vision system high-end protection

Transcription

Modeling, Simulation Tools Grow
as Traditional Engineering
Methods Shift
VISION SYSTEM
AUGUST 2014
Makes Fast Matches
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HIGH-END PROTECTION
for Low-Voltage Power
In With SSR? Out With EMR?
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SOL
100’s
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actuatorrelay
© 2013 Phoenix ContaCt
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CONTENTS
Volume 18, No. 8
FEATURES
22
COVER STORY
Merging Mechatronics
Modeling, Simulation Tools Grow as Traditional Engineering
Methods Shift
Hank Hogan, contributing editor
31
39
VISION SYSTEMS
Match Game
Machine Vision Verifies Printed Codes at 800 Cans per Minute
Russ Butchart, Puffin Automation
PRODUCT ROUNDUP
Buttons, Switches, Indicators
Discrete Standalone Devices Still Play an Important Role in
Industrial Automation
CONTROL DESIGN EXCLUSIVE
46
PEPPERL+FUCHS
Fast, Sharp Distance Measurement
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfield Rd., Suite 400N, Schaumburg,
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Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©Putman Media 2014. All rights
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August 2014 Control Design
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An Electrocomponents Company.
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CONTENTS
Volume 18, No. 8
COLUMNS
9 Editor’s Page
50 OEM Insight
Walk the Talk
Inside IANA 2014
Joe Feeley, editor in chief
Larry Turner, president and CEO, Hannover Fairs USA
11 Machine Builder Mojo
Process the Variables
Dan Hebert, PE, senior technical editor
HOT BUTTONS
13 Live Wire
Say Servos, Seriously
Jim Montague, executive editor
21 Embedded Intelligence
Who Do You Sell? How?
15 OEM Spotlight
Lightened Loads
for Diverse Users
17 InDiscrete
NI Week Explores Industrial IoT
Jeremy Pollard, CET
37 TechFlash
High-End Protection for Low
Power
Jim Montague, executive editor
42 Real Answers
47 Product Showcase
Choose a Square D Brand Limit Switch.
Select an actuator from a vast range of options.
Your detection solution is now backed by more
than 100 years of innovation and reliability.
Simply easy!
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• Global libraries for reuse of code
across complete PLC portfolio for
reduced development time and
increased configuration flexibility
• Integrated safety, security, and
diagnostics for increased productivity
Value
• Long-term compatibility and
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into future technologies
• Global network offering sales,
service, parts, training, and support
• Operating within our Totally
Integrated Automation (TIA) Portal,
our solution can improve your ROI up
to 30% through increased productivity
and reduced costs
Answers for industry.
CD1408_FPA.indd 8
8/12/14 6:03 PM
Joe Feeley
In Memory of Julie Cappelletti-Lange,
Vice President 1984-2012
•
editor in chief
•
[email protected]
editor’s page
Walk the Talk
1501 E. Woodfield Rd., Suite 400N
Schaumburg, Illinois 60173
630/467-1300
Fax: 630/467-1124
mation supplier demonstrates how
editorial team
it uses its products and services
down, but we were lacking that
to improve its own manufacturing
MES level,” Murphy said. A good
capabilities. There’s some cred-
example of the success of the com-
executive editor
ibility to be gained when it shares
pany’s FactoryTalk ProductionCen-
Jim montague
[email protected]
stories about confronting the same
tre MES solution is the company’s
issues and concerns as most any
printed circuit board assembly
other global manufacturer.
process. Taking the Monterey,
editor in chief
Joseph Feeley
[email protected]
managing editor
nanCy bartels
[email protected]
managing editor, digital media
Katherine bonFante
[email protected]
associate editor, digital media
erin massey
[email protected]
senior technical editor
Dan hebert
[email protected]
leslie gorDon
[email protected]
contributing editor
hanK hogan
[email protected]
editorial assistant
lori golDberg
[email protected]
columnist
Jeremy pollarD
[email protected]
design/production
I’m happy when a major auto-
Rockwell Automation took a
that blurred the global picture.
“We had the machine level
Mexico, plant as example, he said,
shot at that during its RSTechED
on a single day, they place about
conference this past June.
1.5 million to 2 million parts on
“Today, we produce about
boards. They’ll use 6,500 raw ma-
387,000 catalog-level SKUs across
terials, assemble 10,000 to 15,000
20 plants,” said Bob Murphy, vice
different boards off 300 different
president of operations. “It’s a con-
workorders that necessitate 65 to
figure-to-order and engineered-
70 different line changeovers.
to-order product portfolio ranging
from a $100 stack of LED tower
lights that might have a two- or
three-day lead time to a $500,000
large, medium-voltage drive system with a 22-week lead time.”
As the company grew, it was
“At the manufacturing
process level, the middle
layer of MES was pretty
much missing.”
“If we were dealing with older
also growing the number dispa-
technologies and custom applica-
rate ERP and other supply chain
tion programs for these 55,000
anetta gauthier
systems it was running to the
transactions, we simply couldn’t
assoc. art director
point that it no longer could keep
do it effectively, productively and
up. It had to change the structure.
accurately. This new MES layer
“In one case there were five ERP
provides us a highly automated,
888/644-1803
systems interacting in one plant
predictable means.”
circulation
audited december 2013
and countless custom software ap-
Murphy noted similar success
plications. And at the manufactur-
at the Mequon, Wisconsin, plant
ing process level, the middle layer
that produces low-voltage drive
of manufacturing execution was
assemblies, then closed with the
pretty much missing,” he said.
benefits the manufacturing group
senior production manager
angela labate
subscriptions
customer service
Air & Gas Compressors
925
Engineering & Systems
Integration Services
8,493
Engines & Turbines
1,650
Food Products Machinery
2,150
Industrial Fans, Blowers
& Air Purification Equipment
798
Industrial Heating, Refrigeration
& Air Conditioning Equipment
1,464
Industrial Process Furnaces & Ovens
795
Machine Tools
3,888
Materials Handling, Conveyors
& Conveying Equipment
1,868
Metalworking Machinery
3,553
Mining Machinery & Equipment
619
Oil & Gas Field Machinery & Equipment 1,191
Packaging Machinery
946
Paper Industries Machinery
351
Printing Trades Machinery & Equipment 508
Pumps & Pumping Equipment
778
Rolling Mill Machinery & Equipment
156
Semiconductor Manufacturing
Machinery
1,406
Textile Machinery
233
Woodworking Machinery
273
Other Industries & Special Industrial
Machinery & Equipment NEC
7975
total
40,020
CD1408_09_EDITOR.indd 9
As part of a five-year plan to
has seen, noting that at the plant
overhaul the supply chain and ERP
level, inventory was reduced from
puzzle, Rockwell formed an APOS
120 days to 82 days; at the supply
(advanced process operations sup-
chain level, lead times came down
port) group with subject matter
by half; and it realized a 50% re-
experts from a variety of disci-
duction in ppm quality failures.
plines to create a small, dedicated
All of these intitiatves, Murphy
group of MES specialists. They
said, added up to 4% to 5% produc-
standardized core workflow pro-
tivity gains/per year.
cesses, and that meant winning
over local loyalties to embrace a
global standards approach and
give up locally created solutions
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9
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CD1408_FPA.indd 10
8/12/14 6:04 PM
dan hebert, Pe
•
•
[email protected]
machine builder mojo
Process the Variables
IndustrIal machInery automation systems
The flowmeter measures volume flow and temperature
typically use mostly digital I/O, but some do need to
like a high-end vortex meter. With these parameters
measure and sometimes control analog variables.
and an integrated flow computer, the device can calcu-
On the other hand, process skid OEMs routinely deal
late mass flow, corrected volume flow, energy flow and
with multiple analog variables, both for measure-
heat-flow difference for a broad variety of liquids and
ment and control. In either case, these analog variables
gases. Options extend operating turndown to 100:1, al-
are used to monitor operating conditions, and they’re
low for short inlet installations, provide steam-quality
often are used in conjunction with analog outputs for
warnings, indicate steam dryness fraction and enable
closed-loop control.
in-situ lifecycle management.
An example of monitoring is measurement of tem-
“This instrument can replace multiple flowmeters
perature on a motor housing. In this case, the tem-
and temperature sensors and does the steam calcula-
perature is monitored, and the measurement is not
tions in the transmitter, thus reducing the need to
used to control the motor, but instead alerts machine
program an external control system,” Stevens adds.
operators of a high-temperature condition.
For closed-loop control, an extruder typically has
Water treatment skids are a common item found in
power, pharmaceutical and beverage plants. “Some water
multiple temperature measurement points, and these
treatment and other related processes need to calculate
measurements are used to control heating elements
the rH value for optimal control,” notes Tracy Doane-Wei-
and cooling water valves to maintain the proper
deman, analytics product manager for Endress+Hauser.
temperature of the melted material in the extruder
barrel. The temperature is the process variable in the
control loop, usually of the PID variety, and the output
of the PID controller drives the heating elements and
regulates the flow of cooling water.
Selecting the right sensor or instrument to measure
each process variable can be a daunting task because
Process skids often have multiple analog
measurements, but some machines have only
single points of analog measurement and are
better served by simple measuring devices.
The rH value is the negative logarithm of partial
there are hundreds, if not thousands, of options on the
pressure of hydrogen and is an indicator of the
market from low-cost analog sensors to multivariable
oxidation or reducing ability of a process solution,
smart transmitters. As with many applications, the
such as when water is treated with an oxidizer
key is to fit the right component to the task.
such as chlorine. Calculating the rH value can be
For process skids and other OEM applications with
difficult. “The pH and ORP values of a solution
multiple analog points of measurement and control, a
must be measured simultaneously to calculate the
multivariable instrument often makes sense. “Mul-
rH value, which normally requires two sensors in
tivariable transmitters are becoming very popular
different locations and an external processor to
with process skid builders because they reduce the
make the calculation,” Doane-Weideman says. “Our
number of sensors needed in an application, minimize
sensor simultaneously measures pH and ORP, and
the amount of wiring needed and eliminate the need
automatically calculates rH, eliminating the need for
to make calculations within the main controller,”
multiple sensors.”
says Jerry Stevens, flow product management lead at
Endress+Hauser (www.endress.com).
Many process plants purchase skids to produce
Process skids often have multiple analog measurement and control points best served by complex multivariable instruments, but many machines have only
steam, requiring the OEMs to precisely measure and
single points of analog measurement and are better
control steam flow rates and other parameters. “One
served by simple measuring devices.
of our vortex flowmeters measures mass and energy
These machines often are controlled by a relatively
flow of wet, saturated and superheated steam,
low-end PLC that can accommodate analog I/O,
gases, liquids and cryogenic fluids. The flowmeter
but not to an extensive level. In these cases, the
measures virtually every steam flow parameter of
best choice is often a low-cost instrument that
interest, making it suitable for use in industrial,
simply measures the desired analog parameter, and
building, utility and power-generation applications,”
transforms this measurement into a 4-20 mA signal
Stevens explains.
that becomes a PLC input.
controldesign.com
CD1408_11_MOJO.indd 11
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Jim Montague
•
executive editor
•
[email protected]
LIVEWIRE
Say Servos, Seriously
What do I know about servos? Not much off the top
and backward compatibility with the revamp. After
of my head. I know I’m covering them in more stories,
evaluating options from more than 15 suppliers, Mark
but I thought it was because people just like saying
Andy’s engineers settled on a Mitsubishi Electric
the word “servo” over and over. This is much like Jerry
(www.mitsubishielectric.com) automation platform
Seinfeld’s old observation that people repeatedly say
with safety servos, HMI and software, and developed
“salsa” because they love how it sounds.
and tested them for six weeks.
Other than that, I thought servos were drives and
“The software and servos improved our tension con-
motors that produced extra feedback—usually aided
trol by 500% with more accurate registration and less
by an encoder—and that this information was more
servo following error than other systems we tested,”
detailed and useful than data gained from regular
says Kevin Wilken, Mark Andy’s engineering vice
motors and drives. Well, better data means more ac-
president. Mitsubishi’s servos also preserved Mark
curate control, which is always attractive to builders
Andy’s backward compatibility.
and users. Once again, an apparently simple technical
Likewise, Pfankuch Machinery (www.pfankuch-
advance extends beyond itself to impact unexpected
maschinen.com) in Ahrensburg, Germany, reports
discrete manufacturing applications.
that earlier this year it needed to improve the
How about some for instances? No problem. I’m better at relaying what other people know.
Anyway, because one-third of the energy used by
performance and speed of the motion-control element
in its mid-range SmartFeeder friction feeders for
inserting leaflets and products into sales packaging.
rubber injection molding machines goes to the hydrau-
Previously, the machine used a brushed dc motor and
lic drive, Maplan (www.maplan.at/en) in Ternitz, Aus-
homemade drive to perform real-time registration
tria, switched a couple of years ago to a servo-hydraulic
solution based on B&R Automation (www.br-automation.com) drives networked via Ethernet Powerlink, and
reduced its drives’ energy consumption by 70%, halved
noise levels and accelerated Maplan’s dry cycle up to
15%. These machines have injection volumes from 10 to
The feeder’s new, embedded, brushless
ac servo drive increased its insertion
speed to 150 items per minute with
1-mm position resolution.
26,000 cm3, clamping forces of 150- 10,000 kN and cycle
and insert up to about 100 items per minute with
times from 30 seconds to several minutes. But their
2-mm position resolution. However, besides seeking
previous drive included a pressure-regulated, variable-
to switch to a brushless ac servomotor and embedded
flow pump driven by an induction motor, which had to
servo drive to improve speed and precision and
run continuously, wasted energy and required cooling.
reduce maintenance, Pfankuch also wanted to
Consequently, adopting its new constant-volume
complete its electronics upgrade with no more than
pumps with B&R servo drives and motors gave Maplan
a small increase in manufacturing costs in order to
internal-gear pumps that are 60% smaller than its
keep SmartFeeder competitive.
former axial-piston pumps, but still achieve the same
Consequently, the builder sought help from Metro-
flow volumes thanks to rapid-motion speeds up to
nix (www.metronix.de), which agreed to strip down its
4,000 rpm, compared to just 1,500 rpm by the previ-
servo drive, remove its casing and costly system-level
ous induction motors and variable-flow pumps. In this
connections and allow Pfankuch to add application-
case, using servos enabled Maplan to adapt its pump
specific connections, mounting and firmware. Local
activity and motor speed to how much power was
control intelligence embedded in the drive performs
actually required to perform its rubber injection mold-
control calculations more rapidly and employs a more
ing and save that 70% on its drive-side power, change
sophisticated positioning algorithm that adjusts drive
oil less often, reduce water consumption and cut its
speed more often to enhance registration resolution.
overall energy costs in half.
As a result, its new brushless ac servodrive increased
Similarly, printing press builder Mark Andy (www.
the feeder’s insertion speed to 150 items per minute
markandy.com) in St. Louis recently needed to
with 1-mm position resolution and even gave it a
upgrade and standardize the motion controls on its
CANopen port for future networking.
servo-driven, in-line, flexographic presses, but it didn’t
want to give up some of its existing software platform
controldesign.com
CD1408_13_LIVEWIRE.indd 13
In short, there don’t seem to be many applications
that servos can’t help—and it’s fun to say.
13
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OEM SPOTLIGHT
Lightened Loads for Diverse Users
Fori Automation’s AGVs and Integrated Systems Meet Automotive,
Aerospace and Other Requirements With Care and Global Planning
GRAVITY IS A universal pain in the neck. However,
because we all must struggle against it, those who can
provide labor-saving assistance in one endeavor or industry can often deliver similar aid to others. This is the
logic underlying 30-year-old Fori Automation’s (www.
foriauto.com) worldwide growth and its diversification
into a variety of applications focused mainly on carrying, assembling, welding and testing heavy automotive,
aerospace, and defense parts and products.
Located in Shelby Township, Michigan, just north of
Detroit, Fori was founded by Arthur Koerner, in partnership with an earlier, Germany-based Fori in 1984,
and then bought its U.S. operations about five years
later. The company now is run by Koerner’s son, Bernd,
who serves as president, and a core management team,
including global operations vice president Mike Beck,
AGVS AID NUCLEAR PLANTS
business development director Martin Erni, mechani-
Figure 1: To help move fuel rods in nuclear facilities, Fori’s
automatic guided vehicles (AGVs) must be outfitted to better
handle radiation, but still be able to lift 60,000 pounds.
cal engineering director Paul Doan, controls manager
Peter Karcz and sales vice president Paul Meloche.
“I sailed past the Statue of Liberty in 1954 and said,
‘Well, here I am, and I’ll do my best’,” Arthur Koerner
we’re very organized so the entire landscape of our shop
recalls. “So I watched, learned, tried hard and was re-
floor can change every two weeks.”
warded well.” Bernd Koerner adds, “My father and uncle
Despite its rapid expansion into new applications and
were on the board when we started, and my uncle was
markets, Beck adds that Fori is very careful in how it con-
in the shop with a half dozen guys because he’d worked
trols its growth and diversification, so it can maintain
at General Motors, Fraser Automation and other firms.
consistent quality and performance and preserve the
Good engineering is where everything started for us,
reputation it’s gained over the years. “We don’t want to
and it’s still the key today.”
take on more than we can manage, and sometimes that
Fori started out building automotive wheel-alignment
means turning down some proposals we don’t feel we
machines and equipment for measuring toe and camber
can do our best work on,” Beck says. “Many builders take
angles. Its first installation was at Pontiac’s Fiero plant.
on jobs they can’t complete, and that leads to delayed
Next, it moved into window and final assembly systems,
vehicle launches, which tarnishes their reputations.”
body and paint shop equipment, and other solutions.
To support all its vehicles, systems and customers,
These days, Fori designs and builds automated guided
Fori maintains mechanical and software engineering
vehicles (AGVs), chassis marriage systems, 3D wheel
and manufacturing facilities on four continents, as well
aligners, toe automation, headlamp aimers, fluid fill
as sales and service representation on five continents.
systems, roll and brake testers, and integrated systems
Its subsidiary companies are in Brazil, China, Germany,
for tires and wheels, tire loading and installation, caster/
South Korea, India and Mexico, which allows it to save
camber sets, front corner and engine dress up, motor
customers considerable revenue by splitting tickets. For
and transmission assembly, carpet and cockpit installa-
example, it recently employed five of the subsidiaries to
tion, door and seat installation, and urethane and glass.
deliver a large system to Volkswagen India, including
Because orders and projects can vary so widely, Fori’s
project management by Fori Germany, design by Fori
headquarters and 72,000 sq-ft, primary production facil-
Germany and Fori USA, manufacturing and assembly by
ity in Shelby Township employs 186, but it adds contract
Fori Korea, Fori China and Fori USA, and installation by
engineering and support personnel as needed.
Fori India. Also, Fori worked closely with VW to split the
“This isn’t a steady-state business,” Beck says. “We’re
very project-based. We run on a tight schedule, but
controldesign.com
CD1408_15_16_OEM SPOTLIGHT.indd 15
contract between Fori Germany, Fori USA and Fori India
by issuing scope-specific purchase orders (POs) in local
15
8/13/14 10:19 AM
OEM SPOTLIGHT
“This isn’t a steady-state business. We’re very project-based. We run on a tight schedule, but
we’re very organized so the entire landscape of our shop floor can change every two weeks.”
currencies. This strategy gave the customer the lowest-
Because its AGVs are custom-designed and built, Fori
risk and lowest-cost solutions, including a reduction in
developed its own drive/steer, navigation and traf-
India’s import tax by issuing the installation and com-
fic control strategies—and even adds robots to some
missioning PO directly to Fori India in rupees.
systems. The suspended drive/steer propulsion system
“Each company runs its daily business, but when we
is servo-driven and can achieve ±5-mm accuracy. The
have an international project, we find the best strategy
Active X instructions in the drive/steer mechanism were
to solve it,” Beck explains. “After we decide where’s best
developed with help from Siemens, which also integrat-
to design, engineer and build each part, we talk to each
ed them with the touchscreen on its wired and wireless
region more. We’re also globally integrated, so systems
pendant HMI that users can employ to teach and control
like our rail-guided cart (RGC) chassis marriage system
its RGCs and automated guided carts (AGCs).
are globally standardized across six or seven plants
Fori’s AGVs typically run on 312 V from 24 12-V batter-
worldwide. This enables us to follow our automotive
ies, so they can employ almost any preferred type of ser-
manufacturing clients from Michigan to their plants in
vomotor and servo drive, while their servo-lift systems
Spain, Thailand, Brazil and elsewhere and assist them
can be custom designed to carry up to 120,000 pounds
with local products, support and languages. Our foot-
(Figure 2). These AGVs usually employ 10 10-kW, brush-
print mirrors many of our customers’ manufacturing
less servomotors and eight drives with absolute position
sites, and that can be very valuable.”
feedback. Primary controls include Emerson Control
Besides geographic growth, Fori has diversified be-
Techniques’ servo drives for steering, propulsion and
yond its automotive roots. In 2008, it began developing
lift, and Siemens’ safety PLCs to manage safety bumpers.
custom AGVs and other material handling systems for
The vehicles also have top-side panels for easier access
aerospace firms, nuclear power plants and other users.
and maintenance. Traffic functions on the AGVs are con-
For instance, to move fuel rods in a nuclear facility,
trolled by a PC-based controller, which maps the paths of
Fori’s AGVs must be outfitted to handle radiation, but
all AGVs in a given area and oversees their movements.
still be able to lift 60,000 pounds (Figure 1). Longtime
Communications occur via 802.11a, 5-GHz wireless, and
supplier and supporter Siemens Industry (www.usa.
security is achieved via IPCF protocol.
siemens.com) introduced Fori to Lockheed Martin when
In addition, Fori’s vehicles can interface with plant-
it was seeking a material-handling solution for aircraft
level controls via OPC to a plant’s master PLC, employ
production. Back home, Fori opened a new 15,000 sq-ft,
Profisafe for safety functions and activate end-of-line
high-bay building in 2012 to support its non-automotive
systems for 3D measuring head modules. “We can do
clients, and it’s planning a third building, which likely
the weld line that builds the cradle for our suspensions,
will add another 70,000 sq ft.
and then build the suspension, align and put it in our
chassis-management system, and do end-of-line testing
and vision inspecting,” says Meloche. “Our newer AGVs
also use ladder logic open-architecture programming,
so users can modify their vehicles’ function more easily
beyond the script we give them and add new paths, lifting procedures and safety functions as needed.”
To develop its next-generation team, Fori also participates in local science, technology, engineering and math
(STEM) programs, recruits at tradeshows and supports
continuing education for employees. “Business is busy,
but it can be a challenge finding people who can support
our new designs, so we’re still trying every avenue to
EASIER UNDER THE HOOD
Figure 2: A see-through version of Fori’s AGVs shows how its
batteries, servo drives, servomotors, suspensions and servolift systems can be designed to carry up to 120,000 pounds,
and arranged for simpler configuration and maintenance.
16
Control Design August 2014
CD1408_15_16_OEM SPOTLIGHT.indd 16
build up our core team,” Beck adds. “We have several
staff members at different levels of college, and ultimately we want them to keep working for us after they
graduate. We’re looking to these young people to become
our replacements someday.”
controldesign.com
8/13/14 10:20 AM
INDISCRETE
NI Week Aids Industrial IoT Convergence
THE INTERNET IS bringing even more things together lately—off the plant floor and on—and consumers
and engineers need help organizing and analyzing
all the data coming in. Even their machines and
other equipment are gaining web presences and
communicating via the ballooning Internet of Things
(IoT), but they often need as much aid as their human counterparts.
Luckily, a few developers and organizations have
the tools to manage these incoming data sources
and use their information to make better decisions.
One of these is National Instruments (www.ni.com),
which showcased many of its end users and solutions for more than 3,000 attendees at its 20th annual NI Week, Aug. 5-8, in Austin, Texas.
“What we’ve been working over the last several
decades is now converging to give us a defi nitive,
differentiated position in the area of big analog data
and high-performance, mixed-signal test,” said Dr.
James Truchard, NI’s president, CEO and co-founder.
NI WEEK KEYNOTER
Dr. James Truchard, president, CEO and co-founder of National Instruments
“In this era of big analog data, it’s possible to capture
“We reduced overall test time and optimized
your data over time and turn it into useful informa-
time to market because all the test patterns
tion and ultimately into wisdom. That’s what we see
ran automatically in only 118 hours,” explained
as a convergence of social media, analytics and cloud
Tomohiro Morita, senior engineer in the HEV
computing to make it possible for us to truly trans-
design department in Fuji’s Subaru Engineering
form the way enterprises work.”
division. “This was a 94% reduction in test time
Truchard reported that NI divides IoT into industrial IoT and consumer IoT, and this industrial side is
compared to manual testing.”
• Semiconductor manufacturer Integrated Device
focused on using big analog data, analytics, distrib-
Technology (www.idt.com) uses NI’s Semi-
uted timing and synchronization, and intelligence
conductor Test System (STS) and its open PXI
via cyber-physical systems to help factories, power
architecture to reconfigure its ATE equipment
grids, cities and machines work better.
and improve their capabilities without increas-
End-user solutions presented at NI Week included:
ing their cost. “NI STSs installed on our produc-
• Airbus (www.airbus.com) is using NI’s System on
tion test floor run 24/7,” says Glen Peer, IDT’s test
Module (SOM) and software to add smarts to its
engineering director. “We’ve experienced 10 to
aircraft assembly tools and shop-floor systems,
25% test time reductions, enhanced our measure-
which speeds up prototype development, and
ment capability and accuracy, and cleaned up
simplifies and shortens production. “We estimate
our footprint on the test floor, which makes our
our time to deliver with NI SOM is a tenth of the
testers much more production-friendly.”
time of alternatives because of the productivity
• Bergmans Mechatronics (www.bergmans.
gains of NI’s approach to system design, particu-
com) combined LabVIEW software and HTML 5
larly with NI Linux Real-Time and the LabVIEW
protocol to develop its LabSocket System, which
FPGA module,” says Sébastien Boria, R&D mecha-
allows users to access NI’s virtual instruments
tronics engineer at Airbus.
(VIs) via the web or within a customer’s local
• Subaru’s parent, Fuji Heavy Industries, (www.
area network (LAN). “LabSocket helps users save
f hi.co.jp), employs NI’s hardware-in-the-loop
time because they can drag a VI off a program
(HIL) platform to simulate and test its fi rst
and onto a webpage, and it will be continuously
hybrid car, the XV Crosstrek, before commit-
updated,” added John Bergman, president of
ting to costly, time-consuming real-world tests.
Bergman Mechatronics.
controldesign.com
CD1408_17_20_INDISCRETE.indd 17
17
8/13/14 11:39 AM
INDISCRETE
IMTS Will Land Big Footprint in Chicago
ONE OF THE largest manufacturing tradeshows
• Other pavilions include abrasive machining /
in North America opens next month at McCormick
sawing /finishing; controls and CAD/CAM; EDM;
Place in Chicago. As it does in every even-num-
gear generation; Industrial Automation North
bered year, the International Manufacturing Tech-
America (IANA); machine components/clean-
nology Show (IMTS) will host more than 100,000
visitors from 112 countries during Sept. 8 to 13.
ing /environmental and quality assurance.
The IANA pavil-
More than 1,900 exhibitors from the metal-
ion will showcase
working industry will display their products and
the newest tech-
productivity solutions in displays covering 1.2 mil-
nologies focusing
lion net square feet of show f loor space in product
on new ideas and
category pavilions, including:
topics ranging from
• Metal cutting—contains everything from ma-
resource-efficient manufacturing and network
chining centers and assembly automation to
security to secure industrial control systems and
f lexible manufacturing systems and lathes.
big data. In addition to more than 120 vendors from
• Tooling and workholding systems—features
16 countries, who will demonstrate their products
jigs, fixtures, cutting tools of all types and
and services, IANA will host the Global Automation
related accessories.
and Manufacturing Summit, Motion, Drive & Automation Conference, and ISA training program.
• Metal forming and fabricating /laser
For more information on IANA, go to www.ia-
processes—includes waterjet, plasma-arc
and laser systems, welding equipment, heat
northamerica.com. For more information on IMTS
treating and more supporting equipment.
2014, go to www.imts.com.
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8/13/14 11:39 AM
NEW AND NOTEWORTHY
Mention in the 2014 Best of Sensors Expo Innovation
Ocean Data Systems (www.dreamreport.net) was selected by
temperature M12 molded connectors. The Gold Award winner
Yokogawa (www.yokogawa.com/us) to develop a specialized
was AG-SL900A EPC sensor tag and data logger IC from ams
thermal uniformity survey (TUS) reporting solution to
(www.ams.com ).
Award for its M12LCP thermocouple probes with high-
accompany its broad range of data recorder products.
Industrial-grade networking solutions provider Moxa (www.
Hurco Companies (www.hurco.com) filed a U.S. patent
moxa.com is one of 45 companies recognized by Northrop
application for new technology combining 3D printing and
Grumman (www.northrupgrumman.com) in the company’s
CNC machining.
annual Supplier Recognition Program.
Eplan (www.eplan.us) is adding three new subsidiaries over the
MERGERS, ALLIANCES
AND ACQUISITIONS
course of the coming year. Japan, South Africa and Turkey are the
new direct sales locations of the engineering software provider.
U.S. manufacturer of end-of-line packaging equipment, Combi
Connecticut Spring & Stamping (www.ctspring.com),
Packaging Systems (www.combi.com), is a Machine Builder
manufacturer of precision parts for the medical, aerospace,
Partner in Rockwell Automation’s (www.rockwellautomation.
firearms and defense industries, expanded its machining
com) PartnerNetwork program.
capabilities to include multi-axis, CNC, Swiss machining for use
in medical applications, aerospace and firearms applications.
SKF (www.skf.com) joined the ISA100 Wireless Compliance
Institute (www.isa100wci.org).
Lenze Americas’ (www.lenzeamericas.com) portfolio of
products now fully support the OPC Foundation’s
Yaskawa Electric (www.yaskawa.com) reached agreement with
(www.opcfoundation.org) Open Access specifications.
the owners of The Switch Engineering Oy (www.theswitch.
com), a Finnish supplier of components for wind turbines, to
Omega Engineering (www.omega.com) received an Honorable
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A record 14,135 robots, valued
at $788 million were ordered from
North American robotics companies in the fi rst half of 2014, an
increase of 30% in units and 16%
in revenue over the same period in
2013. The second quarter of 2014
was the main driver of the market’s
record fi rst half, with 8,197 robots
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08.2014 Control Design .333pg - Two Faces.indd 1
7/14/2014 3:16:46 PM
8/13/14 12:14 PM
INDISCRETE
Manufacturing Technology Orders Down in May
U.S. ManUfactUring technology orders in May
“The Purchasing Managers’ Index (PMI) continues to
2014 totaled $351.9 million, according to AMT–The
stay above 50, capacity utilization is on the rise, and
Association for Manufacturing Technology (www.
both auto sales and aerospace backlogs are growing.
amtonline.org).
These are all indications that our customers’ businesses
are healthy. We expect continued investments in capi-
This total, as reported by companies participating
tal expansion through year’s end.”
in the United States Manufacturing Technology Or-
The USMTO report, which is compiled by the trade
ders (USMTO) program, was down 10% from April, and
down 17.5% when compared with the total of $426.4
association, represents the production and distribu-
million reported for May 2013. With a year-to-date
tion of manufacturing technology, provides regional
total of $1,971.8 million, 2014 is down 1.4% compared
and national U.S. orders data of domestic and im-
with 2013.
ported machine tools and related equipment.
Regional leaders in the report included the south-
“Expectations for the 2014 manufacturing technology
market were for a soft first half of the year, followed by
eastern U.S. with $180.6 million in manufacturing
a stronger second half. The fluctuations seen in the past
orders through May, which was a 5.5% increase over
few months are on track with forecasts, and all indica-
the same period in 2013, and the northeastern U.S.,
tions are that U.S. manufacturing activity is and will
which had $337.4 in manufacturing orders through
remain strong,” said Douglas Woods, AMT president.
May, which was a 2.9% increase over 2013.
Total U.S. Manufacturing Technology Orders
Through May 2014
800,000
700,000
$ Thousands
600,000
500,000
400,000
The AssociATion for MAnufAcTuring Technology
300,000
200,000
100,000
0
1998
1999
2000
2001
2002
Total order value
2003
2004
2005
2006
2007
2008
3-month moving average
2009
2010
2011
2012
2013
2014
12-month moving average
Bad drop
Manufacturing technology orders were down 17.5% in May compared to May of 2013, but the year-to-date total is down only 1.4%.
20
controldesign.com
8/13/14 12:15 PM
jeremy Pollard, CeT
•
[email protected]
embedded intelligence
Who Do You Sell? How?
How do you do your marketing and sales? With the
the topic of tradeshows, and how there aren’t any left.
Internet, yes?
ISA Automation week is dead, and most of the open
Many “on-the-road” salespeople have been kicked to
the curb because of cost, lack of effectiveness, reduced
budgets due to slimmer margins and any other excuse
tradeshows and conferences are few and far between.
Regional shows also are waning.
We don’t get to talk much precisely because we nor-
that allows companies, both private and public, to
mally talked at these events, so we have to learn about
increase their bottom line.
this thing called a phone to stay in touch, unless we
This is kind of the same thinking as not marketing
when your sales are down. Why do they do it?
As of July 1, Canada instituted its anti-spam
law (www.fightspam.gc.ca). CASL, as it’s known,
requires companies to register their recipients to
have that perceived personal relationship per CASL and
then we can use email.
But Terry’s dilemma is big. Where does he find
customers?
Since the intent of the legislation is to remove the
send targeted emails to them on marketing, product
spam lists so you simply can’t fire out thousands of
information and the like.
emails to unknown entities, any small business that
If the target isn’t registered, then the vendor has
might rely on email address lists from accredited
to remove said target from its database. Per the CASL
sources could find itself in hot water. So Terry has to
website, however, there’s a three-year grace period,
come up with a different marketing approach. He says
during which implicit consent isn’t required.
he’s not sure what that is just yet. He has an ongoing
So why is this legislation important? To start with,
debate over where to target his expertise. Does he aim
there are 10 million reasons. That’s the maximum fine
for special interest groups (SIGs), end-user group con-
for sending commercial-activity emails or messages
ferences or open, competitive tradeshows?
without the consent of the recipient.
With all the spam and duct-cleaning robocalls, one
wonders why it’s taken so long. Canada has had a donot-call registry for a while, but the robocallers now
have the ability to fake a phone number that would
belong to a residence in your area, so you really have
no idea where the calls come from.
Telephone spam can now be the same as spoofing.
When Rockwell started its Automation Fair,
it couldn’t have known it was starting a
trend toward captive audiences. When in
Rome, you can’t travel anywhere else.
When Rockwell started its Automation Fair, it
couldn’t have known that it was starting a trend
So can the CASL make a difference and/or will it allow
toward captive audiences. When in Rome, you can’t
for other governments to implement a similar ap-
travel anywhere else, which is the way the vendors
proach to the spam issue so we can’t contact anyone
want it—the big ones anyway.
anywhere without permission?
Could this be used as a form of warfare, whereby
What would happen if PackExpo packed it in?
That’s the premier application show and conference
whistleblowers everywhere try to rat out offending
for packaging machine builders. What about Han-
companies? I’m not convinced the legislation has any
nover Fair? These shows can help many companies,
teeth, since the offended party must report the offend-
but the smaller the player, the less help they might
er to Industry Canada. This might be too much trouble,
be. The price of admission isn’t cheap.
but there’s writing on the wall from this to take home.
AutomationXchange was a targeted marketing
Our sandbox has changed. Seems that the sand
effort, but again, it all costs money. So some options
is much deeper than we thought, and the free reign
are still out there, but maybe aren’t specific enough
we’ve enjoyed is coming to a slow and controlled halt.
to help Terry.
I spoke with Terry Divelbiss, president of a small
company that has a patented PLC-on-a-chip product
I can hear you now: “Make up your mind.” I know. I
wish I could.
that it builds products around, as well as designs and
builds en masse for its clients. One of you reading this
jeremy Pollard, CET, has been writing about technology
might very well be a client.
and software issues for many years. Pollard has been
Upon discussing various topics of disarray, since Terry
and I don’t talk as often as I would like, we came upon
controldesign.com
CD1408_21_EMBEDDEDINTEL.indd 21
involved in control system programming and training for
more than 25 years.
21
8/13/14 10:26 AM
Modeling, Simulation Tools Grow
as Traditional Engineering
Methods Shift
by Hank Hogan, contributing editor
T
he same weekend the 2013 Super Bowl went dark
due to a power outage, Russ Klisch, president of
Now we’re up to about 190 bottles a minute.”
These results and how they were achieved illustrate
Lakefront Brewery (www.lakefrontbrewery.com), was
some important points about mechatronics. Thanks to
hoping to avoid a somewhat similar fate. The Milwau-
the greater integration of functions and more soft-
kee-based craft brewer was installing a new filler, the
ware, mechatronic systems are growing more com-
machine that puts a beverage in a bottle.
plex. As a result, modeling is increasingly important.
Unlike the big game, Lakefront’s switchover went
This greater upfront work can pay off in more capable
off without a shutdown. This was, in part, due to
systems and/or the completion of projects in less total
the successful application of mechanical, electrical,
time. But there are downsides to this approach, one
control and software, or mechatronics, expertise. The
being a need for greater modeling and software ex-
new machine has proven effective, Klisch reports.
pertise. Such model-based design methods also take
“Our uptime went from 80-90% to 99% runtime,” he
says. “We were running around 125 bottles a minute.
22
CD1408_22_29_COVERSTORY.indd 22
longer to produce hardware, and this lack of physical
proof of progress can be seen as a disadvantage.
controldesign.com
8/13/14 10:35 AM
Better Bottling
In the case of beer
bottling, the filling machine is
servo drives was proper, so we could have the right
torque requirements for this small application and be
cost-effective in doing it,” Gilberg says.
Accomplishing this involved some simulation,
important to more
using software from SolidWorks and PTC. KHS also
than the quantity
used Rockwell Automation’s motion analyzing and
of product pro-
control logic simulation software, along with one of its
duced. It has to be
programmable automaton controllers tightly synchro-
precise, ±1.5 ml.
nized with the same brand of servo drives and motors
For a 12-oz bottle
via an EtherNet/IP network.
that translates
The hardware provided motion control without a
to 0.4% accuracy.
dedicated network, while the combination of simula-
What’s more, fill-
tion software allowed prediction of torque load to
ing has to be done
within 10%. Getting the simulation right was impor-
without dissolv-
tant, as having too small motors would keep the ma-
ing oxygen in the
chine from working properly, while too large motors
beer, as too much
of the gas makes
would be expensive and inefficient.
There are three servomotors on the machine that
for a flat and stale
handle the motion. These motors are independent
taste. The industry
mechanically, but are synchronized electronically, so
specification is
they appear to act as one, according to Gilberg. Valves
that dissolved oxygen be below 100 parts
per billion. There’s also the
need to ensure the safety of the
and other functions on the machine are controlled
using essentially the same logic and approach that
bigger filling machines follow.
Since the successful rollout of the smaller filler,
beverage by preventing bacterial growth.
KHS has sold additional machines to several of the
The new filler easily betters the oxygen
nearly 3,000 craft brewers in the U.S. One result has
content mark, according to Klisch. It’s also more
been dramatic increases in efficiency, with some end
hygienic and accurate than the old machine.
users getting as much product out in one shift as they
Other improvements include a 50% or better re-
previously did in two.
duction in the time it takes to change over from one
product to another, which is an important benefit in
Growing Complexity
the craft beer market. The new filler is more energy-
As this project shows, the software side of mecha-
efficient and more tightly integrated with other
tronics is becoming more complex, something that
machines in the plant. Thus, when there is a prob-
Tony Lennon, industrial automation specialist with
lem, conveyors and other supporting equipment stop
MathWorks (www.mathworks.com), points out. The
automatically.
mathematical computing software company’s plat-
The filler is a product of Waukesha, Wisconsin-based
form for modeling and simulating dynamic systems
KHS USA, (www.khs.com), a machine builder with
is Simulink, which can help automate the chore of
long experience in the beverage industry. Director of
creating software. It does so by generating code from
engineering Jeff Gilberg says the filler process involves
a model-based design.
pulling a vacuum on a bottle, purging it with carbon di-
This automated approach saves time and prevents
oxide, filling it with a precise amount of the beverage,
errors, Lennon says. “In regard to code generation,
and finishing by injecting water. There are slight varia-
Simulink can generate ANSI/ISO C code for micropro-
tions in the process between different types of beer.
cessors, IEC 61131 structured text for PLC systems and
The new filler was smaller than others the company had built before, and it faced cost constraints while
HDL for FPGAs.”
That software situation could grow significantly
still needing to ensure product quality. That, in turn,
more complex, thanks to the advent of cyber-physical
demanded certain mechatronic performance speci-
systems. Such systems bridge the cyber and physical
fications. “We had to make sure that the fit for the
world, and they will have an effect on mechatronics.
controldesign.com
23
8/13/14 10:35 AM
says Ahmed Mahmoud, senior group manager for
embedded systems marketing at National Instruments
(www.ni.com). He adds that cyber-physical systems
combine elements of computation, communication and
control. This combination of disciplines will become
more important as machines and systems become
more networked, which has implications for design
tools. Mahmoud sees them as evolving to support
cyber-physical systems, which, like mechatronics,
demand multi-domain expertise.
Packing a Salad
Thanks to the power of computers and the fidelity of
MATHWORKS
simulations, an entire mechatronics solution sometimes can be tried out and verified before anything
is actually built. A case in point comes from Pro Pack
THE MATH WORKS
Simulation model of a wind turbine combines electrical,
mechanical and control disciplines in one design environment.
Systems (www.propacksystems.com). The Salinas,
California-based company makes a variety of machines aimed at automating the secondary packaging
process. Thus, Pro Pack’s RoboLoader might take a
“Similar to cyber-physical systems, mechatronics in-
closed, lettuce-filled, plastic tub and place it in a cor-
cludes applications that continuously and dynamically
rugated cardboard case, which would then be sealed
interact with the environment through the coupling of
and shipped to a retailer.
distributed computational and physical components,”
“The customer typically is packing the case by hand,”
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Dave Zurlinden, president of Pro Pack, says of the
company’s target market. “We’ve automated that
case packing.”
According to Zurlinden, mechatronic components are
used throughout the process. Empty cases that come
into the machine arrive on a conveyor, and photosensitive circuits are used to gate this motion. Grippers hold
a box steady, while tubs are packed in it. Servomotors
drive mechanisms that correctly orient both the outside packaging and the tubs of produce.
Then there is a delta robot from Codian Robotics (www.codian-robotics.com) of Veenendaal, the
The Pulse of AuTomATion
Netherlands. Designed specifically for pick-and-place
applications, the robot arm is capable of three-axesof-freedom movement driven by servomotors. For lettuce in plastic tubs, no vision system is used, as that
would add to the cost, Zurlinden says. Positioning to
within 1/16th of an inch is required. Being off can lead
to a crash, potentially opening up a tub, and sending
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lettuce everywhere.
Cyber-physical systems combine elements
of computation, communication and control.
This combination of disciplines will become
more important as machines and systems
become more networked, which has
implications for design tools.
The RoboLoader can handle 115 trays a minute,
with the packaging machine typically running 20
hours a day, six days a week. The robot and the other
elements have to do so in an environment suitable for
produce. That translates to about 36 ºF and +90% relative humidity, and these cold and damp conditions
dictate certain characteristics. “All the electronics enclosures need to be IP65 or better,” Zurlinden says. “All
the machine components need to be stainless steel or
anodized aluminum.
A B&R Industrial Automation (www.br-automation.
com) system runs the robot, with the entire control
system developed and tested before the actual machine was built, says Karl Robrock. He’s co-founder
A product of world-class acoustic engineering expertise,
Pepperl+Fuchs ultrasonic sensors are completely
unaf fected by dust, color variations, gloss, or
transparency. With sub-millimeter precision, software
configurability, and detection ranges from ½ inch to
over 30 feet, ultrasonics are ideal for both switch-point
and analog control of objects as diverse as bottles,
refuse containers, wooden pallets, steel coils, and foods.
of San Francisco-based Automation Resources Group
(www.automationresourcesgroup.com), which acts
as a heavily engineering-oriented sales and distribution channel for B&R.
Pro Pack also had models of the physical machine,
which the developers used for determining where obstacles to motion would be. The same models allowed
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path planning, so motion through physical space
could be tested. Simulation allowed throughput,
Pepperl+Fuchs, Inc. • 330.486.0001 • www.pepperl-fuchs.us
8/13/14 10:36 AM
cycle time and process validation to be done before
any hardware was complete.
“The entire process that runs on a servo drive is
running in simulation in our environment, which is
fun,” Robrock says. “At the end of the day, that means
Proper sizing of the drive is handled by the company’s Drive Solution designer. King says, “This can
rapidly perform in-depth analysis to easily size and
choose between drives.”
Models also can identify the impact of uncertain
Pro Pack can implement JIT [just-in-time] principles
factors such as friction and elasticity. Such information
on new machine designs without affecting the qual-
along with other important data derived from
ity of their product.”
models can simplify the setting control parameters
Mechatronic simulation and modeling are more
complete and closer to reality than ever before, ac-
and shorten the time needed to put a machine into
operation, King notes.
cording to Derrick Stacey, solutions engineer at B&R.
He says that B&R’s Automation Studio is a tool that
Go For a Spin
simulates control logic, and integrates with packages
UltraThera Technologies (www.ultrathera.com) of
that mathematically model systems.
Colorado Springs, Colorado, followed a different path to
The ability to simulate with high fidelity is im-
mechatronic success. The small company’s GyroStim
portant because machine builders see an increase
is designed for carefully controlled vestibular stimula-
in customization requests, Stacey notes. As a result,
tion. This can help treat cerebral palsy, concussion,
systems are designed as modules that are added or
traumatic brain injury, autism and other neurological
dropped as needed, which requires that everything
conditions. Subjecting patients to movement will help
works together seamlessly.
the inner ear and other parts of the vestibular system
The advent of modularity and simulation tools
function more normally, thereby potentially restoring
places certain demands on engineers and project
a sense of balance and other important capabilities
management. In the old days, systems might be built
necessary for daily life.
serially, with the mechanical done first, followed by
Before, such movement was a manual procedure. A
the electrical, controls, safety and software. “You
doctor’s instruction, for example, might be to place a pa-
really need to manage things in parallel,” Stacey says
tient in a swivel chair and spin them in both directions
of the new approach.
150 times. However, securing a patient in a chair so that
movement was safe could be difficult. In addition, such
movement was manual and only along one axis, that of
Component vendors are taking steps to make such
yaw. Being manual, the process was prone to a lack of
management easier on machine builders and system
control and repeatability. Also, the motion recipe could
Ultrathera technologies inc.
Make Things Easier
integrators. Alby King, ap-
not be too complex, again because of the manual nature
plications engineer with
of the process. Automation and the design of a system
Lenze Americas (www.
addressed these issues by enabling safe, controlled,
lenzeamericas.com),
repeatable movement along the yaw and pitch axes.
points to his company’s
The GyroStim is undergoing U.S. Food and Drug
mechatronic modules
Administration evaluation for certification as a device
for in-feed and dual-belt
suitable for treatment of neurological conditions, says
applications, which can
UltraThera’s president, Kevin Maher. It’s also in use for
be used for material han-
pilot training and for research, with all of these differ-
dling and separation of
ent applications arising from the system’s mechatron-
SERVO thERaPY
products. The Lenze solu-
ics. “So many new applications are possible because
Inventor Kevin Maher tests
GyroStim, a computer-controlled,
multi-axis rotating chair that
provides vestibular stimulation
therapy for individuals with
cerebral palsy, concussion, TBI,
autism and other neurological
conditions. This innovative device
uses servomotors and drives and
is the result of a mechatronics
approach used throughout the
development process.
tion consists of a control-
of the ability to provide precisely controlled motion to
ler, inverters and motors.
humans,” Maher says.
26
The functional compo-
Genesis Engineered Solutions (www.genesisengi-
nents of the software
neeredsolutions.com) of Denver supplied the mechatron-
are independent of the
ics expertise that went into the device. The challenge
mechanical details, mak-
was to provide multi-axis motion with as few limits as
ing it easier for users, who
possible, while maintaining safety, robustness, smooth-
they can simply select the
ness, quietness and cost-effectiveness, says Daniel
configuration best suited
Councilman, Genesis’ engineered solutions manager.
to their equipment.
Successfully meeting these requirements involved
controldesign.com
8/13/14 10:36 AM
Mechatronics training
A few years ago, Phoenix Contact (www.phoenixcontact.
com) faced a challenge. The industrial automation
supplier used increasingly complex machinery to make
its own products. Some of the manufacturing machines
deployed had as many as seven PLCs, with some running
the machine and others handling the interface with the
rest of the production line. Dealing with that growing
complexity loomed as a manufacturing issue.
“As we brought more of these highly technical
machines in our facility, we realized we lacked the skills
necessary to support these new machines,” says Jerry
Wise, technical training specialist. “So that’s where we
were lacking in our technician skills.”
So the company developed a four-year, 8,000-hour
training program aimed at producing technicians
proficient in mechatronics, which required skill in
mechanics, electronics, software and control. It did so in
conjunction with the local educational system.
Several of the company’s own technicians have been
through the training. Results so far are positive, as can
be seen in improvements to the process that include
replacing a large linear drive on a particular assembly
machine. Connected to a servomotor and encoder,
the drive is responsible for all precision motion by the
machine. Occasionally, the drive must be swapped out
for repair, and that’s when the training pays off.
“Before we had the mechatronics training, that
operation took us approximately eight hours to
complete. We noticed after the training we were able
to do it in about half the time,” says Keith Shumberger,
mechatronics technician.
The time-savings and resulting line uptime improvement
are attributable to the technicians’ increased expertise,
Shumberger says. For instance, the time to configure and
successfully start up the machine was cut due to greater
knowledge about the sensors and how they interact with
everything else.
Alby King, applications engineer with Lenze Americas
(www.lenzeamericas.com), sees a need for such enriched
education to be present beyond the technician level.
“Engineering companies also need to work with area
colleges to ensure applied engineering and mechatronics
are part of four-year engineering curriculum beyond
theoretical engineering,” he says.
8/13/14 10:36 AM
prototyping several servo drives. One of the reasons was
a string from a lookup table. It then opens up a simple
that GyroStim uses a custom, PC-based drive control
command window to the drive, something a person
system, which had to be secure and flexible. The soft-
might use for basic operation. The command string is
ware also had to keep records such as speed, direction,
then sent to the drive, and the response is captured.
acceleration and deceleration over time.
The need for flexibility and the lack of a predefined
This approach allows changes to be made on the fly,
with the system switching from a velocity to position
set of motions forced a decision about how to talk
mode, for instance, as needed. Precision is about a
to the motion components, Councilman says. “In
degree or so, according to Councilman.
Another value of having a model is it aids
understanding of how a system works. It
allows for such virtual changes as swapping
out a drive of one size for another and
seeing what happens. That can allow
engineers to learn how to make changes
to a machine to address specific problems.
is typical. Usually, Genesis does quite a bit of up-front
This particular project followed a different path than
planning, and performs simulations on the mechanical components and design. However, because of cost
constraints, in this case, prototyping was done without
mechanical modeling. The result was probably the
same as would have happened if there had been the
usual initial planning, but Councilman reports it did
take longer to get there.
the end, we determined to use the most basic drive
The Future
interface, as it gave us ultimate controls flexibility and
As for where mechatronics is headed, Nuzha Yakoob,
allowed us to directly control the drive from the PC,
Festo (www.festo.com) product manager, points to
while allowing the drive to provide precise, closed-
optimized mechanical design. She says the outcome
loop control of the servos.”
can be systems with high-speed positioning, greater
He adds, “We ended up using a simple Telnet session to send and receive data, thus keeping the interface simple and minimizing unnecessary overhead.”
So the software takes the desired motion, decomposes it into the appropriate movement, and then builds
throughput, reduced energy consumption and a
smaller carbon footprint.
Along these lines, Festo has kinematic solutions
that operate off a single belt, making them light and
compact, Yakoob says. She mentions another available lightweight solution: robots that can work alongside people in a collaborative production environment. Festo itself does not currently offer such robots,
according to Yakoob.
Another trend benefiting from mechatronics
involves the greater use by machine builders of
multi-positioning systems. These allow products of
various sizes to be handled on the same machine, an
important plus on factory floors with limited space.
Yakoob says achieving such a capability is only possible with a system that integrates mechanical and
RensselaeR Polytechnic institute
electrical components with feedback sensors, control
electronics and software. “It can be programmed to
adjust to different product sizes, so it provides that
flexibility,” she says.
An important mechatronic need and trend is educational in nature, indicates Mathworks’ Lennon. “Experience with our customers shows that an important
Mechatronic Venn DiagraM
An intersection of technologies, mechatronics optimizes the
tools required for easy and successful machine design by
blending expertise in mechanical engineering, electronics,
instrumentation, robotics, PLC computer systems and
software-based engineering.
28
challenge is overcoming the silo effect,” he explains.
“Too often, development teams work in their own discipline, and they don’t consider the impact of integration until the last stages of the development project,
when prototype hardware and its software begin to
come together.”
controldesign.com
8/13/14 10:44 AM
that can be used to judge an en-
and math.” However, the situation
requirements are easier to
gineer’s productivity and demon-
could be changing, as industry re-
identify when system-level
strate a project’s progress. So the
sponds to the increasing complex-
simulation is used, he says. That
real challenge in industry now is
ity of machines.
will be more straightforward
to get engineers to go from the
with greater integration between
design, build and test approach
we have are so multidisciplinary
CAD and high-fidelity, model-
to this model-based, system
that there’s really no other way to
based design.
design approach using physics
do this.”
Errors and mismatched
As Craig says, “The systems that
Finite element analysis methods can be used today to boost
simulation accuracy. However,
doing so can mean orders of
magnitude increases in computation time, according to Lennon.
That makes this approach too
time-intensive to be routine. With
greater computing power, though,
that might no longer be the case,
and system-level models would
then benefit.
Kevin Craig, Marquette University mechanical engineering
professor, echoes the idea that
modeling of systems can prevent
problems. Such modeling need
not be overly involved and the
simulations complex for an initial
evaluation. “After all, he says, “if
a system won’t work in a simplified or an ideal case, it most likely
won’t work in a more realistic
model or in a prototype.”
Another value of a model is that
it helps in understanding how a
system works. It allows for such
virtual changes as swapping out a
drive of one size for another to see
what happens. That, in turn, can
allow engineers and others to gain
insight into how to make changes
to a machine in order to address
specific problems.
The benefits of a model-based
mechatronics approach are there,
but so too are the old methods.
These typically involve building a
prototype and using that to verify
a design, an approach that Craig
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also produce something tangible
8/13/14 10:45 AM
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sensing & MeasureMent
Match Game
Machine Vision Verifies Printed Codes at 800 Cans per Minute
by Russ Butchart, Puffin Automation
One Of Our clients, a food processor, fills an
average of 800 cans per minute with a wide range of
products such as vegetables, fruit and soup. An important challenge for the company is to ensure that
the code printed on the bottom of each can matches
the product in the can.
Current and upcoming food traceability legislation requires that food-processing companies have
systems in place to provide a trail of information
that follows each food item through the supply
PUFFIN AUTOMATION
chain. To ensure food safety and efficient recalls,
manufacturers must be able to identify and locate
any item in that supply chain, and quickly trace it
back to its source and forward to its destination.
To achieve this, many companies are in the process of implementing 2D barcodes, vision systems
and image-based ID readers to ensure the safety of
the supply chain.
Many food canners use a “bright stacking” pro-
Fast and Fiducial
figure 1: The vision system had to locate the four-character code in the
radial direction—using a pair of fiducials—then read it within the 75-ms
spacing between cans with a near-100% read rate, despite inevitable
distortion of characters and variation in the background.
cess. Bright stacking is the storing of uncased cans
without labels, commonly on pallets in a warehouse
uses pattern-matching to orient the code regardless
after sterilization and cooling. The only indication
of radial position, and then optical character rec-
of what’s inside each can is a text code on the end
ognition reads the code and matches it against the
of it, so when the time comes to put the label on the
product being produced on the line.
can, a vision system checks the code on the end of
the can to make sure the right label is applied, and
Application Challenges
then verifies that the can contents and label match.
The greatest challenges in the application are the
The food processor in this application decided to
high speed of the line, the fact that the code can
begin reading the code on the bottom of each can to
be oriented in any radial position on the can as it
be sure that it’s readable and matches the contents
moves down the line, and the varying finish of the
of the can. The goals were to prevent mislabeled
cans, which can range from dull to bright and can
products from reaching customers, prevent ac-
include watermarks. The food processor asked Puf-
cidental product mixing on the line, and prevent
fin Automation in Eden Prairie, Minnesota, to find a
shipping of mixed products to customers. The code
way to print the code, read the code and reject cans
is inspected directly after the canning process and
with incorrect or unreadable codes. This was our
then again just before the label is applied.
first project with this customer because it previ-
These goals were achieved with the installation of
ously used periodic manual/operator inspection.
a machine vision system that reads the code on the
“We had to locate the four-character code in the
can in just 60 ms—enough time to reject cans with
radial direction, then read it within the 75-millisec-
incorrect or unreadable codes. The vision system
ond spacing between parts,” says Darin Berg, partner
controldesign.com
CD1408_31_35_FEATURE2.indd 31
31
8/13/14 10:47 AM
sensing and measurement
at Puffin Automation. “We needed an exception-
The OCR tool achieves high read rates, even when
ally fast camera that could determine the radial
reading distorted, touching and variably spaced
position of the code quickly, and then provide a
characters or characters printed on uneven or re-
near-100% read rate, despite inevitable distortion of
f lective surfaces that cause lighting variations and
characters and variation in the background.”
background noise (Figure 1).
“What makes OCRMax unique in the industry
Puffin Automation selected a Cognex (www.
cognex.com) In-Sight 5600 series vision system,
is that it can read very challenging text, but is
which is the company’s fastest. In-Sight vision
very simple to use,” states Cognex’s Ron Pulicari,
systems use PatMax, a geometric pattern-matching
marketing manager for the Americas. “The first
technology for part and feature location. PatMax
step is to draw a region, kind of like using an image
dramatically improves the ability to find objects
crop tool, around the characters you wish to read.
despite changes in angle, size and shading. It learns
an object’s geometry using a set of boundary curves
that are not tied to a pixel grid, and it then looks
for similar shapes in the image without relying on
specific gray levels. Image resolution is 640 x 480
VGA for this process.
In-Sight vision systems also offer the OCRMax
optical-character-reading tool. OCRMax segments
a string of alphanumeric characters into individual
regions that each contain one letter or number.
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Lighting enhances accuracy
Figure 2: The vision system and a strobed flat dome light
are mounted in a stainless steel, air-conditioned washdown
enclosure. The dome light provides even, consistent lighting over
the can lid surface. The vision system enclosure is adjustable in
every axis, allowing it to run the full range of can sizes.
32
controldesign.com
8/13/14 10:48 AM
OCRMax then automatically segments each character it finds. If
the text is too hard to read—if,
for example, the characters are
touching, or they’re too poorly
printed to make out—OCRMax
The goals were to prevent mislabeled products from
reaching customers, prevent accidental product mixing
on the line, and prevent shipping of mixed products to
customers. The code is inspected directly after the canning
process and then again just before the label is applied.
allows you to modify the automatic segmentation if necessary
preferred vision sensor at this
signal to the PLC, which in turn
to properly segment the char-
facility. The new OCRMax tool
commands the vision system to
acters. After that, you just train
provided a robust solution, so
acquire an image of the bottom
your characters by simply typing
there wasn’t any need to evalu-
of the can. The PatMax pattern-
in the text that OCRMax is look-
ate other brands and options.”
matching algorithm detects
ing at. Once you’ve trained the
the fiducials, and uses them to
characters, you have the option
The Plan of Inspection
determine the radial orientation
of providing fielding information
The cans come into the inspec-
of the can.
to further improve accuracy.
tion station in single file. An
Fielding essentially allows you
inkjet printer is manually set up
forms pre-processing and image
to tell OCRMax if it should ex-
to print the code on each can,
correction to correct for changing
pect numbers, letters or both in
and also print fiducials around
light conditions, and filters out
certain parts of the text.”
the product code. A photo eye
background noise in the image.
detects each can and sends a
“Puffin Automation engineers
Berg adds, “Cognex is the
The OCRMax tool then per-
8/13/14 10:52 AM
sensing and measurement
“Within 60 ms, the vision system acquires the image on the bottom of the can, locates the
code and performs optical character recognition (OCR). The OCR tool returns not only the
value of each character, but also the certainty of each character on a scale from 1 to 100.
The software is configured, so if one or more characters don’t achieve a 60% score, or if any
character is incorrect, then the code fails. If all four characters pass with a 60% score, then the
code is verified. The vision system sends the inspection results to the inspection system PLC.”
used the segmentation rules in
much more likely to be the let-
OCRMax tool returns not only
the OCRMax tool to train the
ter ‘B’ rather than the number
the value of each character, but
system to recognize the font
‘8.’ Fielding is used to specify
also the certainty of each char-
printed on the cans,” Berg says.
whether each character is al-
acter on a scale from 1 to 100.
“They also used classification
lowed to be a letter or a number
“Our engineers configured the
and fielding to improve read
or either.”
software, so that if one or more
characters do not achieve a 60%
accuracy based on knowledge of
what characters were likely to
Sixty-Millisecond Reads
score, or if any character is in-
appear in each digit of the code.
Within 60 milliseconds, the vi-
correct, then the code fails,” Berg
Classification is used to specify
sion system acquires the image
explains. “If all four characters
the probability of a specific
on the bottom of the can, locates
pass with a 60% score, then the
digit being certain characters.
the code and performs opti-
code is verified. The vision sys-
For example, a digit might be
cal character recognition. The
tem sends the inspection results
to the inspection system PLC. “
When a code is not readable,
Berg says the bad can is tracked
using photo eyes for a few can
spaces to the servo reject kicker.
Each time the first photo eye
is triggered, a number is added
to a buffer in the inspection
system PLC, and each time the
second photo eye is triggered,
a number is removed from the
buffer. Then, when the bad can
hits the servo reject kicker station, the inspection system PLC
activates the servo reject kicker
to remove the can. A third photo
eye located just after this station
checks to make sure the can was
removed.
The user interface displays the
number of passes and fails, and
displays the image of the last
bad code. The operator can easily switch to another screen that
displays index, test and home
buttons for the servo reject kicker, along with alarms and error
messages. The fully adjustable
8/13/14 10:58 AM
vision system enclosure can be quickly resized in
matches the product and that the correct charac-
every axis to run all the various can sizes. The op-
ters are printed clearly for customer safety and
erator sets the vision system to the correct height
brand management. The food processor in this
based on a scale (Figure 2).
application used OCR to make immediate improve-
“Currently, operators manually enter the can
ments in productivity, product documentation and
code to be inspected into the inspection system,”
supply chain management. The food processor now
Berg says. “Future plans will have the can code
has two of these systems in operation at its plant
loaded automatically over the plant network.”
and six more are on the way. The systems have
The PLC connects to the In-Sight vision system
demonstrated the ability to consistently identify
using Ethernet and digital I/O. Digital I/O delivers
and reject cans with the wrong code or with an
pass-fail results from the vision system to the PLC
unreadable code. The customer now typically can
because it provides the highest possible speed.
enjoy a best-case fail rate of 0.01%. One big key to
Ethernet is used to transfer the can code from the
the success of this application was the use of a vi-
PLC to the camera.
sion system with the speed and accuracy to handle
the requirements of this application, as well as the
Reliability Achieved
f lexibility to adapt to the plant’s entire production
The food processing industry is putting increas-
with very fast changeover.
ing emphasis on traceability in the supply chain.
Food and beverage manufacturers can use OCR
Russ Butchart is a partner at Puffin Automation, based
to check that product descriptions and tracking
in Eden Prairie, Minnesota. Learn more about the firm at
have been printed on the product, that the label
www.puffinautomation.com.
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Jim montague
•
[email protected]
TECH FLASH
High-End Protection for Low Power
Just because some circuits carry less juice
still have a lot of education to do, but there’s a clear
doesn’t mean they don’t need and deserve
trend to toward avoiding contact with potentially
protection. In fact, 24-V and other lower-power
hazardous cabinets and removing consumable
circuits are proliferating in devices and networks,
components from inside them. Everyone is
and so are the tools and smarts to safeguard them.
becoming more aware that they need circuit
As always, the trick is to apply them appropriately
protection at low-voltage levels.”
for the most benefit.
“Circuit protection is a mainstay of 24-V products,
Mark Stremmel, U.S. systems manager for Turck’s
(www.turck-usa.com) Engineered Packaged Systems
but besides breakers and fuses, we have increasing
group, adds that, “Old-school system design and
use of electronic circuit protection (ECP) software
circuit protection was regimented and strict, and
and intelligence,” says Aaron Henry, North American
we used circuit breakers on the load side of the 24-V
market manager for Murrelektronik (www.
supply and on the line side as well, so users could
murrelektronik.com). “This is because breakers and
isolate power, test and do maintenance. Breakers
fuses don’t always work as well as they should when
would be distributed for all PLCs and HMIs, but as
protecting low-voltage components.”
OEMs competed more, many no longer did it because
Breakers and fuses are older technologies, Henry
reminds us. They look for heat to identify current-
it wasn’t required by UL508A.”
Stremmel adds that almost all dc power supplies
resistance and other problems, and they have to be
have gained some form of electronic short-circuit
replaced frequently. “However, electronic circuit
protection built into their circuitry over the past 10 to
protection can be turned on and off remotely, it
15 years. “If they read an over-power or short circuit
keeps people out of potentially hazardous cabinets,
monitors entire circuit current levels, handles
current inrushes better and immediately notifies
users of short circuits without having to go through
the usual breaker conditions of resistance and heat.
ECP is really the next generation of breaker and fuse
“Because of electronic monitoring and
protection, many users and OEMs now
think they don’t need circuit breakers as
much on the load side.”
functions,” he says.
Over the 10 years Murrelektonik has been building
condition, then the output side shuts down until the
ECP devices, Henry reports, it’s expanded into
load or short is removed,” he explains. “However,
broader current and voltage levels, and developed
because of this electronic monitoring and protection,
its Mico products, which are similar in shape to
many users and OEMs now think they don’t need
breakers, have adjustable current settings and can
circuit breakers as much on the load side.”
replace 12 traditional breaker styles. The latest Mico
While most control systems and circuits also
product is a 48-Vdc solution. “The microprocessor
migrated from 120 Vac to 24 Vdc during the same 10
and software in an ECP component monitors
to 15 years, Stremmel reports Turck believes breakers
current, and as its panel approaches 90% of a pre-
are still essential in many settings. Turck offers
selected current level, it gives a warning. If the
circuit protection in all its I/O product categories,
current goes beyond that level, it reports if there’s a
including on-machine block, on-machine modular,
fault or overload condition, isolates that circuit and
in-panel block I/O and in-panel modular, which all
cuts the voltage. ECP is a relatively new technology,
communicate via multiple Ethernet-based protocols.
so we’re excited to bring these new products to
market with more functionality.”
Traditional breakers can monitor for short circuits
“Our view is that if you’ve got a PLC, HMI, Ethernet
switch or other dc device such as field power, then you
don’t want all of them to go down when one shorts
or over-current conditions, but not both. However,
out,” Stremmel says. “Consequently, a breaker and
ECP can perform both tasks. “Many circuits are
fuse might be needed ahead of each component, but
getting more sophisticated and becoming involved
you also begin to get into a question of economics
with higher-level fieldbuses, and ECP capabilities
versus convenience. More breakers can help keep a
can assist these changes, which is improving its
system running, but most users probably can’t afford
acceptance,” Henry adds. “In the U.S. markets, we
so many of them. Some users might want a breaker
controldesign.com
CD1408_37_38_TECHFLASH.indd 37
37
8/13/14 11:00 AM
TECH FLASH
at every I/O point to disconnect power from the field
settings, so people can work with them more safely,”
and aid maintenance, but today this can be seen as
Watkins says. “Customers also demand higher-rated
overkill. It just depends what market you’re in, such as
protection, so we’re focusing on testing controls,
packaging machinery or material handling, and how
circuit boards and related devices together as
much they need to drive prices down. They’ll analyze
complete systems.”
more closely where they need circuit protection, add
Watkins adds that Rockwell launched its 140G
fewer where it’s used for connection convenience, but
circuit breakers in February, which are intended for
keep all their breakers in safety areas.”
global applications and carry multiple certifications
“Circuits are getting more sophisticated
and involved with higher-level fieldbuses.
ECP capabilities can assist these changes,
which is improving its acceptance.”
Jerry Watkins, business team leader for power
components at Rockwell Automation (www.
from UL, IEC and others. “These breakers can
be tested and certified to comply with different
standards because the small spacings between their
phases are adjustable, which allows them to meet
the current ratings and voltage ratings required by
the North American and international standards
organizations.”
Besides benefitting from ECP’s intelligence,
rockwellautomation.com), reports that circuit
many newer circuit breakers or other replacement
protection has gone beyond shielding individual
modules are further protected by molded casings
wires, motors and other parts to protecting all-
and are configured so they can take the places
in-one devices more affordably. “Breakers are
of earlier, consumable counterparts. “We’re able
gaining more sophisticated electronics, so they can
to exchange our trip units with core breakers to
do several functions in one device or enable trip
maintain UL certifications,” adds Watkins.
safety
Stop Everything
SVM4001
No sensor required
Back EMF up to 690 V, 1 or 3 Ø
All motor types (Induction, DC, VFD)
Standstill Monitor
Download the data sheet at:
www.wieland-safety.com/SVM4001
1 800 wieland (1-800-943-5263) [email protected]
Wieland - Safety ad 2014.indd 4
CD1408_37_38_TECHFLASH.indd 38
7/30/2014 2:03:11 PM
8/13/14 11:00 AM
[email protected]
PRODUCT ROUNDUP
Push, Pull, Show and Tell
Discrete, Standalone Devices Play an Important Role in Operator Interfaces
Despite a growing reliance on complex indus-
optIcaL Beacon LIghts
trial automation technologies, there is still a need for
Werma 57- and 58-mm optical
discrete, standalone devices such as buttons, switches
beacon lights come in surface,
and indicators. These devices obviously come in many
bracket and tube-mount styles
types and flavors, and can range from indicators with
with permanent incandescent,
highly visible LEDs to switches that guard doors on
permanent LED and flashing Xenon models in red,
machinery, packaged pushbutton controllers and but-
green, yellow, clear and blue with either short or tall
tons that operate remotely. Let’s take a closer look at a
lens options. A 75-mm diameter beacon light is avail-
few examples.
able in surface- and bracket-mount styles with permanent incandescent, LED and flashing Xenon options.
IndIcator LIghts
automationDirect; 800/633-0405;
S18DLH and S22DLH general-
www.automationdirect.com
purpose indicator lights have LEDs
for environments with high levels of
ambient light, including direct sunlight.
MuLtI-VoLtage pILot LIghts
The dc-operated units come in terminal-
The company’s 16- and 30-mm,
wired or cabled versions, and can be used standalone or
multi-voltage pilot light family
enclosed in a panel. A gasket-face flange seals to enclo-
has been expanded from a 20- to
sures, while the 18-mm or 22-mm IP69K-rated housing
240-V range to 20 to 277 Vac/Vdc. One multi-voltage
is rated for harsh washdown applications.
lamp covers a wide range of voltages, and its shallow
Banner engineering; 888/373-6767;
depth supports the design of smaller control panels.
www.bannerengineering.com
c3controls; 724/775-7926; www.c3controls.com
current operated swItches
wIreLess pushButton controLLer
ASC Series current-operated
Limitless wireless operator interface
switches combine a current
(WOI) is a packaged, pushbutton
transformer, microprocessor-
controller with momentary and main-
based signal conditioner and limit alarm contact in
tained contacts. Users choose and
one package. Compatible with most automation sys-
install the needed operator (22-mm rotary or key switch)
tems, ASC switches provide a magnetically isolated
or a pushbutton. WOI Series targets remote monitoring
NO or NC solid-state output for control circuits rated
applications, where wiring or wire maintenance would
up to 135 Vac or Vdc. The user-specified trip point (2
be expensive or is physically impossible.
to 150 A) is calibrated at the factory. The units meet
Honeywell; 800/537-6945; www.honeywell.com
UL, CUL and CE standards.
nK technologies; 800/959-4014; www.nktechnologies.com
BrIght pILot LIghts
AP22M pilot lights use high-inten-
guard-LockIng swItch
sity LEDs for use in direct sunlight.
Guardmaster 440G-LZ switch is for guard
A special optical design makes
doors on machinery where partial body
them twice as bright as standard
access is required. It has a microprocessor
pilot lights when viewed from the front and up to 100
and RFID-coded actuator, which ensures
times brighter than standard pilot lights from the side.
the locking-bolt secures only when the cor-
They have a Type 4X rating, are c-UL-us-listed, comply
rect actuator is detected. The switch uses 2.5-W power,
with the EN standard and conform to AP22M. They
and is TÜV-certified to PLe, Cat. 4 and SIL cl3.
come in red, green, yellow, amber, blue and white, with
rockwell automation; 414/328-2000;
a choice of colored or clear lenses.
www.rockwellautomation.com
iDeC; 800/262-4332; www.idec.com/usa
controldesign.com
CD1408_39_41_ROUNDUP.indd 39
39
8/13/14 11:05 AM
PRODUCT ROUNDUP
ADJUSTABLE LIMIT
SWITCH SENSORS
The active sensing face of
these five-way adjustable
limit-switch style sensors
MORE, MORE, MORE
You’ll fi nd more Roundups on a wide range of
industrial components at www.ControlDesign.
com/roundupsarchive.
can be adjusted for front,
top, bottom, left or rightfacing targets. Special four-corner LEDs provide
360° visibility, letting users monitor the sensors’
TURN TO SAFETY
operating and switching state to help keep machines
Mushroom head in-
up and running. The devices are IP68/69K-rated.
dustrial switches are
Pepperl+Fuchs; 330/486-0002; www.pepperl-fuchs.us
available with 30-,
40- or 60-mm operator
heads. The e-stop switches in-
REMOTE PUSHBUTTON
clude turnkey-to-release, turn-to-
Handy Box pushbutton enclosure turns
release and pull-to-release. The actu-
a wireless pushbutton into a remote
ator structure is suitable to warrant direct-opening
controller. It can hang on a forklift truck
operation with mechanical latching for emergency
or panel, or it can be stored using the
stopping per ISO 13850 and IEC/EN 60947-5-5. The
support mount. The device has a robust
green line around the actuator body indicates when
and ergonomic design.
the emergency stop is activated or at rest.
Schneider Electric; 888/778-2733;
ASI; 877/650-5160; www.asi-ez.com
www.schneider-electric.us
ROCK ON, ROCK OFF
WIRELESS, DIGITAL
789 Series DIN-rail-mount switch
Industrial-grade digital
modules are 17.5-mm wide with
switches and sensors include
rocker switches. 789-800 pro-
limit, magnetic, inductive,
vides automatic and hand modes
foot-operated, pull-wire, push-
to switch a device/machine
button, selector and key-op-
between PLC-driven operation
erated designs. Contact types
and manual mode for troubleshooting, etc. 789-801 on/
feature an internal energy generator for battery-less
off rocker switch lets users manually control typical
operation. Non-contact types have long-life batteries.
accessories within a control cabinet.
All devices are cCSA us, FCC and IC-certified.
Wago; 800/din-rail; www.wago.us
Steute Industrial Controls; 203/244-6301;
www.steutewireless.com
ON/OFF SWITCHES
MSM LA CS on/off switch has
a stainless-steel housing,
ceramic actuator and
mounting diameters of 19- and
SWITCHES AND MORE
22-mm. The one- or two-pole
Otto Series switches include toggle, rocker, Hall Effect
switch has a high impact-
and pushbutton switches, switch guards, grips and
withstand rating of IK 07, and is rated IP64 from the
accessories. Value-added switch assembly services
front to the contact area. Switching voltage is 250
such as switch harnesses, switch panels, and engrav-
Vac/125 Vdc with switching current up to 12 A. Its
ing and hot stamping of legends are available.
operating range is -20 to 85 °C.
Peerless Electronics; 516/594-3532;
Schurter; 707/636-3000; www.schurterinc.com
www.peerlesselectronics.com
40
controldesign.com
8/13/14 11:07 AM
See More LightS
SW44895 quad lamp,
pushbutton SPST-toDPDT switch assembly
options include rubber dust boot for panel
protection and enlarged
Let Us Pick Your Brain
lens cap to match industry-standard sizes. Performance specifications include life capability of
100,000 minimum actuations. Ratings are 2.0-A
In upcoming issues of Control Design,
we’ll explore subjects that include:
resistive and 0.5-A inductive.
Electro-Mech Components; 888/442-7180;
• What’s your company’s design approach to energyefficient machines?
www.electromechcomp.com
• How do you best support legacy controls on installed
machines in the field?
Light ‘eM Up
• What does Mechatronics mean to you today?
LP6US LED surfacered, yellow and clear
• What’s the machine builder’s role in factory network
security?
have six LEDs with
• If you were King of Automation, what would you change?
mount lights in blue,
33 flash patterns. Up to
• Step up and talk to us about these or any other machine
automation topic that’s affecting the way you do your job
today and those that might affect it tomorrow.
four lights can be synchronized to form a larger
warning system. They are rated
We want to hear the thoughts and experiences of our
machine builder and system integrator readers.
for 10- to 30-Vdc operation and are
CA Title 13-compliant and SAE J595-certified.
Joe Feeley
Jim Montague
editor in chief
executive editor
[email protected]
[email protected]
OMPBD7 22-mm pilot devices
Nancy J. Bartels
Katherine Bonfante
offer modular assembly and
managing editor
digital managing editor
interchangeability. A toolless
[email protected]
[email protected]
Dan Hebert
Leslie Gordon
[email protected]
[email protected]
Patlite; 310/328-3222; www.patlite.com
inStaLLation a Snap
mounting latch mates the front
element with the contact blocks and other back-ofpanel components. The latches install with a click and
are removed by pushing a rotating collar to the right.
Omega Engineering; 800/622-2378; www.omega.com
Hank Hogan
Jeremy Pollard
the Key to SecUrity
contributing editor
columnist
These 22-mm key selector
[email protected]
[email protected]
switches are watertight,
tested to meet NEMA Type
Lori Goldberg
4X, 12 and IP65, and are
editorial assistant
UL508- and CSA-recognized.
[email protected]
All contact blocks have
silver contacts for industrial applications; gold plating
is available for signal switching. They’re rated for up
to 10 A thermal current.
Altech; 908/806-9400; www.altechcorp.com
Call us at 630/467-1301
or start the conversation in our Machine Builder Forum on
CD1408_Edit_halfvert_House.indd 3
8/5/14 5:15 PM
8/13/14 11:08 AM
reAl Answers
[email protected]
We’re ready to start changing out electrome-
•
They provide high-speed, high-frequency
switching operations;
chanical relays (EMRs) with solid-state replacements
(SSRs) in our installed base during troubleshooting or
•
They have no mechanical contact failures;
routine customer service calls, as well as use them in
•
They generate little noise;
an upcoming new-generation machine line.
•
They have no operation noise.
We’re receiving mixed reaction from the installed
However, SSRs do have some limitations that need
base and even from a few potential new customers
to be considered when designing the relay into an
that we’re after. The device prices are higher, and we
application. These limitations include the following
have some heat to dissipate, but given the solid-state
characteristics:
device’s advantages in service life, noise generation
•
They’re never truly
and arc resistance, we think we’ll provide notably
off; a small leakage
better performance. Are there applications for which
current might be
present at the load;
there are justifiable reasons not to make this change?
—From June ‘14 Control Design
•
When they fail,
SSRs will mainly
Answers
fail as a short and
no longer control
EMRs Have Their Place
the load that is
operating;
There is always a tendency to resist change, even
while solid-state relays could work in many applica-
•
A multi-pole SSR is
tions. However, there are some types of applications
two or more SSRs in
in which electromechanical relays are definitely
parallel and might
preferred, including whenever:
not operate in tan-
•
leakage current from the SSR is a concern;
dem like an electro-
•
heat could be an issue;
mechanical, multi-
•
normally closed contacts are required;
•
a relay with more than one pole is desired.
You should consider what devices are connected
Figure 1: the main cause
of application failure
with SSrs is not properly
mounting the SSr using a
heat sink.
pole relay will;
•
They generate heat during operation.
Since their introduction, SSRs have gained accep-
to the control and load sides of the relay. Electrome-
tance in industrial applications. These applications
chanical relays are far more forgiving than solid-state
include circuits that previously had been the main
relays if voltage or current spikes are possible. A quick
operating area of the electromechanical relays (EMR)
specification review should be performed when sub-
or the contactor. The SSR is increasingly employed
stituting devices. Electromechanical relays typically
in industrial process control applications, such as
will have a higher contact-current rating and varying
temperature control, lamps, solenoids and valves.
pilot-duty ratings compared to the comparably sized
For those EMR applications requiring two- or three-
solid-state version.
pole operation, today’s SSR technology can incorpo-
Bryan Knapp, product manager for general-purpose relays,
Rockwell Automation, www.rockwellautomation.com
rate two or three poles into one unit as opposed to
using two or more single SSRs. The benefit of this is
that the application can switch all sets of contacts at
Solid for Solid-State
Solid-state relays (SSRs) are different in operation from
the same time like an EMR.
The main cause of application failure with SSRs
mechanical relays that have movable contacts. SSRs em-
is not properly mounting the SSR using a heat sink
ploy semiconductor switching elements such as thyris-
(Figure 1). The load characteristic is also a concern
tors, triacs, diodes and transistors. SSRs consist of these
that will cause application issues with SSRs. The
electronic parts with no mechanical contacts. Therefore,
current requirement characteristics of the load
SSRs have a variety of features that mechanical relays do
should be carefully considered when using SSRs as a
not incorporate. The greatest feature of SSRs is that they
switching solution (Figure 2).
do not use switching contacts that will physically wear
Using SSRs with resistive loads, DC loads, lamp
out. SSRs are ideal for a wide range of applications due to
loads, capacitive loads, or motor and solenoid loads
the following performance characteristics:
all provide challenges that can be overcome in
42
CD1408_42_45_REALANSWERS.indd 42
controldesign.com
8/13/14 11:12 AM
25 AMP MODELS
RMS AMPERES
can be addressed by placing a power resistor sized
30
for eight to 10 times the rated maximum leakage
25
current for the SSR in parallel with the load.
20
Semiconductor-based relays become less efficient
15
as the relay temperature increases, so the current
10
rating for an SSR is de-rated, or reduced, based on
5
the ambient temperature. Add to this the fact that
20 30 40 50 60 70 80 90
AMBIENT TEMPERATURE (°C)
FREE AIR
an SSR generates heat in the “on” position, and heat
management becomes an important consideration.
An SSR is typically mounted on a heat sink to dissipate generated heat, yet even when heat sinks are
used in some applications with high ambient tem-
Mounted on a heat sink
with 2 °C/watt rating
peratures or environments, such as an enclosure
Mounted on a heat sink
with 1 °C/watt rating
be able to supply the maximum steady-state current
Figure 2: the current requirement characteristics of the
load should be carefully considered when using SSrs as
a switching solution.
that is exposed to direct sunlight, the SSR might not
required. Using different types of enclosures, adding air conditioning and other steps to reduce ambient temperature can be cost-prohibitive. For such an
application, an electromechanical relay should be
considered.
circuit design. The possible cost difference and the
Bill SteFFenS, product support group team leader,
increased heat that can be generated by SSRs do not
Opto 22, www.opto22.com
prohibit the SSRs installation. SSRs can be installed
in almost all applications currently using an elec-
[We received the following responses when we posted the
tromechanical relay. With proper circuit design, I
problem to LinkedIn’s Automation Engineers Group.]
would suggest that the SSR has more benefits for
use in industrial applications then an EMR.
Bruce Fink, product engineer,
Omron Automation & Safety, www.omron247.com
Fail Safely
Electromechanical relays do have a very clear safefailure mode. When they fail, they almost always
fail deenergized, so they are more “adequate” for
SSRs Aren’t Perfect
safety applications than regular solid-state output
The semiconductor-based SSR has many advan-
devices. Those devices could fail dangerously (in
tages over electromechanical relays, but two factors
short circuit) or safely (open output). So if safety is a
inherent to SSRs—leakage current and operational
concern, either keep the relays or replace them with
temperature limits—can preclude using them
a good certified safety PLC (way more expensive).
for some applications. Leakage current is caused
Vitor Finkel, CAP, teacher, instrumentation and SIS,
mainly by the SSR’s snubber circuit. When in the
br.linkedin.com/pub/vitor-finkel-cap/1/50/61b
“off” state, the relay will exhibit a small amount
of leakage current, typically a few mA. Although
Detect Critical SSR Failures
slight, this current can keep some loads from turn-
Most failure modes of solid-state devices cause the
ing off, especially ones with a high impedance such
SSR to fail short. Analyze each output circuit and
as a small solenoid or a neon lamp, which have rela-
device that uses an SSR. Not all outputs will be criti-
tively small “hold-in” currents. Leakage current also
cally affected if the SSR fails shorted. Decide which
can cause circuits with SSRs that are switched off
outputs must be protected in case of a shorted SSR.
(electrically open) to still have potentially hazard-
Your electrical design should include a means to
ous voltages on the outputs, in particular for SSRs
detect and disconnect electrical power from those
that switch high voltages.
devices. Perhaps use a contactor that can open if
For applications requiring zero-leakage current,
consider using an electromechanical relay or an SSR
with a mechanical switch and fuses. Note that problems using SSRs with high-impedance loads usually
controldesign.com
CD1408_42_45_REALANSWERS.indd 43
SSR failure is detected—or use circuit protection on
over-current.
Gary FoSter, engineer,
GP Strategies, us.gpstrategies.com
43
8/13/14 11:13 AM
real answers
EMR Easier to Troubleshoot
SSR for Most Applications
Just from personal experience, I have spent much
Electromagnetic relays are more reliable for securing
more time troubleshooting an SSR circuit when it
the system and adopting a fail-safe system. Solid-
fails than I ever have with electromagnetic relays.
state devices are fast, but have some disadvantages
When relays fail, they most often fail completely.
when it comes to implementing fail-safe systems. In
SSRs can partially fail leading to a harder and longer
normal controlling systems, it’s better to use solid-
search to find the root cause. For high switching
state relays, as they occupy less space and are faster
rates, SSRs are great. For ease of use and resistance to
then conventional EM relays.
abuse, I will take a set of relay contacts any day.
Thomas Stevic, controls engineer,
Cincy Integration & Automation,
www.cincyintegration.com
With any new complex electronic system, diagnosis becomes complex, but it doesn’t mean that we
should not go for new systems. We should upgrade
systems regularly ensuring that they are more efficient and advanced than the older ones. We can
It’s New Devices for Me
consider what are the diagnostic and maintenance
I would always favor new electronic devices. These
features it can provide.
relays can be set and operate more accurately. The
Ashish Sharma, asst. manager,
time delays are far superior. Conventional EMRs have
Yokogawa India, www.yokogawa.com
only one advantage in our region: operators and technicians are more comfortable setting, operating and
To Each His Own
using them. With electronic relays, most of the time.
The most important aspects in choosing the right
senior engineers also have to check the settings. In
relays, whether EMR or SSR are:
SCADA interfaces, only compatible relays shall serve
•
Electrical life—both SSRs and EMRs are good;
the purpose. In isolated applications, EM relays can be
•
Ambient temperature—EMRs are better for
used, but in a larger system, I am all in favor of relays
with a computer interface.
higher temperatures;
•
Johns Electric, www.johnselectric.in
Switching frequency—SSRs are better for
higher frequency;
Shashi Bhargava, owner,
•
Environmental conditions—SSRs and sealed
EMRs can be used;.
october’S PROBLEM
Years ago, out of necessity, we started with
machine vision systems built from PCs, frame grabbers,
big cameras with proprietary buses, bad software, etc.
We’ve been able to simplify and move to smart cameras.
Some of our sensing applications are only about color
and shade, so we see possibly more simplification, even
though we expect to need to provide more speed and
sensitivity going forward. Are there practical differences
and limitations between what some companies call smart
color cameras and others call smart color sensors. Are we
beyond RGB at this point?
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include it in
the October 2014 issue, and post it at 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.
•
Isolation/insulation levels—EMRs have better
creepage and insulation;
•
Switching response time—SSRs are faster unless using zero-crossing SSRs for an ac load.
Ashish Manchanda, managing director,
Finder India, www,findernet.com
[We received these responses when we posted the problem
on LinkedIn’s Automation.com group.]
Not for Inductive Loads
I’ve experienced problems when switching inductive
loads, such as solenoids, with an SSR. The back EMF of
the solenoid coil can make the SSR output stay on.
Joe Williamson, sales director,
More Control UK, www.more-control.com
SSRs Do Leak
Leakage currents in SSRs can be a problem, particularly when used to switch PLC or DCS digital inputs.
HAVE A PROBLEM YOU’D LIKE TO POSE to the readers?
Send it along, too.
44
Control Design August 2014 CD1408_42_45_REALANSWERS.indd 44
Dan Mazorra, project engineer,
EMA, www.ema-inc.com
controldesign.com
8/13/14 11:13 AM
SSRs for Alarms
SSR Great for PID Control
SSRs are used for fast switching with respect to
There are pros and cons in most applications. If you
general relays. But their switching capacity is lower
want absolute, guaranteed isolation, then nothing
than a general relay in most of the brands. These
can beat an open contact from an EMR. SSRs come
are good for alarm generations. SSRs can burn out
with very high isolation voltage ratings, but blocking
when used with inductive loads such as solenoids.
isn’t the same as switching, and some leakage is
Vijayant Singh, automation project engineer,
in.linkedin.com/pub/vijayant-singh/16/3/430
always present. In many applications, that doesn’t
matter, so you really need to know what’s important
in your application. Used within its ratings, on
You Get What You Pay For
mainly resistive loads, an EMR will do the job for
My gut says “you get what you pay for” where
years. You also get the benefit of switching multiple
solid hardware designs turning on and off a zero
circuits at the same time. Things like four-pole SSRs
crossing (current) cost money, and snubbing
are pretty thin on the ground.
transients with appropriate circuitry also cost
If severe vibration comes into the equation,
(some) money. So when using a low-cost electronic
an SSR could be the better choice. Also, if the
control product, there are reasons it is low-cost. If
application involves high switching frequencies and/
you use a PLC, contact your supplier and explain
or inductive loads, an SSR could be the only sensible
your application, and I am certain it will provide
option. In the former, because of zero-contact
you with a good solution. Heck, I turn DC motors
erosion that an EMR would be subject to, and in the
on and off with 60 amps of inrush, and it gets ugly
latter because EMRs are limited to a certain number
when you turn them off (they become a generator),
of mechanical operations before the contact tension
but we don’t fail.
(spring) weakens.
Don Pieronek, owner,
One instance where an SSR really comes into its
Real Time Objects & Systems, www.realtimeobjects.com
own is in PID control of heating elements, etc. In a
PID scheme, the load is energized constantly from
Fail On Is Unacceptable Risk
rest to give maximum rate of temperature rise.
Recently, I considered this issue on a critical shut-
Then as it nears the setpoint, the load (i.e., heater) is
down system and put the use of SSR to one side
switched off to minimize overshoot. The control then
in favor of an electromechanical solution after re-
switches the load on and off to maintain the setpoint.
search indicated that the typical fail state of SSR is
This rate of switching can be fairly rapid and the
the on state. This was an unacceptable risk for me.
only practical device is an SSR. But if the heater is
Chris Morony, director of operations,
controlled by a simple hysteresis switching setup
Central Region Middle East and Africa,
with upper and lower temperature limits, a relay/
Emerson Process Management, www.emersonprocess.com
contactor will do the job just as well if the switching
noise isn’t an issue.
[These responses come from LinkedIn’s Indutrial Automation and Process Controls Group.]
Frank Seifert, senior technical consultant,
Mechtric (SA) Pty. Ltd., www.mechtric.com.au
Everything Has Its Place
More Strengths
Of course there are. EMRs are not dead, far from it.
Using SSRs with “zero-crossing” switching will
SSRs are, of course, great, and for many applica-
virtually eliminate radiated emissions. EMRs can
tions it would be silly not to use them. But there
do a NC contact, which is difficult with most SSRs.
will always be the applications where a cheaper
And another thing EMRs do better is a force-guid-
EMR would do the job just as well. Are you building
ed relay, as used in safety circuits. I use a lot of
a quality product, designed to last? Put an SSR into
MOSFETS in my controllers for switching hydraulic
it. Are you designing a “throwaway” product with
solenoids, and they work well doing that, plus you
a low switching frequency? Put an EMR into it. Yes,
can apply PWM and current control to achieve a
we do live in a “throwaway” world.
high pull-in and low holding current.
Stewart Duncan, inside sales engineer,
Crydom SSR, www.crydom.com
controldesign.com CD1408_42_45_REALANSWERS.indd 45
Bob Turner, director,
Salbay Engineering, www.salbayeng.com
45
8/13/14 11:13 AM
EXCLUSIVE
Fast, Laser-Sharp Distance Scanner
DETERMINING DISTANCES is a common metrologi-
tape is needed, a
cal application in automation technology. The indus-
dramatic savings
trial marketplace offers many types of solutions, yet
in cost and instal-
not every technology is ideal for each application.
lation space. Other
Complete, all-round visibility in fast-moving
scanners require
applications is what Pepperl+Fuchs touts with the
reflectors two to
North American market debut of its new R2000 UHD
three times larger.”
laser scanner.
“This IP65-rated 2D photoelectric sensor leverages
A third important
attribute is that
pulse-ranging technology [PRT] and a rotating head to
R2000 UHD is one of
deliver quick, precise, high-resolution distance mea-
the smallest scan-
surement, says Michael Turner, product manager—
ners on the market.
photoelectric sensing. “Combined with a gapless, 360°
“And the wrap-
measuring angle and interactive wrap-around display,
around LED display
the result is highly reliable detection of objects to 10
allows the user
m and/or reflectors to 60 m, with quick visual-status
to quickly make
indication and access to measurement data in one,
changes to some of
compact [4.2x4.2x4.6 in.] device.” Turner calls this
the internal settings,” Turner says. “Also, the graphi-
application of pulse-ranging technology the gold stan-
cal display modes can visualize the surroundings.”
dard for distance measurement sensors. “PRT is the
FOR MORE INFORMATION
Call 330/486-0001, email [email protected] or browse to www.pepperl-fuchs.us.
These laser scanners have an adjustable scan rate
most effective time-of-flight measurement technology
up to 50 Hz (3,000 rpm) that Turner says enables
available today, providing maximum precision and
them to detect protrusions or obstacles over a large
reliability over large distances, even in harsh ambient
area and at high speeds—ideal for material handling
conditions,” he says.
and ASRS applications.
PRT is nothing new to the market. However,
Sensors with PRT emit a very short, high-intensity
Turner says this scanner brings some unique things
light pulse. They calculate object distance based
that haven’t been seen before. “First, it has a visible
on the speed-of-light constant and time-of-fl ight of
red laser, eye-safe (class 1) with an extremely small
the reflected light pulse. Unlike other time-of-fl ight
light spot. As the device spins, a very small, razor-
sensors that transmit a continuous light beam, PRT
sharp scan plane is created. The beam diameter at
sensors emit short pulses of high-intensity light
10m range is less than 20 mm. This creates a scan
up to 250,000 times per second. Compared to a
plane of only ±0.05° and allows for detection of
continuous emitter source, the energy density of one
objects in extremely tight places. At the same 10-m
PRT pulse can be up to 1,000 times greater. “Unlike
range, most other scanners will have a light spot
triangulation-based sensors, the detection range of
size of approximately 200 mm. In addition, the laser
a PRT sensor isn’t limited by the geometric layout
light type on other scanners normally would be
of the sensor optics,” Turner adds. “PRT sensors
infrared, which can’t be seen by the human eye, so
with smaller housings can be used for significantly
it’s hard to align.”
larger detection ranges—providing impeccable
A second important feature is the scanner’s highdensity measurement capability. “Angular resolution
measurement quality.”
The scanner has a fast Ethernet interface capable
is configurable to just 0.014°,” Turner explains. “This
of transmitting data at 100 Mbps. “Distance data is
means that a sample point is taken at increments
received as packets using a separate TCP/IP or UDP/
of 0.014°. This equates to more than 250,000 scan
IP channel, and a simple HTTP command protocol is
points per second.” Turner claims other scanners
provided to configure the device,” Turner explains.
typically provide angular resolution of 0.2° at best.
“End users can develop software to meet their re-
“The combination of the scanner’s small light and
quirements. Additionally, a robotic operating system
angular resolution allows AGVs to navigate with
(ROS) driver is available for use with the scanner.
very small reflectors down to 40 mm, even at 60-m
ROS provides libraries and tools to help software
range. This is beneficial because less reflective
developers create robot applications.”
46
CD1408_46_EXCLUSIVE.indd 46
controldesign.com
8/13/14 11:19 AM
[email protected]
PRODUCT SHOWCASE
PANEL PC
are labeled for accurate installation, troubleshooting
PPC-6120 panel PC lets users use
and maintenance.
any fourth-generation processor
Festo; 800/993-3786; www.festo.com/us
from Celeron to Intel i7. The PC has
a 12.1-in., five-wire, resistive touchscreen that connects directly to
LINEAR MOTOR STAGES
devices through an integrated, isolated RS-422/485
MMG series precision lin-
port, which protects the port in the event of power
ear motor stages feature an
spikes. The device has an input range of 12 to 30 V,
integral, anti-creep, linear
and includes a IP65 front bezel, four RS-232 and USB
guideway that eliminates the
3.0 ports and dual Gigabit ports.
need for homing moves typically required to reset
Advantech; 800/205-7940; www.advantech.com/ea
standard, crossed-roller-bearing retainer cages. Four
models deliver 25, 50, 100 and 150-mm travel. Accuracies range from 6 to 14 μm, and resolution ranges 1
SS ETHERCAT BOX
to 5 nm. Each model delivers repeatability to ±0.4 μm
EQ series EtherCAT Box I/O comes
and is rated for 10-kg load capacity.
in V2A stainless-steel housings
Kollmorgen; 540/633-3545; www.kollmorgen.com
rated IP69K. Each distributed I/O
box is a self-contained EtherCAT
device and an EtherCAT slave, which can be connect-
LINEAR POSITION SENSORS
ed directly to any other EtherCAT device via a stan-
PTP Series of open-
dard Ethernet cable with 100BaseTX. A wide range of
housing linear position
digital and analog units are available.
sensors have a profi le of
Beckhoff Automation; 877/894-6228;
13 mm × 11.6 mm. Length is dependent on the ap-
www.beckhoffautomation.com
plication, and is typically 10 to 300 mm. The units
have a lifetime of up to 50 million movements with
a resolution ≤ 0.01 mm, linearity of ±0.05% and re-
CABLES FOR SEMICONDUCTOR
peatability of ±0.01 mm.
Flexx-Sil rubber-jacketed ca-
Novotechnik; 508/485-2244; www.novotechnik.com/ptp
bles are made with an extrusion process that places each
tubing or multi-wire bundle in
LONG-RANGE
ULTRASONIC SENSORS
a flat, parallel profile to precisely control the spacing
UA30CAD60 Series
of components, insulation thickness and overall cable
ultrasonic sensors with
shape. The cables are certified by UL and CSA, conform
digital and analog output
to CE, comply to RoHS and REACH standards, meet the
configurations provide sensing distances of 250 mm
air cleanliness requirements of ISO 146441, and exceed
to 6,000 mm. They’re available in cabled or M12
the outgassing requirements of ASTM E595.
quick-disconnect versions. The sensors are rated to
Cicoil; 661/295-1295; www.cicoil.com
IP67 and NEMA 1, 2, 4, 4X, 5, 6, 6P, 12.
individual power conductor,
Carlo Gavazzi; 847/465-6100; www.carlogavazzi.com
COMPACT CONTROL
VFOF, VBNF and VBQF
SHORT-STROKE ACTUATORS
multi-functional pneu-
Z standalone actuators provide a peak
matic actuator control
force to 120 N, a continuous force
valves provide one-way speed control, manual override
to 30 N, acceleration to 30 g and
and emergency stop capability—holding a piston even
speeds to 1 m/s. The small form
in the vertical position—in one compact unit. The unit
factor devices have Teflon-coated
bolts directly to the actuator port and lies flat against
plain bearings for low friction.
the actuator for space savings. The unit’s multiple ports
Etel; 847/490-7812; www.etelusa.com
controldesign.com
CD1408_47_49_SHOWCASE.indd 47
47
8/13/14 11:37 AM
PRODUCT SHOWCASE
[email protected]
SMART MACHINE VISION CAMERA
RazerCams are ultra-small machine
SENSOR-HEAD-MOUNTED
TRANSMITTERS
vision cameras equipped with a dual-
PR 5343 is a sensor-head-mount-
core ARM, user-programmable FPGA
ed, two-wire, programmable
and 10 free, programmable I/Os. The
level transmitter in two ver-
cameras come with CMOS or CCD sen-
sions, both of which are ATEX-
sors, a variety of industrial fieldbus standards and
and DNV Marine-approved. “A” version has IECEx
an IP65-rated body.
and Inmetro certification for Zone 2, and “B” version
EVT; 800/468-6009; www.evt-web.com
has IECEx, Inmetro and FM certification for Zone 0,
Division 1 installation.
PR Electronics; 440/974-7757; www.prelectronics.com
SMART CONTROLLER
Nanospark controller lets users and developers of sensors,
MODBUS MODULES
machines and other devices
Modbus modules let Control-
convert them to smart devices,
Logix or CompactLogix PACs
integrate them with the web, and
or PLCs read and write data to
use iPhones, iPads and iPods to monitor and control
Modbus devices. MVI56E-MCM
their equipment. Users can wire equipment to any or
and MVI56E-MCMXT modules
all of Nanospark’s 10 outputs, then create schedules
plug into the ControlLogix backplane, have two se-
for when individual machines should run, or put an
rial ports that can be independently configured as a
entire system on the same schedule.
master or slave, and can operate on different Modbus
Nanospark; 715/831-6353; www.nanospark.com
networks. MVI69E-MBS, MVI69L-MBS and ILX34-MBS
Get Up to
Speed Quickly
With the Control Design Essentials Series
Written by the editors of Control Design, our new Control Design
Essentials series is designed to provide industry professionals with
an up-to-date, top-level understanding of a range of key machine
automation topics. Our intent is to present essential engineering
concepts in a practical, non-commercial fashion, together with a review
of the latest technology and marketplace drivers—all in a form factor
well suited for onscreen consumption. Get in and get out quickly with
just the information you need.
To download your complementary copy,
visit ControlDesign.com/Essentials
CD1408_Essentials_Half.indd 1
Essentials of
Electrical
CAE Systems
Made
Possible By
Now available at
ControlDesign.com/Essentials
8/13/14 11:28 AM
8/13/14 11:37 AM
modules plug into the CompactLogix L3x, L2x or L1x backplanes and can be configured as
a master or slave. The Modbus modules let users remotely configure and view diagnostic
data via Ethernet.
is the only magazine exclusively
dedicated to the original equipment
manufacturing (oEM) market for
instrumentation and controls—the
largest market for industrial controls.
ProSoft Technology; 661/716-5100; www.psft.com/modbuscd
630/467-1300
Fax: 630/467-1124
Mini PC
LPC-681 mini PC has an Intel fourth-generation Haswell Core
i7-4800MQ mobile processor. The PC includes Intel HD Graph-
publishing team
ics 4600, providing for three video ports with optional adapter
GRoUP PUBLISHER & VP, CoNTENT
cables for VGA and DVI connectivity. Other features include 1-Gigabit LAN, two USB
Keith Larson [email protected]
3.0, two USB 2.0, one serial, two eSATA and audio in/out ports, as well as optional
DIRECToR oF CIRCULATIoN
802.11 b/g/n wireless networking.
JaCK Jones [email protected]
Stealth Computer; 905/264-9000; www.stealth.com
sales team
northeastern and mid-atlantic regional manager
Wireless Air QuAlity sensor
Dave Fisher [email protected]
IAQM-THCO2 IEEE 802.15.4 wireless sensor is compatible with DM-124
508/543-5172 Fax: 508/543-3061
wireless Modbus networks, and measures air temperature, relative
24 Cannon Forge Dr.
Foxboro, Massachusetts 02035
humidity and CO2 levels. The device is fully Modbus RTU-compatible,
MIDWESTERN AND SoUTHERN REGIoNAL MANAGER
which means that any PLC, controller or PC connected to the DM-124
GreG Zamin [email protected]
coordinator can retrieve data with standard Modbus RTU commands.
630/551-2500 Fax: 630/467-1124
The sensor’s configuration software enables configuring the device via radio.
Advanticsys; +34-91-189-05-21; www.advanticsys.com
WESTERN REGIoNAL MANAGER
Laura martineZ [email protected]
Wireless outdoor Bridge
310/607-0125 Fax: 310/607-0168
APX-120N5 long-distance, point-to-point, preconfigured, wire-
218 Virginia, Suite 4, El Segundo,
less, outdoor bridge comprises two units, is IP67-rated, and has a
California 90245
frequency range that complies with IEEE 802.11a/n. The bridge is a
DIGITAL SALES SPECIALIST
powered device that complies with IEEE 802.3af. Each unit con-
Jeanne FreeDLanD
sumes 7.5 W with an output of 800 mW. Users need not log onto the
[email protected]
wireless devices to set up software or configure a wireless network.
805/773-4299 Fax: 805/773-0451
Antaira; 844/268-2472; www.antaira.com
INSIDE SALES SPECIALIST
PoLLy DiCKson [email protected]
630/467-1300 Fax: 630/467-1124
ad index
executive staff
Adalet . . . . . . . . . . . . . . . . . . . . . . .18
Red Lion Controls . . . . . . . . . . . . . . .27
Aerotech . . . . . . . . . . . . . . . . . . . . .33
SEL-Schweitzer Engineering Labs . . . .29
John m. CaPPeLLetti
Allied Electronics. . . . . . . . . . . . . . . . .6
SEW-Eurodrive . . . . . . . . . . . . . . . . .51
cfo
AutomationDirect. . . . . . . . . . . . . . . .52
Siemens Industry. . . . . . . . . . . . . . . . .8
AVG Automation . . . . . . . . . . . . . . . . .2
B&R Industrial Automation . . . . . . . . .12
Baldor Electric . . . . . . . . . . . . . . . . .10
Beckhoff Automation . . . . . . . . . . . . . .4
president & ceo
riCK KasPer
vp, circulation
Telemecanique . . . . . . . . . . . . . . . . . .7
Jerry CLarK
TRC Electronics. . . . . . . . . . . . . . . . .30
vp, creative services, production
UBM Canon Communications . . . . . . .35
Harting . . . . . . . . . . . . . . . . . . . . . .19
Unitronics . . . . . . . . . . . . . . . . . . . . .32
Novotechnik . . . . . . . . . . . . . . . . . . .34
Wago . . . . . . . . . . . . . . . . . . . . . . . .14
Pepperl+Fuchs . . . . . . . . . . . . . .24, 25
Weidmüller . . . . . . . . . . . . . . . . . . . .36
Phoenix Contact . . . . . . . . . . . . . . . . .3
Wieland . . . . . . . . . . . . . . . . . . . . . .38
steve herner
RepRints
Foster rePrints www.fosterprinting.com
JiLL KaLetha
[email protected]
866-879-9144 ext. 168
controldesign.com
49
8/13/14 11:37 AM
OEM INSIGHT
Larry Turner • [email protected]
Inside Industrial Automation NA 2014
NORTH AMERICA IS on the path to a sustainable
and hardware encryption methods that can protect
industrial automation expansion, and we understand
industrial automation systems from cyber-attacks. The
the urgent need for North American manufacturers
Global Automation and Manufacturing Summit attend-
to adopt advanced production ideas and tools.
ees will hear thought leaders discuss how to secure
If you attend Industrial Automation North America
connectivity across the plant, as well as off the factory
(NA) 2014 during Sept. 8-13, 2014, at McCormick Place
floor. Learn what the future holds for technologies and
in Chicago, you will find the latest industrial automa-
services that will support much more sophisticated
tion innovations in a dynamic setting where global
levels of human interaction with machinery.
solutions providers demonstrate and discuss best-in-
Secure Industrial Control Systems—The ISA Inside
class technologies. Following our successful launch
accredited educational conference will detail how
of the Industrial Automation NA show co-located
the ANSI/ISA99 standards can be used to protect
with IMTS in 2012, the 2014 focus is new ideas and
your critical control systems. The conference also
topics ranging from resource-efficient manufactur-
will explore procedural and technical differences
ing and network security to secure industrial control
between the security for traditional IT environ-
systems and big data. In addition to more than 170
ments and those solutions appropriate for SCADA
technology providers from 16 countries, thought
or factory-floor environments. During the two-day
leaders will conduct detailed discussions about how
course, you’ll be able to:
to navigate the latest trends at the Global Automation
and Manufacturing Summit, Motion, Drive & Automation Conference and the ISA training program.
Here are some of the trending topics that will be
showcased and discussed.
• Discuss the principles behind creating an effective
long-term program;
• Interpret the ANSI/ISA99 industrial security guidelines and apply them to your operation;
• Define the basics of risk and vulnerability analysis;
• Learn the principles of security policy development;
The conference will explore differences
between security for traditional IT
environments and security for SCADA
or factory-floor environments.
• Explain the concepts of defense in depth and zone/
conduit models of security;
• Analyze the current trends in industrial security
incidents and methods hackers use to attack a
system; and
• Define the principles behind the key risk mitigation
Resource-Efficient Manufacturing—One of the top
concerns for this year’s show visitor is resourceefficient, cost-effective manufacturing. Whether your
techniques, including anti-virus and patch management, firewalls and virtual private networks.
Big Data—The factory of the future will need to rely
priorities include improved decision-making, reduced
on big data for shop floor management. Data avail-
risk or improved production efficiency, you’ll find
ability, utilization, performance and measurement are
smart manufacturing systems, machinery produc-
all critical components of big data. This year you can
ers and software platform providers to address these
preview a range of tools to analyze large amounts of
challenges and discuss your needs.
data and learn how to best harness data to accelerate
The shortage of skilled workers is now one of the
plant productivity. If you work for a small or medium
greatest hindrances to U.S. manufacturing competi-
enterprise (SME) and are tasked with adopting big data
tiveness, so efficiency experts will showcase how to
solutions, you’ll find everything from software for live
safely implement new technology or leverage existing
reporting to visualization to smartphones for captur-
automation technologies to clean up waste, eliminate
ing and using data to improve operations, eliminate
downtime and significantly reduce labor costs.
errors and lower costs. Progressive machine builders
Network Security—To take advantage of Internet
and automation suppliers will be on hand to discuss
of Things capabilities for industrial automation, such
the best big data solutions for your specific network.
as remote diagnostics, manufacturers need secure
systems. Improving industrial automation system
LARRy TuRNER is president and CEO of Hannover Fairs USA, the
cybersecurity is critical. During this year’s show, you
U.S. division of Deutsche Messe. HFUSA develops and manages
can experience cloud applications, software solutions
marketing programs at Deutsche Messe events worldwide.
50
CD1408_50_OEMINSIGHT.indd 50
controldesign.com
8/13/14 11:24 AM
Byte Me!
Go ahead...talk nerdy to us. We’ll byte
back. That’s because our fieldbus cards
and gateways can speak your language.
We can also eliminate all of your C++
or C# programming. That’s right...no
engineer needed! Finally, you can easily
and dramatically reduce the startup time
on conveyors, hoists, turntables and many
other applications. So, keep your bus and
leave the driving to us.
seweurodrive.com / 864-439-7537
CD1408_FPA.indd 51
8/12/14 6:04 PM
Big HMI, little price!
C-more Micro series gets big brothers
10” Color TFT
$
00
899.
u.s.
EA3-T10CL
Serial comm.
$
8” Color TFT
749.00
u.s.
EA3-T8CL
Serial comm.
®
FREE Windows-based configuration software!*
Get a big bang for your buck with 8- and 10-inch panels
Need basic graphics and text but lots of real estate? The latest additions to our C-more
Micro panel series can accomodate up to 133 lines of static text in portait
orientation, and up to 100 lines in landscape mode. You can also use dynamic text
with embedded variables. Take advantage of the clear and colorful graphics on the
TFT color touch screen to create a vibrant and intuitive operator interface. Serial
communications keeps the cost down for simple installations.
FREE programming software offers the choice of using many built-in objects, such
as buttons, bar graphs and data entry keypads. Or import your own custom graphics,
and save to libraries for use in multiple projects. Alarm control, recipes and a built-in
project simulator are time-saving tools for more complex applications.
All these features at a competitive price, in a rugged and reliable package, give you a
sweet HMI for even the smallest control system.
* The programming software is free when downloaded from the AutomationDirect
Web site, or the CD-ROM package can be purchased for $25 (part # EA-MG-PGMSW).
Go online for complete list
Lots of screen space for graphics and text
32k color TFT touch screen display
800 x 600 dot resolution
Expansive 30 MB memory
Seven durable function keys with LED indicators
Standard Type B USB programming port
15-pin and RJ12 serial communications ports
Enhanced objects and graphics
Up to 999 screens (dependent on complexity)
Recipes
Built-in project simulator
UL, cUL, CE agency approvals
3-inch touch and
non-touch panels
Check out over 80
C-More Micro tutorials online
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Order Today, Ships Today!
* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
CD1408_FPA.indd 52
•
•
•
•
•
•
•
•
•
•
•
•
Also Available
Popular protocols/devices supported
• All AutomationDirect programmable controllers
• Modbus® RTU
• Allen-Bradley® DF1 half/full duplex,
PLC-5® DF1 and DH485
• Siemens PPI
• GE SNPX
• Omron Host Link and FINS serial
• Mitsubishi MELSEC®
Standard features
4-inch TFT
touch panels
6-inch STN and TFT
touch panels
Research, price, buy at:
www.c-moremicro.com
1-800-633-0405
the #1 value in automation
8/12/14 6:05 PM

vision system high-end protection

Transcription

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