
Acquisition & Display Station
1.Hoffman
2.Rittal
3.Saginaw Engineering
46%
18%
9%
Hoffman Fusion G7 Global
Wall-Mount Enclosures
Encoder/Resolver
1.CST/BEI Sensors
Danaher
Sick/Stegmann
5.Encoder Products Co.
Heidenhain
20%
9%
8%
7%
6% 6%
Industrial Enclosure
Purge System
Parker Hannifin Hydraulics
Group Products
Control Design September 2010 50%
18%
3.Rittal
12%
Industrial Network
Components—Wired
Hydraulic Components
1.Parker Hannifin
2.Bosch Rexroth
3.Eaton/Vickers
4.Festo
1.Pepperl+Fuchs/BPS
2.Hoffman Pepperl+Fuchs 6000 Series
Purge/Pressurization System
33%
13%
13%
6%
Turck A-Size Powerfast
Connectors
1.National Instruments
3.Invensys
4.Yokogawa
24
17%
16%
13%
7%
Industrial Electrical
Connector/Cordset
45%
14%
6%
6%
5%
Data Acquisition System
CST/BEI Sensors
Industrial Encoders
1.Advantech
Rockwell Automation
3.Dell
4.Siemens Industry
29%
20%
12%
6%
Rockwell Automation Stratix
8300 Layer 3 Managed Switch
2.Belden/Hirschmann
Cisco Systems
4.N-Tron
Phoenix Contact
Turck
Moxa
16%
13%
12%
8%
7%
7%
6%
controldesign.com
8/30/10 3:17 PM
CD1009_FPA.indd
33
CD_EthSw_Sept10 o.indd
1
8/30/10
AM
8/18/10 11:04
2:20 PM
Industrial Network
Components—Wireless
Linksys E-Series Router
1.Cisco/Linksys
2.Phoenix Contact
Emerson Process
Banner Engineering
ProSoft
6.Cooper Bussmann/Elpro
Moxa
B&B Electronics
N-Tron
Measurement, Flow
18%
9%
8%
7%
7%
6%
6%
5%
5%
1.Emerson Process
2.Endress+Hauser
3.Siemens Industry
ABB
Yokogawa
Emerson Process Management
Flowmeter Family
Measurement, Level
Industrial Network Hub/
Router/Switch
Cisco Industrial Ethernet
3000 Series
1.Cisco/Linksys
2.N-Tron
Belden/Hirschmann
4.Moxa
Phoenix Contact
26%
14%
13%
8%
6%
5400 Radar Level Transmitter and
E+H Levelflex M FMP40 GuidedWave Level Instrument
34%
8%
7%
Mettler Toledo IND131 and
IND331 Process Control
Weighing Terminal
Rockwell Automation 1799
Embedded I/O
Pepperl+Fuchs HiC
Intrinsic Safety Isolators
Parker Motion 400XR Family
Thomson LES Electric Slide
Table Actuator
Measurement, Pressure
1.Pepperl+Fuchs
29%
2.Cooper Crouse-Hinds/MTL 14%
3.Turck
11%
8%
1.Emerson Process
2.Endress+Hauser
3.Yokogawa
Siemens Industry
ifm efector
Invensys
3051S Pressure Transmitter
27%
12%
11%
8%
27%
10%
7%
6%
5%
5%
Measurement, Temperature
1.Parker Motion
Thomson
3.SMC
Festo
Rockwell Automation
1.Emerson Process
2.Omega Engineering
3.Endress+Hauser
Honeywell
10%
8%
7%
5%
5%
Control Design September 2010 CD1009_24_32_CvrStory2.indd 26
24%
16%
9%
7%
Linear Actuator/Slide/Guide
1.Cognex
2.Banner Engineering
Keyence
26
1.Mettler Toledo
2.Rice Lake
Hardy
4.Vishay/BLH
Intrinsic Safety Components
3144P Temperature Transmitter
Machine Vision System
Cognex In-Sight 5605
5-Megapixel Vision System
1.Emerson Process
Endress+Hauser
3.Siemens Industry
Ohmart Vega
Measurement, Load
Cell/Weighing
Input/Output Systems
2.Siemens Industry
Opto 22
31%
17%
6%
5%
5%
19%
11%
8%
6%
Measurement, Vibration
45%
12%
10%
6%
1.GE Energy
2.Emerson Process
Metrix
35%
14%
9%
8%
GE Energy Bently Nevada Asset
Condition Monitoring
controldesign.com
8/30/10 3:18 PM
We’ve got what you need to build your
control panel, in stock and ready to ship.
With direct prices, fast shipping and free
tech support, you can count on us for the
best value in automation.
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www.automationdirect.com/wiring
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Wire duct and
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*All prices are U.S. published prices. AutomationDirect prices from March 2010 Price List. Hoffman prices are taken from www.hoffmanonline.com
2/1/10 .Prices may vary by dealer. Many other part numbers are available from all vendors.
Universal signal
conversion
www.automationdirect.com
Go online or call to get complete information,
request your free catalog, or place an order.
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CD1009_FPA.indd 27
8/30/10 11:02 AM
Motor, Industrial Electric
Pneumatic Components
1. Baldor
2. Regal-Beloit
Siemens Industry
General Electric
5. ABB
1. Festo
SMC
3. Emerson/Numatics
4. Parker Hannifin
37%
10%
10%
9%
7%
Baldor Premium Efficiency
Super-E Motor
Festo VTSA Valve Terminal
SMC EX250 Compact Interface for
ControlNet Networks
Motor, Servo
Rockwell Automation RDD-Series
Servo Motor
1. Rockwell Automation
2. Siemens Industry
Yaskawa
Fanuc CNC America
Mitsubishi
6. Baldor
Power Supply
24%
8%
8%
7%
7%
5%
5%
Emerson SolaHD SDN Series
Power Supplies
Kollmorgen PowerMax Stepper
Motor Family
13%
10%
9%
6%
6%
5%
Rockwell Automation Guardmaster
Safety Laser Scanners
Banner Sensors
Motor Starter
1.
2.
3.
4.
Rockwell Automation
ArmorStart Distributed Motor
Controller
Rockwell Automation
Schneider Electric
Siemens Industry
ABB
Eaton Electrical
General Electric
1. Emerson/SolaHD
2. Phoenix Contact
Rockwell Automation
4. Puls
Siemens Industry
Acopian
TDK-Lambda
40%
16%
11%
7%
7%
6%
Banner Engineering
3. Turck
4. Pepperl+Fuchs
5. Keyence
ifm efector
Schneider Electric
Rockwell Automation Compact
GuardLogix Programmable
Automation Controller
2. Siemens Industry
Pilz Automation Safety
4. Banner Engineering
Invensys/Triconex
Relay
2. Siemens Industry
3. AutomationDirect
Pro-face/Xycom
Schneider Electric
1.
2.
3.
4.
5.
37%
10%
7%
7%
6%
Rockwell Automation
PanelView Plus Pro HMI
Rockwell Automation E3 Plus
Solid-State Overload Relay
Panel Meter
Red Lion Controls Panel Meters
18%
16%
14%
10%
7%
6%
5%
Programmable
Safety Controller
Operator Interface Terminal
1. Red Lion Controls
2. Precision Digital
Omega Engineering
Yokogawa
5. Newport Electronics
22%
10%
9%
7%
6%
5%
5%
Presence Sensing
Motor, Stepper
1. Kollmorgen
2. Fanuc CNC America
Parker Hannifin
4. Schneider Electric
Siemens Industry
Oriental Motors
21%
20%
16%
8%
Rockwell Automation
Omron
IDEC
Schneider Electric
Tyco/Potter&Brumfield
31%
11%
9%
7%
5%
25%
15%
12%
8%
5%
Safety Network Components
30%
10%
8%
8%
5%
2. Siemens Industry
3. Banner Engineering
Pilz Automation Safety
26%
12%
7%
6%
Rockwell Automation KwikLink
Lite Flat Cable System
Differences less than 3% are not statistically significant.
28
controldesign.com
8/30/10 3:20 PM
all-in-one.
Data Station Plus™. One product has it all. Protocol conversion, data logging and web server capabilities
built-in. Web-enable your dissimilar Ethernet, serial and fieldbus devices onto a universal communications and
control platform in minutes. www.redlion.net/dsp
Operator Interface
Protocol Conversion
Signal Conditioning
Panel Meters
Data Acquisition
Red Lion Controls ph: (717) 767-6511 fax: (717) 764-0839 www.redlion.net
©2010 Red Lion Controls
All brands and trademarks are the property of their respective companies.
RL-406 DSP Way More Ad_ControlDesign.indd 1
CD1009_FPA.indd 29
8/12/10 2:56 PM
8/30/10 11:03 AM
Safety Relay
Rockwell Automation
Guardmaster Minotaur MSR57P
Safe-Speed Monitoring Relay
2.Pilz Automation Safety
3.Omron STI Phoenix Contact
5.Banner Engineering
Schneider Electric
Siemens Industry
Software, Motion Control
28%
15%
9%
7%
5%
5%
5%
2.Siemens Industry
3.Mitsubishi
Rockwell Automation RSLogix
5000 Programming Software
Single-Board Computer
Advantech PCM-9362 Single
Board Computer
1.Advantech
2.Adlink/Ampro Axiomtek
VersaLogic
WinSystems
Software, PC-Based
Machine Control
32%
5%
5%
5%
5%
Rockwell Automation
SoftLogix Software
Software, PLC Programming
2.AutomationDirect
Schneider Electric
Siemens Industry
Software, Data Acquisition
Stack Light Tower
Invensys
Siemens Industry
Schneider Electric
2.Banner Engineering Schneider Electric
4.Patlite
5.Eaton Electrical
22%
14%
13%
6%
6%
5%
Terminal Blocks
55%
12%
7%
Phoenix Contact Push-In
Terminal Blocks
Autodesk AutoCAD
Electrical 2011
Software, HMI
2.Invensys
Siemens Industry
5.Schneider Electric
Control Design September 2010 37%
12%
10%
8%
5%
Rockwell Automation 855
Control Tower Stack Light
50%
8%
7%
6%
6%
Rockwell Automation RSLogix 5000
Design and Configuration Software
1.Autodesk
2.Eplan
3.Bentley
30
22%
17%
11%
10%
1.GE Intelligent Platforms and/or
Fanuc CNC America
25%
2.Siemens Industry
15%
3.MasterCam
11%
Software, E-CAD
Rockwell Automation
FactoryTalk ViewPoint
3.Siemens Industry
Beckhoff Automation
Software, CNC
GE Intelligent Platforms and
Fanuc CNC America CNC Software
National Instruments
Ethernet NI CompactDAQ
38%
10%
5%
1.Phoenix Contact
3.Wiedmüller
Wago
5.ABB/Entrelec
26%
22%
13%
12%
6%
Wire & Cabling
27%
16%
9%
9%
5%
1.Belden
2.Lapp USA
3.Alpha Wire
Anixter
40%
12%
5%
5%
Belden Industrial
Ethernet Cables
controldesign.com
8/30/10 3:21 PM
AD RS2180-R1P
CD1009_FPA.indd 31
8/31/10 4:51 PM
The 20010 Readers’ Choice Awards Service and Support Leaders
Control Design’s readers tell us these companies provide very good (4.0) to excellent (5.0) service in these categories.
Only those companies that received the minimum 5% vote share in the preceding pages were considered.
4.4
National Instruments...................................HMI Software
Rockwell Automation....................Motion Control Software
AutomationDirect ..................Operator Interface Terminals
National Instruments.................................Machine Vision
Rockwell Automation................................................. PLC
Precision Digital............................................ Panel Meter
Newport Electronics...................................... Panel Meter
Rockwell Automation........ Programmable Safety Controller
Ohmart/Vega.......................................Level Measurement
Rockwell Automation.....................................Safety Relay
4.3
Omega Engineering.................. Temperature Measurement
AutomationDirect....................PLC Programming Software
Pepperl + Fuchs............................ Intrinsic Safety System
Banner Engineering...................................Machine Vision
Phoenix Contact............................................Safety Relay
Banner Engineering............................... Presence Sensing
Red Lion Controls.......................................... Panel Meter
Banner Engineering.......... Programmable Safety Controller
Rockwell Automation................................Electronic Drive
Banner Engineering................. Safety Network Component
Rockwell Automation..............................Motion Controller
Belden............................ Network Hubs/Routers/Switches
Rockwell Automation................................... Motor Starter
Emerson Process Management.............Level Measurement
Rockwell Automation............. Operator Interface Terminals
SMC............................................ Pneumatic Components
Encoder Proucts.....................................Encoder/Resolver
Rockwell Automation..................................... Panel Meter
Turck................................................Connectors/Cordsets
Endress + Hauser...........................Pressure Measurement
Rockwell Automation...............PLC Programming Software
Wago.......................................................Terminal Blocks
Invensys..................................... Data Acquisition System
Rockwell Automation............................................... Relay
Yokogawa.................................... Data Acquisition System
Invensys.................................................... Data Recorder
Rockwell Automation.............. Wired Network Components
Yokogawa............................................ Flow Measurement
National Instruments.......................................DAQ Software
Rockwell Automation................... Data Acquisition System
National Instruments..... PC-Based Machine Control Software
Schneider Electric....................................... Motor Starter
N-Tron............................. Network Hubs/Routers/Switches
SKF.................................................Ballscrew/Leadscrew
Pepperl + Fuchs/BPS.............................. Enclosure Purge
SMC........................................................ Linear Actuator
Phoenix Contact................................Connectors/Cordsets
Turck............................................ Intrinsic Safety System
Puls........................................................... Power Supply
Turck.................................................... Presence Sensing
Rice Lake Weighing........... Load Cell/Weight Measurement
Turck..................................... Wired Network Components
Rockwell Automation.........................Connectors/Cordsets
Tyco Electronics...................................................... Relay
Rockwell Automation....................... Input/Output Systems
Yokogawa...................................................... Panel Meter
Rockwell Automation................................ Linear Actuator
Yokogawa................................. Temperature Measurement
Schneider Electric.......................................HMI Software
Schneider Electric.........................................Safety Relay
Siemens Industry................................ Flow Measurement
Siemens Industry...............................Industrial Computer
Siemens Industry......................................Loop Controller
Siemens Industry...........................Pressure Measurement
4.0
ABB.......................................................... Electric Motor
ABB........................................................Electronic Drive
Advantech....................................Single-Board Computer
Anixter.....................................................Wire and Cable
Autodesk................................................ E-CAD Software
Cognex.....................................................Machine Vision
Kollmorgen................................................ Stepper Motor
Eaton/Vickers................................. Hydraulic Components
Rockwell Automation............................. Presence Sensing
Rockwell Automation..................................... Servo Motor
4.1
Emerson Process Management....Wireless Network Components
Saginaw Engineering..........................Industrial Enclosure
AutomationDirect...................................................... PLC
Eplan..................................................... E-CAD Software
Vishay/BLH....................... Load Cell/Weight Measurement
Baldor....................................................... Electric Motor
GE Intelligent Platforms................................. Servo Motor
Yokogawa................................................... Data Recorder
Banner Engineering.............Wireless Network Components
General Electric......................................... Electric Motor
Yokogawa..................................................Loop Controller
Belden.....................................................Wire and Cable
Yokogawa.......................................Pressure Measurement
Bentley/ECT............................................ E-CAD Software
Cisco Systems.................. Network Hubs/Routers/Switches
4.2
Cisco/Linksys......................Wireless Network Components
ABB........................................................... Motor Starter
Cooper Bussman/Elpro........Wireless Network Components
Acopian...................................................... Power Supply
Cooper Crouse-Hinds/MTL............. Intrinsic Safety System
Honeywell......................................Pressure Measurement
Honeywell................................ Temperature Measurement
IDEC...................................................................... Relay
Mitsubishi Automation................................... Servo Motor
Moxa..................................Wireless Network Components
National Instruments................... Data Acquisition System
Banner Engineering.......................................Safety Relay
Emerson Process Management...... Pneumatic Components
Cisco..................................... Wired Network Components
Endress+Hauser..................................Level Measurement
CST/BEI Sensors....................................Encoder/Resolver
General Electric.......................................... Motor Starter
Omega Engineering....................................... Panel Meter
Dell Computer....................................Industrial Computer
Hoffman............................................Industrial Enclosure
Omron STI....................................................Safety Relay
Emerson Process Management................... Flow Measurement
Honeywell.................................................. Data Recorder
Opto 22.......................................... Input/Output Systems
Emerson Process Management.........................Loop Controller
ifm efector.....................................Pressure Measurement
Pepperl + Fuchs.................................... Presence Sensing
Emerson Process Management............. Pressure Measurement
Invensys.....................................................HMI Software
Phoenix Contact..................Wireless Network Components
Emerson Process Management....... Temperature Measurement
Invensys...................................................Loop Controller
Pilz Automation Safety..................................Safety Relay
Emerson/SolaHD......................................... Power Supply
Keyence............................................... Presence Sensing
Rittal.................................................Industrial Enclosure
Endress + Hauser..................... Temperature Measurement
Lapp Group...............................................Wire and Cable
Endress + Hauser................................ Flow Measurement
Mitsubishi Electric.................................... CNC Controller
Fanuc CNC America...................................... Servo Motor
Omron.................................................................... Relay
GE Intelligent Platforms............... Data Acquisition System
Opto 22.......................................... Input/Output Systems
Hardy Instruments............. Load Cell/Weight Measurement
Parker-Hannifin........................................ Linear Actuator
Hoffman................................................. Enclosure Purge
Phoenix Contact..................... Wired Network Components
Invensys.....................................................DAQ Software
Rockwell Automation...................................DAQ Software
Invensys........................................Pressure Measurement
Rockwell Automation..............................Encoder/Resolver
Siemens Industry........................................HMI Software
Mettler-Toledo................... Load Cell/Weight Measurement
Rockwell Automation...................................HMI Software
Siemens Industry....................PLC Programming Software
Mitsubishi Electric...................................Electronic Drive
Rockwell Automation..........................Industrial Computer
Siemens Industry............. Programmable Safety Controller
Moxa............................... Network Hubs/Routers/Switches
Rockwell Automation..................... Intrinsic Safety System
Yaskawa..................................................Electronic Drive
32
Control Design September 2010 CD1009_24_32_CvrStory2.indd 32
National Instruments.................................. Data Recorder
Rockwell Automation.... PC-Based Machine Control Software
Rockwell Automation................. Safety Network Component
Schneider Electric...................PLC Programming Software
Schneider Electric................................................... Relay
Schneider Electric...................................... Stepper Motor
Siemens Industry....................................... Electric Motor
controldesign.com
8/30/10 3:21 PM
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CD1009_FPA.indd 34
8/30/10 11:05 AM
machine c ontrol
Simulations Branch Out
Models and Simulations Spread Beyond Former Boundaries Into Machine and
Production-Line Optimization and Can Even Aid Real-Time Operations
by Jim Montague, executive editor
Virtual reality is getting more real every day.
For example, P&G experimented with a more user-
Historically, simulation was the realm of NASA, aero-
friendly bottle shape for dish soap a few years ago,
space, large automotive production-line applications and
but found it didn’t move along a race track/produc-
other big-ticket applications. However, faster and cheap-
tion line very well.
er data processing is bringing simulation to new users
“The production guys talk about how a bottle design
and types of equipment in a data-driven and seemingly
needs two points of contact and needs to address its
inevitable progression from design and configuration to
center of gravity,” explains Lange. “The product-identity
training for routine and exceptional events, and more
guys say the new design is needed to reach consumers.
recently to optimization, which even seems poised to
However, a physical experiment still takes a long time.
knock on the door of real-time operations.
You have to make a mold and bottles and then get into
a plant and run them. This can take three months and
Seeking Realism
$100,000, even though it only takes about five minutes
“Modeling and simulation are starting to transform
to find out if the new design worked. If designers can
our consumer packaged goods industry for the same
create a virtual bottle race track in 1-4 hours, we can
reasons as other industries—it costs too much and it
check how a new bottle design will run on it in an hour,
takes too long to build physical learning cycles, and
and everybody can see if it works. And, because it’s a
so the products they produce aren’t innovative,” says
simulation, we can test bottle designs we’d never actu-
Tom Lange, Procter & Gamble’s (www.pg.com) model-
ally want to make.” (Figure 1)
ing and simulation director.
“We look at things before they really exist because
Simpler Models, Better Robots
computers now are faster than the fastest computers
Similarly, programming robots and their complex mo-
in the world just 10 years ago. This power allows us to
tions never has been a picnic, but computer-aided de-
replace physical cycles with virtual ones and pursue re-
sign (CAD) tools and early simulations used to validate
alism,” explains Lange. “So, instead of building a model,
designs also evolved to make implementing robotics
doing some calculations, getting close to the physi-
easier, according to Andy Jones, general manager for
cal experiment and securing some guidance, realism
Applied Manufacturing Technologies’ (AMT, www.ap-
means making a model that’s indistinguishable from the
pliedmfg.com) automotive business in Orion, Michi-
physical experiment. This requires using our computing
gan. AMT is a complete manufacturing and engineer-
power for much bigger and more complex problems—
ing systems designer and builder, mostly for discrete
doing parametric studies instead of point estimates.”
machines and robotic applications.
“AMT’s owner started 21 years ago when offline pro-
Really Simulated
This article provides some evidence of
simulation software has big savings and
productivity potential for machine builders
and customers alike. What have you learned?
Discuss your simulation projects and pitfalls, real or
simulated, at ControlDesign.com/realsimulation.
grams were just beginning to be added to robots,” says
Jones. “Since then, data handling has grown to process
far more information, so CAD and other data translates
more seamlessly. This means it’s easier to program and
validate robots off-line in a generic language and then
pour that knowledge back into plant-floor robots in their
native language. Likewise, simulation environments are
getting more generic, and so simulation packages can
controldesign.com CD1009_35_39_Featr2.indd 35
35
8/27/10 11:38 AM
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CD1009_FPA.indd 36
8/30/10 11:06 AM
machine c ontrol
throughput,” adds Jones. “We can
tion has reached its full capabilities,
link a simulation model to actual
something new comes along.”
PLCs, validate logic before building
anything, and then make changes
Better Math = Closer Reality
later when new capabilities need to
At the root of all simulations,
IOServer_Half_CD.ai
5/10/2010
ARC Advisory Group and Procter & Gamble
be added. When you think simula-
A C R O M A G
10:53:16 AM
driving them and their software’s
I N D U S T R I A L
P C
S O L U T I O N S
Now Serving I/O.
Virtual Bottle
Track Wins Race
Figure 1: Setting up and running a
physical experiment such as a bottle
race track can take months and
thousands of dollars, but P&G reports
that a virtual track can provide the same
feasibility data in just a few hours.
C
program each robot controller clos-
M
er to how the robots will run in the Y
real world. Basically, the simulationCM
environment talks to the emulator MY
for each robot manufacturer. This
CY
means the simulation runs just like
a real robot. Ten to 15 years ago,
CMY
there was about a 20% difference inK
cycle times between the simulation
and real operations. Now it’s a fraction of 1%.”
Jones adds that AMT sees simula-
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functions, and for communicating
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8/27/10 11:39 AM
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SurvIvAl Of the fItteSt
MACHINE C ONTROL
increasingly sophisticated capabilities and new applications, is a pile of mathematics and faster calculations.
What’s sometimes lacking is user understanding.
“A good simulation can check that all your inputs and
outputs act as they should, but people still think they
have to do manual trial-and-error with devices such as
VFDs,” says Neil Koepke, marketing manager, Yaskawa
America’s Drives and Motion division (www.yaskawa.
com). “They don’t think you can simulate hardware. So,
four years ago, we developed simulation software for our
1000 Series products. Now users wire drives to the software, connect power, run programs and punch keys as if
they were using real equipment.”
“We can link a simulation model to actual
PLCs, validate logic before building anything
and then make changes later when new
capabilities need to be added.”
Similarly, to increase the realism of its offshore, quayside and gantry crane simulators, Applied Research Int’l
(www.arisimulation.com) in New Delhi, India, recently
worked with machine builder Electropneumatics & Hydraulics near Pune, India, to add a three-axis motion platform based on Baldor Electric’s Powerlink- and Ethernetcompatible drives with its MicroFlex e100 ac servo drives
in basic Ethernet mode. The drives allow the simulator’s
replica cabin to move in synchronicity with computergenerated images, better emulate the real cranes and give
trainees a more realistic, fully immersive environment
where they can get truer hands-on experience in moving
containers and other bulk-handling tasks.
Virtual Snacks, Coming Attractions
Once simulation improves a user’s machines, production
lines and packaging, they might look for other items to
simulate—even potato chips. Lange says P&G now makes
its Pringles potato chips so fast—about a billion every few
hours—that it recently simulated the aerodynamic forces
acting on the chips to keep them from flying off its production machines and to better coat them with seasonings.
“We found that air pressure was building up on the front
and back edges of the chips, and we had to find a way to
keep them on the line, so they wouldn’t end up as pig food,”
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www.pepperl-fuchs.us
says Lange. “Distributing seasonings evenly was an even
more serious problem. The simulation showed that we
couldn’t just blow the seasonings into this airflow, and so
we learned that we had to spray them on instead.”
Pepperl+Fuchs, Inc.
Twinsburg, Ohio
330.486.0002
controldesign.com
CD1009_35_39_Featr2.indd 39
8/27/10 11:39 AM
SW119
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CD1009_FPA.indd 40
8/30/10 5:39 PM
Alarms Simplified
ernet-enabled controllers contain a file server. After
events and data are logged, they can be exported
indicators and pushbuttons. Most advances have
into a comma-delineated file as part of an email
been due to three technologies: programmable
alert. Recipients can review data leading to an error,
graphics terminals, Ethernet/Internet communi-
as well as the actions occurring after the error. This
cations and controllers with PC-like functionality.
tracking, handy in root-cause analysis, enables a
“With modern HMIs, OEMs have a full-blown
resentations of what’s actually taking place in
supervisor to see who was logged on at time of error
and who pressed the acknowledge button.”
Time-stamping has become increasingly impor-
their machines and robots, as opposed to just an
tant in several applications, adds Norz. “We had a
assortment of flashing lights,” says Ben Orchard,
customer with an extensive network of controllers
application engineer, Opto 22 (www.opto22.com).
leading back to a main system for multi-facility
Orchard points to Opto’s G4 Handler, a large
supervision,” he relates. “The primary concern was
machine for final assembly and testing of the
to ensure all clocks were synched for time-stamp-
company’s G4 I/O modules. “We recently installed
ing events and alarms. The solution was simple
an HMI to view diagnostic and other data,” he says.
network time protocol (SNTP) synchronized with a
“Our operators clearly see if a screw gets jammed, if
common time server via Ethernet.”
air cylinders move up and down as they should or if
another machine malfunction has taken place.”
PLCs are great relay and timer replacements, but
Chris Vitale, senior product manager with
Turck (www.turck.us), details other benefits of
Ethernet. “The bandwidth and speed of an Ether-
poor data handlers. Today’s programmable automa-
net backbone allow greater amounts of data to be
tion controllers (PACs) have PC-like data-handling
collected and shared,” he states. “Each device can
capabilities, ideal for alarm and event handling.
share not only the status of an individual input
“Machine and robot control system PACs contain a plethora of data points related to machine
conditions, events and causes,” notes John Dart,
program manager of the global OEM solutions
business at Rockwell Automation (www.rockwellautomation.com). “Using unmodified Ethernet
“With modern HMIs, OEMs have a fullblown graphical interface that provides
realistic representations of what’s
actually taking place in their machines.”
with PACs enables use of standard notification
or output, but also diagnostic data coupled to
tools such as email, paging, text messaging,
the same messages, all without a decrease in the
secure remote monitoring and other technolo-
performance of the network.”
gies. Unfortunately, the task of finding this data
A combination of PAC power and Ethernet can
in a custom-programmed control system is often
simplify alarm and event systems and speed
expensive, time-consuming and prone to error.”
implementation. “Most modern automated
Dart says, to reduce customization, machine
machinery alarm and notification systems offer
builders should first implement standard ways
remote connectivity as an important option, with
of describing machine entities, conditions and
alarming often originating at the controller,” notes
events. “Once these standards are implemented,
Alan Cone, HMI marketing manager at Siemens
then a consistent alarm and event-handling meth-
Industry (www.usa.siemens.com/industry). “Many
odology integrated with the machine’s overall
controllers now include built-in process and system
control system can be implemented,” he concludes.
diagnostic routines that automatically report on I/O
Ethernet and Internet technologies can provide
and device alarms. They also report specific sensor
many of the remote links that increase the utility of
alarms such as wire-off or under-range of analog
alarm and event notifications systems. “Advanced
signals, eliminating manual logic development.
Ethernet controllers can send email to opera-
These alarms often have automatic connectivity to
tors and supervisors about an alarm or an event,”
compatible HMI operator panels or to networked
observes Charlie Norz, product manager of I/O
SCADA systems for intranet/Internet accessibility
systems at Wago (www.wago.us). “Some of our Eth-
without manual configuration.”
controldesign.com CD1009_41_Techflash.indd 41
Dan Hebert, PE • senior technical editor • [email protected]
graphical interface that provides realistic rep-
techflash
Alarm systems have progressed significantly since the days of light boxes, illuminated
41
8/26/10 10:38 AM
[email protected]
PRODUCT ROUNDUP
Drives and Motors Accelerate Growth
Advances in Microprocessors Fuel Motion Networks and Capabilities
There’s not much dis-
use has risen,” offers Adam Will-
input, programmable notch
agreement among motion
werth, sales and marketing man-
filters to eliminate mechanical
control companies about what
ager at Electro Static Technology
resonance effects.
changes in technology have
(www.est-static.com).
Baldor Electric; 479/646-4711;
the biggest impact on the use
“Cost and ease of use have
of motors/drives in machine
had huge impacts on the
building and performance.
use of motors and drives in
machines,” adds Joe Kimbrell,
DIRECT DRIVE
control platforms via field-
motors and drives product
Direct-drive SGMCS servo mo-
buses vs. localized control had
manager, AutomationDirect
tors include six frame sizes
the biggest impact on the use
(www.automationdirect.com).
in 17 models, ranging from
“The advent of distributed
of motors/drives in machine
The power of microproces-
15 in.-lb peak in a 135 mm
building,” argues Warren Osak,
sors and DSPs have been the
diameter package to 5,310 in.-lb
president of Servo2go.com
driver, adds Atef Massoud, mo-
peak in 360 mm diameter, up
(www.servo2go.com).
tion and drives engineer, Au-
to 500 rpm, 20-bit resolution
Modern, high-performance
tomation Technologies Group,
fieldbus networks eliminated
Omron (www.omron247.com).
the bottleneck in communica-
“The ever-decreasing cost
tion between drives and the
of brushless motors and servo
motion control system, adds
amplifiers allows machine
Joey Stubbs, PE, PMP, North
builders to use brushless mo-
American representative of
tors where they would not have
EtherCat Technology Group
been able to afford to in the
(www.ethercat.org).
past,” concludes John Walker,
per rotation and integrated
vice president of customer
bearings that allow 16,000 lb of
tion of the communications
service and marketing at Exlar
axial thrust load and 350 Nm of
interface—allowing drives to
(www.exlar.com).
radial moment load.
“It has to be the evolu-
become much more flexible
Yaskawa; 800/yaskawa;
and controllable,” agrees David
High Compatibility
Greensmith of Baldor Electric’s
e100 drive is compatible with
motion control business unit
EtherNet/IP, Modbus TCP,
(www.baldor.com).
Powerlink, standard TCP/IP
Direct Application
networks and the Mint system-
ASRT IP66-rated, direct-drive,
enhanced the performance and
building environment. The
sealed rotary stage provides
versatility of motors,” concurs
three-phase drives have a dc
precise angular positioning
Max Wietharn, vice president
bus system to share regener-
in hostile environments. Dual
of sales and marketing for IMS
ated power with other axes.
large-diameter bearings control
Schneider Electric Motion (www.
With local I/O and CANopen
tilt-error motion (3 arc sec),
schneider-electric-motion.us).
expansion, many drives have
moment stiffness, and repeat-
option card slots, and include
ability (1 arc sec). Maximum
universal encoder feedback
rotary speeds are 100–200 rpm,
“Drives and controllers have
It’s customization, believes
Jay Schultz, product manager,
www.yaskawa.com
Parker Hannifin (www.parker.
and the unit uses a brushless,
com). “Product differentiation
slotless motor, so there are no
is becoming more difficult at
brushes to wear, no gear trains
the component level and the
to maintain and high accelera-
machine level,” he says.
tion and high speeds.
“With the rising cost of energy,
variable frequency drive (VFD)
42
CD1009_42_48_Roundup.indd 42
www.baldormotion.com
Control Design September 2010 Aerotech; 412/963-7470;
www.aerotech.com
controldesign.com
8/27/10 11:52 AM
Go Direct
servo drive has a compact design and
RDD-Series direct-drive, rotary
supports SERCOS III. It has a multi-
servo motors minimize the need for
encoder interface, supporting Hiper-
power transmission devices and can
face, EnDat 2.1 and 2.2, 1Vss, 5 V TTL,
reduce machine complexity, system
and MSM and MSK servo motors,
and can be equipped with Safety-OnBoard features such as Safe Torque
Off and Safe Brake Control
Bosch Rexroth; 630/654-0170;
www.boschrexroth-us.com/brc
compliance and energy consump-
Gear Up
tion, while delivering high dynamic
WX gearhead motors with all-steel
performance, fast settling times and
helical gear trains use synthetic
better overall load control.
lubricants to produce more torque
Rockwell Automation; 414/328-2000;
and operate in a wide temperature
www.ab.com/motion/servomotors
Bring the Power
C
120 kW module for Acopos mult-
M
servo drives provides inverters
Y
and power supply modules with
CM
maximum rated values to 165 A.
range. Forty-eight models provide 12
Startup currents are reduced up
MY
gear ratios, ranging 4:1 to 312:1, and
to 60%, minimizing wire size and
rated output speeds 658 to 8 rpm
fuse/circuit breaker size. Stabilized
used with type 34B, TENV, 1/5 hp CMY
dc bus means motors have identi-
(149 W) brushless dc motors.
CY
Bodine Electric; 773/478-3515;
K
www.bodine-electric.com
Field Ready
EP7041 Motion Box IP 67-rated
cal characteristics globally, and it
module enables EtherCAT motion
eliminates upstream transformers.
applications to be implemented
B&R Industrial Automation; directly in the field without a protec-
770/772-0400;
www.br-automation.com
Talk to the Encoders
IndraDrive Cs Economy low-power
tive control cabinet with its stepper
motors up to 50 Vdc and 5 A. An
integrated incremental encoder connection permits the implementation
of a single servo axis.
Beckhoff Automation; 952/890-0000;
www.beckhoff.com/EP7041
controldesign.com CD1009_42_48_Roundup.indd 43
43
8/27/10 11:52 AM
PRODUCT ROUNDUP
COOL TORQUE
PROVIDE QUALITY POWER
UL-CERTIFIED
Self-cooled, high-interia 1FK7
VLT low-harmonic drives
SD17040, SD31045 and SD17060
servo motor provides stall
perform real-time analysis
series stepper drives are
torque in the 3–20 Nm range
and actively impose currents
certified as UL-listed products,
in IP64 or IP65 with IP67 flange
rated for operation in ambi-
protection, with options for
ent range of 0–50 °C, and are
plain or keyed shaft, holding
self-contained with their own
power supplies, and range
4.0–9.8 Arms of output current.
to ensure the high quality sine
brake and 22-bit incremental
waves from the power supply
or absolute encoders. They are
grid. The drives are individu-
configured to interface with
ally configured according to the
Sinumerik CNC and Simotion
customer needs and are avail-
motion controller for general
able 132–630 kW high overload,
A 230 Vac version is available
motion control.
160–710 kW normal overload
from AMCI to meet European
Siemens Industry;
and 380–480 Vac, 50–60 Hz.
standards.
800/879 8079;
Danfoss Drives; 800/432-6367;
AMCI; 860/585-1254;
www.usa.siemens.com
www.danfossdrives.com.
www.amci.com
3640 AW half Horz ad for Ind Hyg News FINAL.pdf 1 6/29/2010 1:27:36 PM
8/27/10 11:53 AM
ALL-IN-ONE LINEAR
torques, reversible rotation and
MDrive linear actuators inte-
dynamic braking.
grate step motor and driver
AutomationDirect; 770/889-2858;
technolog y in three motor sizes
www.automationdirect.com/dc-motors
SAFE INTEGRATION
Safety certification for 3G3MX2
ac, open-loop drives allows integration into new or existing safety systems with less hardware
and two shaft styles. They have
12–75 Vdc inputs, nominal load
limits to 200 lb, and full (256
x 200) microstepping. Options
include a motion control version with integrated programmable controller with RS-485 or
CANopen.
and simpler wiring. The drives
Intelligent Motion Systems;
have 200% at 0.5 Hz, position-
860/295-6102; www.imshome.com
ing control and built-in Modbus
communications. Safety features
eliminate need for a redundant
RECTIFY THE PROBLEM
dual-contactor setup at the drive
IronHorse permanent magnet
output. The built-in safety func-
56C-frame TENV and TEFC dc
tion is certified to EN60204-1 Stop
motors, available 0.33–2 hp
Category 0.
Omron Industrial Automation;
866/88-omron; www.omron247.com
ALL-IN-ONE
Line of 34 frame integrated brushless servo motors with rated
torques to 195 in.-oz has a closedloop with built-in driver, controller, feedback device and 110/220
Vac universal power supply. Up to
with a base 1800 rpm, are for
32 index motion profi les in veloc-
unfi ltered SCR (thyristor)-type
ity or positioning are integrated
115 or 230 V rectified ac inputs,
with QuickLaunch software.
when used with an appropri-
There are five standard models,
ate SCR drive, or with PWM, dc
both high speed (6,900 rpm) and
drives. They have linear speed/
high torque (3,600 rpm).
torque characteristics over the
Bison Gear & Engineering;
entire speed range, high starting
800/at-bison; www.bisongear.com
controldesign.com
45
8/27/10 11:54 AM
OEM Pressure Transmitters
Absolutely Frameless
KBM frameless, brushless motors come in 14 sizes ranging
60–825 mm in diameter for 240
or 480 Vac operation. On request,
windings can be offered for 12 or
24 Vdc. Each frame size has three
• Pressure ranges up to 25,000 psi
• Wide variety of physical and electrical formats
• Construction materials for use with most media
or four stack lengths. They have
encapsulated stator windings for
thermal and environmental performance and internal windings
are rated for continuous duty
Toll
Free!
877-253-5537
www.kelleramerica.com
[email protected]
operation to 311 °F. Maximum
speeds at rated power range of
105–18,600 rpm.
Kollmorgen; 540/633-3545;
Equipment
Can
you That
Measures
read
this Up.
meter?
www.kollmorgen.com
Simply Machine Design
ACS355 general machinery drive
offers four degrees of environmental protection, control of
standard ac induction motors
and permanent magnet motors,
so up to eight sequences can
be created, reducing the need
for external logic components.
You could if it was OTEK instrumentation.
Whether off-the-shelf or custom designed, our innovative process control
instrumentation is designed to be accurate, reliable and completely viewable.
And, they are easily customized for any
application. When you’re ready to see
your control room clearly, set your sights
on OTEK.
The Safe Torque Off (STO) safety
function keeps the drive energized when the motor has been
stopped and ensures no torque
on the machine.
ABB; 262/785-3502; www.abb.com
controldesign.com
www.otekcorp.com
8/31/10 9:52 AM
CAST-IRON FRAME
OUT WITH THE OLD
MoviIMot motor-integrated
OME series industrial-duty ac
D700 compact variable-fre-
variable-frequency drive
motors are three-phase, 208-
quency drive replaces S500E
provides vector-oriented mo-
with 150% more motor torque
tor control and four-quadrant
at 1 Hz using general-purpose,
operation to 5 hp. D series in-
magnetic-flux-vector control with an open-loop speed
230/460 V motors available with
1-5 hp and speeds of 3,600, 1,800
and 900 rpm. TEFC T-frame motors have cast-iron frames with a
PRODUCT ROUNDUP
All Together Now
ribbed design and class F insulacludes DR high and premium-
tion. They are inverter-duty ca-
efficient motors, bus commu-
pable with a 5:1 speed turndown
range of 60:1. Communications
nications, PC connection for
for variable torque applications
include Modbus RTU and Mit-
diagnostics and configurable
and a 2:1 speed turndown for
subishi’s RS-485 programming
parameters.
constant torque use.
protocol as standard.
SEW Eurodrive; 864/661-1120;
Omega Engineering; 203/359-1660;
Mitsubishi Electric Automation;
www.seweurodrive.com
www.omega.com
847/478-2100; www.meau.com
TMdrive -10e2
®
An evolution in
ac system drives.
• High reliability
• Simple configuration and maintenance
• Low cost of ownership
• Compact design
USA: 1+540-283-2000
www.tmeicge.com
metals | cranes | paper | oil & gas | utilities | cement | mining | rubber & plastics
8/27/10 11:54 AM
Small systems can now
ACT BIG !
With a Nano-class programmable logic
controller that comes with full
functions, built-in Ethernet and lets you
set up your own controller web page
without writing any program.
MORE, MORE, MORE
Find additional motor and drive product information from companies
such as DynaMotors, Empire Magnetics, Exlar, GE Intelligent
Platforms, Johnson Electric, Ormec, Schneider Electric, TMEIC, WEG,
and Zero-Max at www.ControlDesign.com/roundupsarchive.
FOR HAZARDOUS APPS
nicated to the drive. When a motor
NEMA-rated, C-Face Motors for
is added to the system a fully popu-
Class 1 Group C and D, Class 2
lated data object is created for use
Group F and G locations are UL-
by certified and tested templates.
listed EPNV (explosion-proof, non-
Elau; 847/490 4270; www.elau.com
ventilated) motors and have an
LIGHT AND POWERFUL
Athlonix high power-density brush
dc motors in a lighter package
(15-53 g depending on frame size)
with output power up to 9 W have a
coreless design with an optimized
… on IE6, Firefox or Safari
explosion-proof conduit box and
… on iPhones
automatic overload protection.
Davis Instrument; 800/358-5525;
Nano-10
www.davis.com/8002
$129
Perfect for small but
sophisticated OEM machines!
Features
Qty
Another
1
Yes
Yes
Yes
Intelligent servo module combines
motor and amplifier in one pack-
self-supporting coil and magnetic
age. Cabling system reduces cabinet
circuit, and are available in 12, 16
space requirements and cabling for
and 22 mm frame sizes.
servos. Motor info is stored on the
Portescap; 610/235-5499;
encoder and automatically commu-
www.portescap.com
Remarks
10/100 Mbps
User-customizable to control I/O
and data
Max. 5 clients and 1 server
RTU, ASCII & Native
RS485 / Modbus
1
2
12-bit, 0-5 V
Analog Inputs
4
24V NPN
Digital Inputs
Quadrature, up to 10 KHz
High Speed Ctrs
2
Pulse Measure
Freq, period or width
4
Interrupts
4
Rising, Falling or both edges
4
2x NPN, 2x Relays (5A)
Digital Outputs
Pulse/Direction <= 10K pps
Stepper Motor
1
PWM Control
2
0.01% res. 50Hz to 50 KHz
Battery-backed RTC Yes Optional FRAM-RTC
Program Memory
8K Flash. Expand to 16K
FRAM Data
11K Optional FRAM- RTC
ETHERNET
Web Pages
Emails
Modbus / TCP
INTELLIGENT MODULE
TR i LOG I PLC
CLASSIFIED
EQUIPMENT
LOOKING TO ADVERTISE?
Contact: Polly Dickson
[email protected]
630-467-1300 ext.396
by
Triangle Research Int’l, Inc.
www.tri-plc.com/cd.htm
1 877 TRI-PLCS
48
controldesign.com
8/31/10 9:53 AM
Programmable Safety Help
Another issue is that each time the resolution
modifications to the blanking patterns for safe-
increases, the location of the sensing field in re-
ty light curtains at the product feed and takeoff
spect to the hazard (safety distance) also must
stations of our presses. We think programmable
increase. So, for each programmed resolution,
light curtains can speed this up. We’re unclear
the mounting of the emitter and receiver must
if we can just include them as automatic chang-
be moved. This might eliminate any efficiencies
es inside the stored part profiles we provide, or
gained due to the automatic programming of
do they require some sort of redundant check
the light curtain.
A simple option is to configure the safety light
before first use?
—From July ’10 Control Design
Answers
curtain for the worst-case resolution (i.e., the
biggest “hole”) and install the sensing field at
the specified safety distance for that resolution.
Yes, anytime you change configurations in a
Placing the safety light curtain at the worst-
safety system, the system must be checked for
case distance sufficiently protects operators in
proper installation and operation before it is used
scenarios where the largest products must be fed
in production. In the case of safety light curtains,
into the machine. The same arrangement can be
one of the items that you’ll need to verify is that
used for smaller products without adjustment—
the resolution is correct for your application.
the operator is granted a larger safety distance
Typically, this is accomplished through a resolu-
than is required for the small object, but it does
tion check or trip test, in which an appropriate
not compromise the operator or the production
test piece is manually passed through the sensing
process in any way.
field in several locations to ensure detection.
This is very important if the resolution is being
Of course, if the resolution is so large (a very
big hole) that safety distance becomes an issue, a
selected by some machine logic automatically. If
vertically mounted safety light curtain might not
it’s not being checked every time the resolution
be the correct safeguarding choice.
changes, at a minimum, the means of selection
would need to be accomplished at the same level
[email protected]
real answers
Product changeovers require manual
Mike Carlson, safety products marketing manager,
Banner Engineering, www.bannerengineering.com
of safety performance as the safety light curtain
(i.e., control reliability, Category 4/PLe, SIL3, etc.).
Even then, it would still be required to verify the
operation periodically.
november’S PROBLEM
A growing number of potential new
customers don’t like that we use pneumatics to
power some simple linear motion requirements.
Simplicity is being pushed aside by users who don’t
want the air supply and maintenance hassles and
who aren’t aware of the increasing comparable
digital connectivity of many pneumatic devices. We’d
prefer to keep it simple. Who’s right?
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include
it in the November ’10 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.
controldesign.com CD1009_49_RealAnswrs.indd 49
49
8/27/10 12:32 PM
Jack Chopper • [email protected]
oem insight
Design, Build With Trouble in Mind
Some efficiency experts argue that we
• Consider printing drawings on adhesive-backed
spend too much time looking for things. They argue
stock and affixing them to the inside of the con-
that by organizing, discarding unneeded clutter and
trol cabinet doors. This ensures a set of draw-
categorizing what remains, the time we spend look-
ings always will be in the cabinet. A duplicate
ing for things can be reduced significantly.
We can apply those same ideas to machine con-
(mobile) set can reside in the print pocket.
• Keep similar things together, and use meaning-
trols. With very little additional effort as design-
ful names to identify those components. The
ers, we can provide the critical information that is
names “VFD-1” and “VFD-2” are definitive, but I
often so hard to find, or worse yet, is misleading
often witness technicians referencing drawings
or incomplete. Penalties for this lack of organiza-
several times to make sure they are testing the
tion include mistakes during original construc-
correct components. Instead, try “VFD-1, Infeed
tion and additional time required for commis-
Conveyor” or “VFD-2, Outfeed Conveyor” or
sioning and troubleshooting events. No big deal?
whatever applies to your particular situation.
Maybe so, but if we include damaged equipment
• When similar components are used more than
in the list of penalties, most would agree that we
once, locate them in the panel in the same
need to look no further for incentive.
order as they serve in machine operation. This
The points that follow can be done in addition
to a minimum set of requirements as outlined
in specifications. This additional information is
helps reduce confusion and, as a result, reduces
troubleshooting time.
• Neatness counts. Provide sufficient space to
intended to provide quick, on-the-spot reference
make connections neatly and properly. Lack of
for the individual responsible.
space, especially near terminal strips, encourag-
ith very little additional effort as
W
designers, we can provide the critical
information that is often so hard to
find, or worse yet, is misleading.
• Cross-reference the high-target items, solenoid
es less-than-optimal connections. This ultimately invites intermittent, hard-to-find problems.
• Similarly, arrange terminal connections in
logically sensible groups. Keep the PLC inputs together and keep them in order. Ditto that for PLC
outputs, safety interlocks and analog test points.
Clearly mark terminal locations that serve as test
valves and motor starters, and show the draw-
or calibration points, referencing the appropri-
ing number and grid location on that cross-ref-
ate documentation pages so there’s no question
erence. For example, provide a chart that shows
regarding safe and appropriate test procedures.
the drawing location for the coils for every relay
• Show 2-D face views for components with mul-
used in the panel. When troubleshooting, the
tiple connectors. Bubble the locations, clearly
technician won’t have to scan drawings inces-
defining each connector and its purpose. Use
santly. Ditto that for analog sources, proximity
this same face view for line diagrams, so the
switches and motor brakes. Provide this cross-
troubleshooter won’t need to search and question
reference for every type of device, and list the
whether the proper connector is being tested. It
components in alphabetical order.
also will help the shop when it builds the panel.
• Mount the devices most likely to require inter-
• Consider installing some lighting in every control
action while troubleshooting in a convenient
panel you build. Good lighting encourages neat-
location. Resist the urge to mount the PLC at the
ness and saves time while servicing the panel.
very top of the enclosure, if that puts it out of
the normal field of view for the average person.
• Label the wireway covers (on the back of the
A well-lit, well-marked, well-documented control panel, although perhaps the most inviting, is
the one that technicians will spend the least time
cover), especially if several different lengths are
inside. Ultimately, that means increased uptime
used. It will encourage technicians to re-install
for your machine.
them after removal for a troubleshooting event.
Show the locations on the layout drawing to
Jack Chopper is chief electrical engineer at Filamatic
save time when reinstalling.
(www.filamatic.com) in Baltimore.
50
CD1009_50_Insight.indd 50
Control Design September 2010 controldesign.com
8/27/10 11:07 AM
SW1197-Movimot AD-Control Design-FINAL:Layout 2
6/28/10
12:31 PM
Page 1
The world’s best-selling
motor mounted inverter
just got better (and smarter).
The NEW MOVIMOT D.
®
SEW-EURODRIVE’s MOVIMOT was first introduced in 1997. Since then over 600,000
of these rugged integrated frequency inverters have found their way onto gearmotors
used in standard variable speed applications around the globe. The hallmark of its
ongoing sucess has been its simple, fast installation and start-up. And the newest
generation MOVIMOT continues this tradition. The MOVIMOT D carries a drive identity
module (DIM) which stores individual motor parameters on board, eliminating motor
MOVIMOT D is optimized for integration
with SEW’s next-generation DR motor
series. These motors are available in
three energy efficient classes. The DRP,
our most efficient option, meets NEMA
Premium® efficiency requirements.
commissioning at start-up. And most variable speed applications can be easily set
through DIP switches. Its “smarts” can now be further enhanced through SEW’s free
MOVITOOLS® MotionStudio software. MOVIMOT D’s easy integration and scalability
make it an ideal entry-level decentralized drive solution.
WWW.SEWEURODRIVE.COM
GEARMOTORS
CD1009_FPA.indd 51
|
DRIVE ELECTRONICS
|
DRIVE AUTOMATION
|
SERVICE
8/30/10 11:07 AM
Easiest to configure system you’ll ever meet
Use the technology built into the Productivity3000 programmable controller to
make your job easier. Build systems with up to 33 total base groups - one local and
32 remote (Ethernet). Each base group can have
up to five local (USB) bases for over 115,000
possible I/O points. The convenient USB
port on each remote slave module
lets you program and monitor
from any remote location.
One click is all it takes to
auto-configure all I/O
hardware connected to the
system, including up to 64
AutomationDirect AC drives
on the Ethernet I/O network,
saving you hours of setup.
And most analog modules
are software configurable
with easy dialog boxes.
The FREE Productivity Suite
software makes it all possible!
Read more, watch free videos, and download the software at:
www.productivity3000.com
CD1009_FPA.indd 52
8/30/10 11:08 AM

Steps Above the Rest

Transcription

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