innovations build new markets

Transcription

HARTING’s Technology Newsletter
12
INNOVATIONS BUILD NEW MARKETS
PROF. DR. BULLINGER: TAKING THE LEAD WITH INNOVATIONS _ PARTNERS IN INNOVATION _ SWITCH TECHNOLOGY _
IN-BETWEEN ETHERNET SWITCH ESC 67-30 _ CONVERGING OFFICE AND INDUSTRIAL NETWORKS _ HARTING‘S
COOPERATION WITH LPKF _ APPLIED TECHNOLOGIES _ NO HALFWAY MEASURES _ RUGGED ETHERNET TECHNOLOGY
FOR CLEAN WATER _ WIND POWER PLANTS SEE THE LIGHT _ CONNECTION RELIABLE AS STEEL _ THE SIEMON COMPANY
AND HARTING COLLABORATE _ OBSAI _ CAB RADIO SYSTEMS _ HAN-CONNECTORS USED BY CERN _ AUTOMATED
BAGGAGE HANDLING _ HAN-MODULAR INSERTS IN TRAIN COUPLING DEVICES _ PRESSING ARGUMENTS _ HARTING
FAIR ATTENDANCES 2004 _ PICMG-AMC
HARTING tec.News 12-I-2004
HARTING’s Technology Newsletter
12
PROF. DR.-ING. BULLINGER: VORSPRUNG DURCH INNOVATION_PARTNER FÜR INNOVATION_SWITCH TECHNOLOGIE
INBETWEEN ETHERNET SWITCH ESC 67-30_BÜRO- UND INDUSTRIENETZWERKE WACHSEN ZUSAMMEN_HARTINGS KOOPERATION
MIT LPKF_APPLIED TECHNOLOGIES_KEINE HALBEN SACHEN_ROBUSTE ETHERNET TECHNOLOGIE FÜR SAUBERES WASSER
HARTING SORGT FÜR SICHERHEIT_CONNECTION FIRM AS STEEL_HARTING AND THE SIEMON COMPANY COLLABORATE
OBSAI_CAB RADIO SYSTEMS_HAN-CONNECTORS USED BY CERN_AUTOMATED BAGGAGE HANDLING_HAN MODULAR INSERTS
IN TRAIN COUPLING DEVICES_PRESSING ARGUMENTS_HARTING FAIR ATTENDANCES 2004_PICMG-AMC
people | power | partnership
The twelfth issue of tec.News, our technology magazine, reports on the ways in which innovations are utilized in actual,
real world customer applications. Consequently our current
title is “Innovations build new markets”. We are covering application fields ranging from steel mills and water treatment
plants, to factory automation solutions and the evolution of Ethernet from the office world to the manufacturing area and on
to the fields of railway technology and telecommunications. In
addition, our present issue is showcasing topics such as wind
energy, new microtechnology techniques and the design and
production of printed circuit boards. In addition to looking into
the pros and cons of switch technology in Industrial Ethernet
solutions, the latest issue of our magazine is rounded off by a
presentation of our expertise in the manufacture of tools and
special purpose machines.
We are especially pleased to be featuring Professor Hans-Jörg
Bullinger, the President of the Fraunhofer Gesellschaft, whose
article “Taking the lead with innovations” calls for a new innovation culture. As dialogue partners of German Chancellor
Gerhard Schröder, Professor Bullinger and Dietmar Harting,
together with many other policy makers, members of the business community and major associations have, since the beginning of 2004, been discussing the issues of creating the basic
conditions and an environment that will enable and promote
the continuous creation of innovations.
The vital issues of innovation – our cover story – hold more
critical significance than ever before.
W. Padecken
Chief Editor
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C o n t e n t s
Contents
EDITORIAL
Innovations build new Markets _4
GUEST CONTRIBUTION
Taking the Lead with Innovations _6
TECHNOLOGY
Partners in Innovation advise the Federal Chancellor: Dietmar Harting attends Innovation Summit _10
Switch Technology: The magic Formula for Industrial Ethernet _16
Rugged Ethernet Technology for clean Water _22
A feed through Connection: In-between Ethernet Switch ESC 67-30 _24
Converging Office and industrial Networks _42
Success with the small and fine: Micro Packaging Solutions from harting are strengthened by Cooperation with LPKF _46
No halfway Measures _48
Applied Technologies – Projecting the Future _53
INTERNATIONAL
The Siemon Company and harting collaborate on Factory Automation Solution _12
Connections reliable as Steel _14
OBSAI – Enabling an open Market for Base Station Modules _26
Cab Radio Systems, easy to use, easy to maintain _32
Han-Modular® inserts in Train Coupling Devices _34
Wind Power Plants see the Light _36
Technology Group supports Technology Activities _38
Pressing Arguments: Backplane Assembly as next Module for Technology Approach _50
STANDARDS
PICMG-AMC – harting parecon® Technology leads the Way _28
APPLICATION
Automated Baggage Handling with intelligent Connections _40
FAIRS
harting Fair Attendances 2004 _55
Publication details.
Published by: harting KGaA, M. Harting, P.O. Box 11 33, 32325 Espelkamp (Germany), Phone +49 5772 47-0, Fax: +49 5772 47-400, Internet: www.harting.com | Chief Editor:
W. Padecken | Vice Chief Editor: Dr. H. Peuler | Editor: K. Jording | Overall coordination: Public Relations and Communication Department, W. Padecken | Editorial Adviser: Bickmann &
Collegen Unternehmensberatung, Hamburg | Design and Layout: Contrapunkt, Berlin | Production and printing: Druckerei Meyer GmbH, Osnabrück | Circulation: 20.000 copies worldwide
(German and English) | Source: If you are interested in obtaining this newsletter on a regular basis, free of charge, contact your nearest harting branch, your harting sales partner or one of the
local harting distributors. You can also order tec.News online at www.harting.com. | Reprints: Complete reprints and excerpts of contributions are subject to approval in writing by the Editor.
This also applies to input into electronic databases and reproduction on electronic media (e. g. CD-ROM and Internet). | All product designations used are trademarks or product names belonging
to harting KGaA or other companies. | Despite careful editing it is not possible to completely rule out printing errors or changes to product specifications at short notice. For this reason
harting KGaA is only bound by the details in the appropriate catalogue. Printed by an environmentally friendly method on paper bleached entirely without chlorine and with a high proportion
of recycled paper.
© 2004 by harting KGaA, Espelkamp. All rights reserved.
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S p e c i a l
t o p i c
EDITORIAL
Dr. Joachim Belz
Innovations build new Markets
Dear tec.News Readers,
With technological leadership and new, innovative products
In order to function as an engine of growth, innovation must be
Germany will reclaim its foremost position among the lead-
brought to bear in equal measure on manufacturing procedures
ing industrial nations. On this point, economic and research
and processes, logistics, sales and marketing, the utilisation of
policy makers agree wholeheartedly with many decision mak-
information technology, the pragmatic application of knowledge
ers and CEOs in the industrial field. Naturally, it is the task of
and not least on the framework of conditions put in place by gov-
industry to implement these bold demands for technology and
ernments. An innovative product is consequently the end result of
innovation in the form of new and competitive products. The
a process of innovation that comprises both internal and external
necessity for politicians to put the right framework in place is
factors and not only involves development engineers, but all those
self-evident. This tec.News editorial is not, however, the place
who contribute to or are in a position to influence the value chain
to pursue this aspect of the discussion.
as a whole.
Such demands for innovation, however, must be viewed in the
Allow me instead to elaborate on the terms ‘technology’ and
following context. Innovation becomes a dangerous end by it-
‘innovation’. Modern economies derive their specific powers of
self if it is not measured against planned market success. Such
innovation on the one hand from the systematic exploitation of
success will not be forthcoming unless innovative products are
a constantly developing, scientifically founded knowledge base,
geared to customer benefits and the actual needs of individuals.
and on the other from the positive effect of competition within
Consequently, technological progress and innovation derive their
a market-directed economy. Technology in the meaning of the
existence and substance directly from the world we live in, a world
availability and application of knowledge, skills and abilities
that can only be improved through constant process of reciprocal
to manufacture products is a basic prerequisite for innovative
interaction.
developments.
By now it should generally be accepted that innovations can only
Yet the all too frequent practice of restricting innovation exclu-
have a stimulating effect on national economic growth provided
sively to products is inadequate and misleading.
that other links in the value chain – apart from development – also
4
remain competitive. First and foremost among these must be
tions, to find them and implement them in the form of products
manufacturing. In order to be competitive, the process of creating
and services. We adapt our technology portfolio, as well as the
value must itself be innovative and deliver innovative products.
technologies we access via networks, to reflect the needs of our
Clearly, innovation cannot be defined exclusively in terms of tech-
customers and their applications and create new solutions. This
nology, but is decisively determined by applications, markets and
process frequently goes hand in hand with necessary changes or
industries that in turn have a strong technological character.
innovations in internal processes all along the value chain.
In summary, innovation in this sense is always synonymous
This issue of tec.News once again offers you detailed insight into
with entrepreneurial dynamics, the search for viable alterna-
the diversity of innovation practiced by harting. The products and
tives, proximity to customers, and the transformation of leaps of
services developed in close cooperation with our customers are to
knowledge into new processes and marketable successful products
be found in applications ranging from environmentally friendly
and services.
wind energy and water treatment plants to modern logistics sys-
It is precisely these fields of activity that the harting Technology
tems and future-proof data transmission systems.
Group perceives to be of primary importance for its individual
We, the harting Technology Group, are implementing the demands
divisions. The technology portfolio extends from basic techniques
for leading edge technology and innovation – to the benefit of our
such as injection moulding, die-casting, precision pressing and
customers, the success of our own company, and not least as a
galvanising through to the key areas of software development,
contribution towards local corporate citizenship in more than 20
circuit engineering, PCB design and high-flexibility component
countries around the globe.
insertion, as well as future-oriented Laser Direct Structuring
(LDS) and opto-electronics data transfer for high speed communication in optical networks. With these tools at their disposal, our
staff daily address the challenges presented by our customers to
seek out innovative solutions for today’s and tomorrow’s applica-
Dr. rer. nat. Joachim Belz
Senior Vice President
New Technologies
HARTING Führungs AG
[email protected]
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S p e c i a l
6
t o p i c
GUEST CONTRIBUTION
Prof. Dr.-Ing. Hans-Jörg Bullinger
Taking the Lead with Innovations
The famous British physicist Michael Faraday, when asked
tion, we are teetering on the brink of mediocrity. Not because we
by the Chancellor of the Exchequer to explain the object of
have got worse, but because others have become better.
his experiments, replied laconically: “Sir, one day you will be
able to tax it!” It would be hard to put it more succinctly: Only
The present crisis in which Germany finds itself is above all a cri-
when new value is created can the state increase its income.
sis of innovation, in economic, administrative and political terms.
The importance of innovation for prosperity and employment
The sustained economic downturn and the collapse of the Neuer
in Germany is summed up in the formula which states that
Markt have resulted in a far-reaching sense of insecurity. Many
“research turns money into knowledge, whereas innovation
companies are crippled by the fear of making mistakes, while
turns knowledge into money”. Innovations are the force
politics is hampered by the fear of scaring off the electorate. In
which drives the economy.
both cases, there is a lack of courage, imagination and the ability
to instigate change and see it through. The pressure to innovate
Germany was once regarded as the homeland of inventors, crea-
is growing steadily, and the questions we must ask are growing
tive thinkers and improvement obsessed engineers and tinkerers:
ever more urgent: Have we become too contended, too lethargic,
The names of many German inventors are remain alive today by
too inflexible?
the companies they founded – among them Siemens, DaimlerChrysler and Bosch. There was a time when Germany was the
Besides the urgent need to change the terms of reference within
research laboratory, pharmacy and workbench of the world. The
which we operate, we also need to launch an innovation offensive
phrase “Made in Germany” was a byword for high quality and
on a broad front. The power to instigate political, economic and
cutting edge technology. Nowadays, other countries are setting
administrative change can only be mustered by working in con-
standards which we struggle to keep up with. Since the early
cert. It is essential that we mobilize the most creative minds and
90’s, Germany has fallen behind on several fronts. We have been
the most agile entrepreneurs. An innovation offensive will not
unable since then to improve on our position as the country with
only open up new economic perspectives, but will point the way
the lowest economic growth in the European Union. Worldwide
out of Germany’s identity crisis.
comparative studies such as the PISA report on education and
investigations into technological performance capabilities have
At last, we can look forward to some growth, albeit at a low level.
ruthlessly laid bare the fact that in terms of research and educa-
And we are not quite as bad as we protest to be. However, we must
7
not allow positive signals to lull us into a sense of false security.
Korea 2.7 and Switzerland with 2.7 percent. If our investment in
Some marginal growth in Germany’s economy is far from suf-
research remains mediocre, then we will achieve no more than
ficient. Our companies are better than the location in which they
mediocre results in the long term. Other industrialized countries
are doing business. Worse still, German companies are working
have consistently increased their research spending. From 2000
hard to improve their competitiveness – at the expense of Germa-
to 2002, Sweden increased its expenditure on research by 30
ny itself. Despite healthy balance sheets, companies continue to
percent. The USA invested 25 percent more and even recession-
cut jobs in Germany and expand abroad. Cutting costs alone will
plagued Japan hiked its spending by 15 percent. Over the same
not make businesses in Germany competitive, they must counter
period, Germany managed an increase of just six percent.
the challenge from low-wage countries with innovations – with
new products, processes and services. In brief, we must make
The EU will only achieve its ambitious aim of becoming the most
better products for which consumers are prepared to pay a higher
competitive economic area in the world by 2010 and increasing
price. For a high wage country such as the Germany, there is no
research spending to 3 percent of GDP if there is a significant
alternative. If we wish to enjoy a significantly higher standard of
increase in outlay. That goes for industry as well, as industry ac-
living than in countries such as Malaysia or Brazil, then we must
counts for two thirds of all research and development spending.
make things and do things which these countries cannot offer.
We must make up our minds whether we want to lead the field,
or simply be an also-ran.
The power of German industry to innovate has withered. Last
year only 53 percent of companies presented new technical
Increasing globalization puts companies under steadily growing
innovations. By comparison, from 1997 to 2000 the figure was
pressure to innovate. The majority of small and medium-sized en-
just under 60 percent. The only sector to increase its pace of in-
terprises have discontinued research activities in the meantime.
novation was the automobile industry. The balance between new
The longer companies ignore or postpone investments in new
products and those at the end of their life cycle is the worst since
technologies, the more their achievement potential and their com-
1982. However, what is particularly worrying is the fact that over
petitiveness will suffer. Only those players who put money into
half of all companies – based on their own data – are operating in
research and development during the crisis will have sufficient
stagnating or shrinking markets. According to a current study by
attractive products ready when the economy resurges. The abil-
the Institut der deutschen Wirtschaft (IW), the German economy
ity to innovate, however, is the key competence required by any
is focused on products whose markets show disproportionately
business enterprise aiming to hold its own in the world market.
low growth rates.
Yet companies are finding it harder and harder to persevere with
such long-term strategies in the face of shareholder demands for
In many areas we have lost the technological lead. There remain
short-term returns.
but a few rays of hope, such as the automobile industry and
mechanical engineering, that continue to be lead markets. The
As the financial markets acquire an increasingly global character
frightening fact is that when it comes to the dynamically growing
and the global economy knits together, the process of “creative
technologies of the future, we are being left behind. For years
destruction”, as Schumpeter so aptly summed up innovation, is
we have been living off our capital and investing too little in the
becoming ever more dynamic. Revolutionary business models are
future.
destroying traditional corporate structures, while old and ponder-
Education, science, research and technology are the foundations
The only option open to companies unwilling to be overwhelmed
that underpin Germany’s position in international competition
by this development is to hurl themselves into a process of change
ous concerns are being swallowed up by aggressive newcomers.
and provide a basis for prosperity and employment. Germany will
at least as rapid and rigorous as that embraced by the capital mar-
be risking its ability to survive in the future if it does not invest
kets which head off in pursuit of the highest returns regardless
significantly more in research and education. The 2.5 percent of
of the consequences. This compels companies to promote high-
GDP that Germany expended on research in 2002 put us in
7 th
place behind Sweden with 3.9, Finland 3.7, Japan 3.0, USA 2.8,
8
return areas of business and shed those that are less profitable.
They must adopt the advantages of their young challengers.
An essential prerequisite is a culture of innovation at both societal and corporate levels. New ideas need an innovation-friendly
environment if they are to develop to full effect. We must not
simply demand creativity, we must promote it. The ability of a
country to compete and innovate is to a large extent dependent
on a highly qualified, motivated workforce. Creative minds are
the only raw material which Germany has at its disposal. And now
the most important resource which the knowledge-based society
of the future can call on threatens to run short as fewer and fewer
young people opt for technical or scientific careers. We must make
better use of the available potential and offer the new generation
the kind of development opportunities which match up to even
the highest international standards.
The Fraunhofer-Gesellschaft is supporting the offensive aimed at
strengthening Germany by a wealth of activities. The 12 leadingedge innovations which we presented at the beginning of the year
2004 provide concrete examples of the areas of research which
will in our view offer the best prospects for German industry in
the years to come. Recognizing and utilizing trends is one thing.
The other important task is to heighten the pace of innovation.
Success is reserved for those who are the first to turn ideas
into marketable products. Once, German firms could enjoy an
extended advantage in terms of product quality and technological
Prof. Dr.-Ing. Hans-Jörg Bullinger
know-how. Nowadays their competitors are able to imitate suc-
President of the Fraunhofer-Gesellschaft
cessful products and marketing strategies with increasing speed
and frequency. This means that companies must implement in-
BRIEF RÉSUMÉ
novations much faster and with greater precision. And they must
Hans-Jörg Bullinger was born April 13, 1944 in Stuttgart. Af-
respond to the wishes of their customers. The ability to plan
ter attending school in Stuttgart, he served an apprenticeship
and implement innovations with greater speed and consistently
as a workshop mechanic with Daimler-Benz AG in Stuttgart-
control their direction is becoming an essential prerequisite for
Untertürkheim. After graduating from the Stuttgart Technical
future economic success. The exceptional significance of “time
Highschool, he went on to study mechanical engineering at the
to market” is so crucial that the Fraunhofer-Gesellschaft has
University of Stuttgart, taking a degree in 1971, a doctorate
launched a Presidential project aimed at accelerating innovation
in 1974 and a post-doctoral lecturing qualification in 1978.
processes. We will subsequently make the methods and tools
In 1980 he was appointed as Professor of Ergonomics at the
developed through the project available to industry, in order to
University of Hagen.
enable German companies to progress faster from idea to product
From 1981 he became head of the newly established Fraun-
and thereby take the lead on world markets.
hofer Institute for Ergonomics and Organisation (IAO) in Stuttgart, adding a professorship in ergonomics at the University of
Stuttgart in 1982. In 1991 he was also appointed to head the
newly founded University of Stuttgart Institute of Ergonomics
and Technology Management.
He has been President of the Fraunhofer-Gesellschaft since
October 2002.
9
S p e c i a l
t o p i c
TECHNOLOGY
Wulf Padecken
Partners in Innovation
advise the German Federal
Chancellor:
Dietmar Harting attends
Innovation Summit
10
“Innovation policy is about
more than just education
TASKS AND OBJECTIVES
The objective in establishing “Partners in Innovation” is to
and research. It is equally
strengthen Germany’s system of innovation at every level, break
important that we have
down barriers and stimulate fresh confidence in Germany’s
a body of entrepreneurs
achievement potential. The creation of a joint “Innovation Office
who appreciate innovation
Deutschland” will help to identify central future markets and
as a core element of their
establish a new culture of innovation. By launching projects for
business success.” There’s
school students and young people, the innovation partners hope
no denying the truth of what Dietmar Harting says. Germany
to generate interest in science and technology at an early stage.
will only regain its role as the engine of innovation provided
A process of reform which extends all along the education chain
if we succeed in creating a climate in which corporate crea-
will create the necessary conditions in schools and universities.
tivity, innovation-friendly public policies and research and
Greater emphasis will also be attached to promoting compatibility
development activities are each in tune with one another.
between family and professional life and exploiting the knowl-
Federal Chancellor Gerhard Schröder has declared 2004 as the
are being made at a European level to develop European industrial
year of innovation. To start the ball rolling, he invited top-ranking
policy to promote employment and innovation.
edge and experience of the older generation of employees. Moves
representatives of industry, politics and trade organisations to
an innovation summit. In addition to the President of the Fraun-
The members of the Federal Chancellor‘s innovation group in-
hofer-Gesellschaft, Prof. Dr.-Ing. Hans-Jörg Bullinger, Chancellor
clude: Foreign Minister Joschka Fischer, Minister of Economic
Schröder invited Dietmar Harting to attend both in his role as
Affairs Dr. Wolfgang Clement, Education Minister Edelgard
a leading entrepreneur in the SME sector and as President of
Bulmahn, the head of the Chancellor‘s Office Dr. Frank-Walter
the electrical and electronics industry federation ZVEI and Vice
Steinmeier, corporate consultant Prof. Dr. Roland Berger, the
President of the BDI (German Federation of Industry).
President of the Fraunhofer-Gesellschaft, Prof. Dr.-Ing. HansJörg Bullinger, the Chairman of the Board of Schering AG, Dr.
“An initiative to promote greater innovation in this country is
Hubertus Erlen, Vice President of the BDI and general partner in
the right signal at the right time,” commented Mr. Harting.
harting KGaA, Dietmar Harting, Acatech President Prof. Dr.-Ing.
“It is now a matter of actively writing the next page of
Joachim Milberg, Chairman of the Board of Lufthansa, Wolfgang
Agenda 2010. We need three things: Long-term commit-
Mayrhuber, the President of the Humboldt-Universität Berlin,
ment, the integration of politics, research and business
Prof. Dr. Jürgen Mlynek, Chairman of the Board of Siemens AG,
enterprise, and a courageous body of entrepreneurs.”
Dr. Heinrich von Pierer, DGB board member Heinz Putzhammer,
Chairman of the Board of Deutsche Telekom AG, Kai-Uwe Ricke,
In Mr. Harting’s view the “Partners in Innovation” initiative is
Chairman of the Board of Bertelsmann AG, Dr. Gunter Thielen,
a chance to strengthen the bonds between politics, science and
the Deputy Chairman of BASF AG, Eggert Vorscherau, and the
industry: “Provided we all pull together, promoting innovation
Director of the German Research Center for Artificial Intelligence
will enable us to develop markets which will rebuild employment
GmbH, Prof. Dr. Dr. h.c. Wolfgang Wahlster.
and prosperity in this country. New legislation on its own will
not get us anywhere.” The electrical engineering and electronics
industry regards itself a major driving force with a proactive role
to play in the process of innovation which the Chancellor has now
set in motion.
Wulf Padecken
General Manager
Public Relations and Communication
HARTING KGaA
[email protected]
11
S p e c i a l
t o p i c
INTERNATIONAL
Bob Lounsbury (Rockwell), Randy Below (The Siemon Company), April Mayse, JoAnne McLeod
The Siemon Company and HARTING collaborate
on Factory Automation Solution
A new age exists in Factory Automation and real time com-
The Siemon Company, a respected leader in wiring and structured
munication using Ethernet is taking over. Designers and
cabling for commercial purposes for over 100 years, answered the
engineers in the field are seeking effective ways to link the
market’s demands with a field-attachable RJ 45 connector encased
factory floor with the front office, and along with that has
in its Industrial MAX® ODVA approved IP 67 shell.
come the demand for reliable industrial connectors.
The ODVA (Open DeviceNet Vendor Association), is an international association of manufacturers bringing together the world’s
leading automation companies and is an independent organization
that offers conformance testing to help ensure that products built
to its specifications operate in multi-vendor systems. The ODVA
chose Siemon’s Industrial MAX connector as the standard connector in its Ethernet Industrial Protocol (Ethernet IP) Physical Layer
Specification in 2001. The Industrial Max was the first such connector specifically designed for Industrial Ethernet applications
approved by ODVA for use in Ethernet IP systems.
ACTIVITIES OF ODVA
The ODVA, which currently has over 300 members, was founded
in 1995 by Rockwell Automation/Allen Bradley to support worldwide growth of the DeviceNet Specification by assisting vendors,
Metal MAX®
distributors and end users through tools, training, conformance
testing and marketing activities. Over time, the need arose for
a closer interaction between the Enterprise Resource Planning
(ERP) system and the factory floor. In 2000, ODVA selected Eth-
THE SIEMON COMPANY
ernet as the carrier medium of choice. A major reason for this
choice was that Ethernet had been adopted by countless companies across the world in the office environment and its operating
characteristics are well understood, many tools exist to work with
Randy Below
Vice President of OEM Business
it and it is broadly accepted. The Ethernet IP standard, based on
classic Ethernet and using Industrial Protocol was released by
ODVA in the same year. The transmission standard used in Eth-
Siemon, a world leader in designing and manufacturing high-
ernet IP is IEEE 802.3 and has transmission parameters according
performance network cabling systems and connectivity compo-
to TIA/EIA Category 5e. While there are subsequent revisions in
nents, offers the most comprehensive cabling solutions including
existence or planned (cat. 6, cat. 7) ODVA, in common with most
unshielded, shielded and fiber media. With products and solutions
industry professionals, felt that cat. 5e was mature enough and
available in Category 5e, 6, 7 and fiber, the Siemon Cabling Sys-
stable enough to be used in an environment where mistakes or
tem is providing the foundation for business success.
software “crashes” could potentially cost hundreds of thousands
Siemon is la privately held company located in Watertown, Con-
of dollars or more in capital equipment damage or lost produc-
necticut, and has been serving its customers for over 100 years.
tion revenue.
12
Bob Lounsbury
As principal engineer of Rockwell Automation Bob Lounsbury is responsible for
all core network physical layer designs and
technology.
Rockwell Automation is a leading indus-
THE CONNECTOR SOLUTION
trial automation company focused to be the most valued global
The connector is based on unshielded twisted pairs (UTP) of wire
provider of power, control and information solutions.
size 24 or 26, terminated to an industry standard RJ 45. The con-
In his function as chairman of the ODVA Ethernet / IP Joint
nector is field installed and encapsulated into the IP 67 housing
Special Interest Group Bob Lounsbury is responsible for the de-
which is the Industrial MAX connector.
velopment of network physical layer architectures including the
While the Industrial MAX answered the protection and quality
standardization of the core networks for Rockwell Automation.
needs of the factory automation world, a desire for a standardized
connector with a stronger housing, preferably metal, existed. According to Bob Lounsbury Principal Engineer of Rockwell Auto-
The Metal Max® connector with a metal housing is under develop-
mation, and Chairman of the Joint Special Interest Group (JSIG),
ment by a team of engineers from both harting and the Siemon
the ODVA committee responsible for standardizing connectors for
Company. Production is scheduled for mid 2004 with an official
the industrial environment, “there is a perception in the factory
product launch in April 2004, at the Hanover Fair in Germany.
automation industry that metal connectors are very rugged and
“We’re excited about the opportunity to work with harting on this
more suitable for use on the factory floor.” Harsh elements such
project,” says Randy Below – Vice President of OEM Sales at the
as dust, temperature, moisture, electromagnetic interference, and
Siemon Company,” The Metal Max will bridge the product gap
vibration have been constant obstacles in the search for reliable
between IS and the plant floor, and provide users with another
connectivity. Rough handling by factory personnel also causes a
robust, high performance connector option.”
high failure rate of connectors. The standard RJ 45 connectors do
not survive these harsh conditions and as a result, the standard RJ
HOWEVER, THE STORY DOES NOT FINISH HERE …
45 needs to be encapsulated in an easily handled, rigid sheath of
In addition to the Industrial Max connector, ODVA has also re-
protection. However, protection isn’t the only issue. Manufactur-
cently standardized on a metal 2 pair UTP solution, specifically
ers also are searching for ways to connect systems from multiple
geared towards the control devices themselves. These connectors
vendors, using a standardized interconnect system. The Industrial
will also carry cat. 5e transmission data and will work in an IP 67
Max connector system will function largely on the “backbone” of
protected environment. This connector is based on an industry
data transmission between the central ERP system and the switch
standard 4 pin M12 connector, with a specially designed “D-coded”
cabinets or field switches on the factory floor, allowing for the
interface that prevents accidental mis-mating with standard I/O
first time manufacturers to execute manufacturing changes and
devices. harting’s product is based on the patented HARAX® axial
to capture production data in real time.
IDC field termination system and is available in 5 pin DeviceNet
SIEMON AND HARTING SOLUTION
As a result of the successful joint development effort with the
The Technology Group harting has partnered with The Siemon
Siemon Company, harting now offers a complete range of ODVA
configurations as well as the 4 pin Ethernet IP version.
Company to develop a connector that encapsulates an RJ 45 con-
standardized connectivity solutions available either as discrete
nector in a new metal housing. harting has long been a leader in
connectors or as cord-sets, patch cords and field-installable con-
developing connectors for various types of cables for industrial
figurations. harting IP 67 Ethernet switches are supplied with
environments. This new connector, the “RJ 45 Metal Max®” will
ODVA interfaces, as are the new range of industrial outlets. So
not only provide the protection manufacturers are looking for, but
the users can always count on harting to be the leader in the
will also easily allow for the connection of systems from multiple
IP 67 industrial connectivity environment.
vendors, raising the standard of network communication on the
factory floor to the next level. It incorporates bayonet style locking
lugs that ensure a full connection and the rugged metal hood and
housing provide a robust IP 67 degree of protection. Built-in toggle containment means you don’t have to operate the RJ 45 toggle
lever in order to disconnect it. The hood and housing hold the plug
and jack rigidly together for trouble-free connections.
April Mayse
Marketing Communications Intern
HARTING, Inc. of North America
[email protected]
JoAnne McLeod
Executive Assistant
HARTING, Inc. of North America
[email protected]
13
S p e c i a l
t o p i c
INTERNATIONAL
Andre Beneke & Bart Van Biesen
Connections reliable as Steel – Ethernet Switch
and HARTING RJ Industrial® System Cabling Network
in a Steel Production Plant of SIDMAR, Belgium
Industrial Ethernet components are typically used in auto-
The harting Switch offers 5 Ethernet ports, and one additional
mobile manufacturing and robotic processes, etc. There are
Han 4A connector for the necessary 24 V power supply. The
many other sectors, however, in which solutions based on
application at SIDMAR uses a version with five harting
switches and system cabling may offer interesting potentials
RJ Industrial connections. Additionally very reliable
worth leveraging.
and industrially proven Ethernet cables with AWG
22 wire gauges are used. The ambient conditions in
The Belgium company SIDMAR N.V. focuses on the production
which the product can be used are -40 °C up to +70 °C
of flat steel products, ranging from thin rolled steel plates to
and a non-condensing humidity of 30 % to 95 %.
thick massive plates of high quality. High quality is a must for
Users have the option of 10 and 100 Mbit/s data trans-
SIDMAR’s customers as the steels finding use in the automotive
fer rates, and features such as auto-negotiation and
industry, for example, must be of a premium type. The company
auto-crossing are realized as well as status LEDs and
ensures optimal quality with the help of vision control and track-
non-blocking Store and Forward Switching mode. The
ing systems.
product also provides several mounting possibilities to
In order to guarantee high quality standards, SIDMAR has in-
be used directly in the field.
stalled a camera system along production lines. At different steps
The harting RJ Industrial connectors offer Cat. 5 trans-
of the production process photos are taken of each individual
mission based on RJ 45 connector technology in addition
product. The cameras make four photos per product, and these
to proven mechanical stability and robustness. A special
photos are stored in addition to the normal production data. In
product feature is the incorporation of IDC field termina-
this way SIDMAR realizes a complete follow-up of the production
tion technology (HARAX®) that also allows the use of AWG
process of each end product. An Ethernet system based on hart-
22 wire gauges in addition to a very easy and time saving
ing technology solutions links the cameras.
termination process. The choice of this wire size is crucial for long
NETWORK WITH SWITCHES AND CABLE ASSEMBLIES
proven cables.
Industrial Ethernet switches are the core elements of the Ethernet
The complete design, in other words the combination of the metal
distance Ethernet transmissions (up to 100 m) with industrially
system.
switch, the metal connectors and the industrially proven cables
The harting Ethernet Switch ESC 67-10 TP05U offers switch func-
represent a perfect solution for the harsh environmental condi-
tionality in connection with a very robust, shock- and vibration
tions prevailing at SIDMAR manufacturing facilities. The harting
resistant metal housing offering IP 65/67 protection. Thanks to
solution enables the realization of decentralized star structures
the specific metal material of the housing, the switch provides a
for Ethernet transmission, helping to ensure the perfect quality
very high mechanical stability. It is highly shock and vibration
of the SIDMAR products.
resistant, and additionally incorporates very good resistance
against electromagnetic interferences.
Andre Beneke
Market Manager Car Industry & IT
HARTING Electric GmbH & Co. KG
[email protected]
14
Bart Van Biesen
Manager Industrial Business
HARTING N.V. Belgium
[email protected]
SIDMAR
Based in Ghent, SIDMAR N.V. is the largest steel manufacturing
company in Belgium. On a total production area of approximately
2,100 acres some 5,200 employees are producing flat steel products.
These flat steel products, mainly in deep-drawable grades, are
especially well suited for the automotive industry, as well as
household appliances, furniture, heating equipment and other
applications and product areas. Annual SIDMAR production
capacity is in excess of 5 million tons of steel products.
SIDMAR N.V. is part of the French ARCELOR Group, the world’s
largest producer of flat carbon steel and long carbon steel, and
ranks among the leaders in stainless steel production and among
the European leaders in the distribution, transformation and trading of steel. With a workforce of more than 34,000 employees
ARCELOR generated sales of near € 27 billion in 2002.
15
S p e c i a l
TECHNOLOGY
t o p i c
Andreas Huhmann
Switch Technology:
The magic Formula for Industrial Ethernet?
Segment (Maximum 500 meters long, maximum of 100 stations)
min. 2.5 Meter
Terminator
Transceiver/MAU
DB15
AUI-cable
max. 50 m
Terminator
DB15
Station 1
Station 2
Station 100
Once upon a time
Ethernet topology was originally synonymous with using the
“yellow cable”. Stations were strung together along this coaxial cable just like beads on a string. This was accomplished
24 V Power Supply
by connecting the network stations via external transceivers,
which used vampire taps to tap the signals directly from the
bus cable, without interrupting the bus line.
A linear topology, similar to today’ field bus solutions, was the
Ethernet
way things were done. The advent of new technologies, such as
full duplex Ethernet over twisted pair cable, necessitated some
rethinking of the topology. This was accompanied by a change in
the installation paradigm. The line arrangement was substituted
in favor of the star.
For the first time, it was possible, in addition to simple passive
distributors, to also deploy intelligent distributors for consistent
point-to-point cabling. This network component, which actively
switches a connection between two stations, was – logically
enough – called a switch.
The switch connects two subnetworks, so-called collision domains,
on layer 1 and layer 2 in the OSI layer model. Ethernet uses the
CSMA/CD (Carrier Sense Multiple Access with Collision Detection) method for transmission. Due to the fact that stations can
send data on the bus simultaneously, collisions occur in this ac-
16
Star cabling
Switch
Linear topology based on a switched Ethernet
17
cess method. If the subnetworks connected via a switch represent
individual devices, collision-free communication is ensured.
If the industrial user wants to continue to install according to linear topology, the switch functionality must be integrated in each
device, assuming that freedom from collision is a requirement.
Cascading results in high switch demands, however, because the
forwarded data packets have to be temporarily stored in order to
then be forwarded to a target (store and forward). The situation
is even more troublesome when there are telegram packets that
receive preferential treatment due to prioritization. Switch technology is therefore facing new challenges in industrial applications that extend well beyond office requirements.
THE NEED FOR SWITCHED ETHERNET
So-called switched Ethernet is necessary in order to avoid collisions. Such collisions always occur with the CSMA/CD access
method. They are detected, however, and all stations causing the
collision stop sending and subsequently re-send according to a
statistical time unit (see the flow chart).
The Ethernet protocol based on CSMA/CD does not rule out collisions. This is why providers of Industrial Ethernet solutions are
opting for different ways to either prevent such collisions by way
of the protocol or by providing a feasible method using switches.
One thing is indisputable, however, data packet delays caused by
collisions are not acceptable.
1. Cyclic Ethernet operation (for example, PowerLink Protected
Mode or EtherCat)
2. Standard Ethernet with additional real time extensions (for
example, PROFInet, Ethernet IP)
3. Or a combination of the mechanisms from 1 and 2 (for example,
PROFInet)
CSMA/CD flow chart
Accordingly, there is either the philosophy of avoiding to send
simultaneously and thereby preventing collisions or of using
temporary storage to group these by time.
If collisions are fundamentally allowed in standard Ethernet,
switched Ethernet, they allow cyclic communication even on a
concurrence can only be cancelled with switches.
protected channel (for example, PROFInet with IRT).
Where the Ethernet CSMA access method is supplemented in the
To summarize, all protocols that cancel out the CSMA/CD access
direction of established field buses in the first case, and therefore
method do not need a switch. On the other hand, in heterogeneous
the protocol is not compatible with standard Ethernet devices,
systems, in which collisions can occur, switches may represent
communication with all TCP/IP devices is fundamentally non-
an expedient solution.
critical when standard Ethernet is used.
The following table provides an overview showing systems in
Interestingly, Ethernet protocols with cyclic operation also allow
which switches can be employed:
non-cyclic communication, for which a switch is again optimal
This means that there are protocols permitting collision-free
(for example, Powerlink Open Mode), and, on systems based on
communication.
18
Collisions should be avoided in order to make sure that data does
technologies into industrial applications, switch technology is also
not arrive at a time that cannot be predicted (determinism).
moving from the office into the field.
In this connection, however, the topic of real-time is often labored,
The problems with real-time capability were not of immediate
which takes up where the discussions along the lines of the drive
significance in the office. It was not until the advent of multimedia applications that real time became im-
System
Switch
possible
Switch
not possible
Switch improves
Performance
Switch
has to be used
portant, while entailing requirements that
differ from the demands of industrial real
time. The necessary prerequisite for multi-
PROFInet
X
media applications in the office area is the
availability of a bandwidth enabling the
Ethernet IP
X
transmission of tremendous data volumes.
X
Individual network components must not
Powerlink
X
Open Mode
EtherCat
X
restricted
Standard
TCP/IP
X
Protected
Mode
X
Open Mode
restrict the usable bandwidth. Methods
such as cyclic operation, which restricts
the amount of data possible, are not viable
in the office environment. All methods in
X
cyclic operation restrict the effective use-
X
ful data in favor of real-time performance.
Here the switch is the only instrument to
The protocols enabling switch use
offer the capability of preventing collisions
engineering of existing field buses left off. Because most field
without restricting the bandwidth. Consequently, and for good
buses do not have a bandwidth sufficient for drive solutions, Fast
reasons, switches have become standard technology in office
Ethernet is seen here as the philosopher’s stone.
environments.
The real-time topic is considerably more complex, however, be-
In other words, switched Ethernet installations are looking in
cause what is important in industrial automation is ensuring
to the industrial world from the office side. As the direction of
that properties are maintained that are critically important
migration is progressing from the office, and its first step in
to the operation of a plant. In the case of a larger load on the
industrial applications only entails the recording of conditions or
network, collisions can statistically delay the transmission of a
writing information on operation into the controllers, switched
message in the second range, in spite of Fast Ethernet. It is also
Ethernet is found on practically every machine.
not ensured that messages in the automation network arrive at
A second, seemingly smaller, step then involves Ethernet grow-
the receiver in the correct time order. Systems such as real-time
ing beyond the switch cabinet and replacing the conventional
expansion of Ethernet IP CIP Sync or SRT for PROFInet can only
classic field bus. This substitution only makes sense, however, if
be implemented on the basis of switches, because only switches
consistency is maintained from the office through to machines.
allow information to be forwarded in a defined time slot.
This would result in a framework retaining existing office tech-
There are protocols, however, that enable collision-free com-
nologies, and therefore also retaining switches in industrial
munication. Nevertheless, the use of switch technology is
applications.
expedient.
INDIVIDUAL INDUSTRIAL ETHERNET PROTOCOLS
THE PATH FROM THE OFFICE TO THE FIELD LEVEL
All proven protocols for Ethernet in industrial surroundings use
Ethernet was first implemented in the office area and evolved
real-time mechanisms.
into a standard in this field. It was only after becoming firmly
All protocols must meet the high demands of drive control appli-
established here and gaining additional technical sophistication
cations. Most Ethernet protocols can be scaled, as these require-
that this standard was actually mature for industrial applications.
ments account for no more than roughly 15 % of all applications.
Considering this migration of Ethernet and the associated office
Consequently, there are several protocols behind a single name,
19
redundant connection
Office building / Switch technology
Manufacturing area / Switch technology
Explanations:
CD-Campus Distributor
FD-Floor Distributor
BD-Building Distributor
PMD-PROFInet Machine Distributor
MO-Machine Outlet
TO-Telecommunications Outlet
Use of switch technology
and these protocols cannot be implemented without additional
IRT applications, a special switch ASIC is needed to administer
hardware. Consequently, there are protocols that are comparable
the IRT channel.
to standard Ethernet TCP/IP, while others extend all the way up
to high end solutions.
ETHERNET IP
Ethernet IP uses CIP Sync protocol, regardless of the network
PROFINET
and therefore also of the physical layer. Clocks are synchronized
PROFInet supports three channels. In addition to the standard
with a time stamp in accordance with IEEE 1588 for this purpose.
TCP/IP channel, which is not real-time compatible, there are soft
Clock synchronization requires additional hardware. Cyclic data
real-time (SRT) and isochronous real-time (IRT) channels avail-
is exchanged with the help of prioritization. Switches are crucial
able. While the SRT channel is primarily based on prioritized
in order to ensure smooth, collision-free data transmission. CIP
telegrams, the IRT channel has a cyclic setup. In one cycle, there
Sync protocol is fully compatible with standard Ethernet. There-
is an IRT channel available, in addition to the standard channel;
fore, additional devices that do not support CIP will not interfere
this IRT channel is evaluated on the basis of a hardware expan-
with data transmission.
sion called “Switch ASIC”. The PROFIbus user organization (PNO)
Ethernet IP does not stipulate the use of special infrastructure
has decided to generally use switches that offer data technology
components and therefore real-time performance depends on the
advantages as well as installation advantages on all channels. In
correct component selection.
20
ETHERNET POWERLINK
SWITCH TECHNOLOGY DEVELOPMENTS
Ethernet Power Link has two modes: protected mode and open
To a large degree, switch functionality will move into the devices
mode. In protected mode, a sub-network is formed for demanding
that are primarily intended for building up a linear topology.
real-time traffic; this sub-network is connected to the standard
This results in an integration of topology and device function.
network via a router. Within this sub-network, cyclic data is ex-
The network would lose the autonomous character it holds in
changed between the stations, while avoiding collisions. The se-
the office world based on the standard for structured cabling
quence is coordinated by a managing node, which works similarly
(ISO/IEC 11 801).
to a bus master. This sub-network is not compatible with standard
The cabling for these devices will then only be device connec-
Ethernet and requires hubs as network components.
tions. Following this line of thinking far enough, networks would
Open mode can be seen as similar to other real-time concepts,
lose their structure entirely. Loss of network structure, however,
such as Ethernet IP. Switches are generally usable here.
is neither desired in terms of safety, nor from a performance
standpoint, and especially with regard to drive applications. In
ETHERCAT
addition, functions will be combined inside a switch cabinet that
EtherCat differs from the standard topology. EtherCat is always
are executed in a pluggable form, via switches that are situated
implemented as a ring, in which the Ethernet telegram runs
between the switch cabinet and the outside world (in between).
through each station. There is no direct addressing. The station
Switches decouple segments mechanically, and not only in terms
knows which data in a telegram is meant for it by using the
of data technology.
sub-telegram, which is also implemented by way of additional
With the CBA, or the component model, the PNO has taken a
hardware. EtherCat also synchronizes clocks according to IEEE
clear step forward towards structuring, because reproducible
1588.
structures also simplify the engineering considerably.
Unlike rings based on standard Ethernet technology (Layer 1 +
The final goal is consequently not to lose all structure, but rather
2), in which the ring is separated by the spanning tree algorithm,
to create useful structures. This could mean:
the ring in EtherCat is physically closed. This means that, seen
l
Areas of networked drives
from this layer, a switch is not expedient.
l
Safety areas
Virtual switches are offered, however, that forward the telegrams
l
Components of a plant or mechanical units
to a connected standard Ethernet device via the master.
l
Areas for operation and observation
All switches that will be supporting these segments in future are
necessary elements. Switches for these jobs have extended functions, such as those of a firewall or router. Additional functions
from the diagnosis area are conceivable.
The switch will be equipped with new functions in industrial
surroundings and must be completely reassessed. It will continue
to be called a switch, even if its job has nothing more to do with
actually “switching”. It will increasingly become the medium for
structuring and segmenting networks.
In-between switch
Andreas Huhmann
Market Manager Industry
HARTING Deutschland GmbH & Co. KG
[email protected]
21
S p e c i a l
t o p i c
TECHNOLOGY
Lutz Herrmann
Rugged Ethernet Technology for clean Water
Ethernet is also increasingly being used in the industrial
therefore, one single, powerful network will be frequently be in
environment, as a replacement for, or supplement to the clas-
place that will handle all jobs.
sic field bus systems. Especially thanks to the higher data
rate Ethernet delivers, it is far easier to provide enhanced
THE HARTING APPROACH
maintenance with standardized protocols or remote main-
Currently, IP 20 components are mainly employed in Ethernet
tenance. Consequently, installing Ethernet as a supplement
network structures. They elements do not offer any special protec-
to the existing field bus system in the first step is often an
tion against environmental influences, such as dust and splashed
expedient option, thereby reducing the load that service and
water or jets of water. They must be installed in switch cabinets
maintenance jobs impose on this system.
(centralized) or terminal boxes (decentralized).
Thanks to high data throughput and globally standardized pro-
In many Ethernet network structures in the industrial branch, it
tocols, however, Ethernet can do considerably more than simply
is necessary to deviate from the traditional star structure, which
relieving the service and diagnosis job load on field bus systems.
represents the optimum connection from the transmission point
In additional to “normal” data transmission, audio and image
of view, as the cabling effort and costs make this structure un-
transmission are easily possible. Standardized protocols, such
feasible. In this case, the network structures are adapted to the
as Voice-IP, are available for such applications.
bus or linear structure commonly encountered with field bus
systems.
Once Ethernet has proven its capability and stability in the realtime area at customers, it will become increasingly possible to
This means that decentralized Ethernet stations in the field,
incrementally replace field bus systems with Ethernet. In future,
meaning outside the switch cabinet, are executed in the IP 67
Application
22
degree of protection, or are housed in decentralized terminal
With the help of the Ethernet network, monitoring of the water
boxes, in IP 20 degree of protection. As a result, the active net-
filter unit’s valves and pumps is released for service and main-
work components, such as switches and hubs that are also needed
tenance purposes, and monitoring, service and maintenance
for Ethernet, are installed decentralized and close to the stations,
data is exchanged, all independently of the control network and
either as IP 67 devices only or inside already existing terminal
without influencing the control data. Consequently, for example,
boxes. One advantage of the IP 67 only solution is the option of
control personnel are always informed as to whether the filters
installation at almost any point in the plant without additional
and accompanying controlled system are in the necessary operat-
protective measures. Retrofitting an existing plant with IP 67
components is also easier to accomplish.
harting’s Ethernet product program supports these optimized,
decentralized structures, with switches and hubs in different
models, as well as with passive infrastructure components, and
consequently offers an integrated solution approach in industrial
surroundings.
Integrated solution approach for Ethernet in industrial surroundings without switch cabinet, by using components with the following properties:
l
High degree of protection IP 65 / IP 67
l
Temperature range from -40 °C to +70 °C
l
Active network components
High EMC and mechanical compatibility against shock and
vibration
l
Rugged metal housing
l
Plug & Play
ing range. In addition, one Ethernet switch port is always freely
available as a diagnosis port, so that maintenance personnel can
log in to the system directly at the site with a hand-held PC, in
AN INDUSTRIAL DIAGNOSIS NETWORK
order to obtain the necessary information.
BASED ON ETHERNET
The British enterprise Earthtech Engineering Ltd. plans and
SUMMARY
designs water treatment, such as monitoring water filter units,
Using this application as an example, it is clear that the harting
for industrial plants.
approach harnessing an integrated Ethernet solution in IP 65 /
IP 67 provides customers with distinct advantages that are also
One of their requirements was the clear separation of control and
readily utilized. The main reasons for selecting this solution were
diagnostic data. Added to this is a hostile, unprotected environ-
the network and solution expertise, the high degree of protection
ment, which calls for rugged components with a high degree of
offered by the components (IP 65 / IP 67), Plug & Play aspects for
protection. Furthermore, the shortest possible installation and
shortening installation and commissioning times, as well as the
commissioning times had to be guaranteed.
rugged construction suitable to the hostile environment in water
THE HARTING SOLUTION
approach.
treatment and harting’s integrated, comprehensive Ethernet
The solution delivered by harting, that is already in use in this
form, consists of a small Ethernet network for a hostile environment, with two ESC 67-10 TP05U Ethernet switches. This
network works parallel to the control network, which is based
on ControlNet/DeviceNet. Both networks are connected to the
Lutz Herrmann
Product Manager Devices
[email protected]
SCADA system in the control center.
23
S p e c i a l
t o p i c
TECHNOLOGY
Heiko Frese
A feed through Connection:
In-between Ethernet Switch ESC 67-30
Pure star topology for Ethernet, the standard encountered
and a height of 40 mm, is mounted on the outside of the switch
in the “office world”, is not always expedient in industrial
cabinet and offers 2 pluggable Ethernet interfaces that provide
automation with its typical plant structures. The trend here
a high degree of protection and are suitable for industrial use.
is towards ring or line topologies or combinations of the
There are 3 Ethernet interfaces, one interface for the power supply
two, which are implemented by using active network com-
and an alarm contact on the back or bottom of the device. These
ponents.
IP 20 interfaces are sealed towards the switch cabinet with a
In order to keep a lid on wiring input and installation costs, it
the respective Ethernet stations (controllers, I/O modules, drives,
is necessary to execute active network components, such as
service interfaces) can be networked via the switch, using stand-
sealing ring when the housing is screwed on. Inside the cabinet,
switches and hubs, with a high degree of protection, even for
ardized IP 20 patch cables.
decentralized plant structures.
After the IP 20 Ethernet devices inside the switch cabinet have
been installed, the network to additional switch cabinets or de-
THE SITUATION TO DATE
centralized modules is built up with a high degree of protection
At this time, there are also IP 20 switches available on the market
via the 2 Ethernet ports outside.
for collision-free networking of Ethernet stations (such as controllers and I/O modules) inside a switch cabinet; these switches
Switch cabinet
machine module 1
take into consideration the increased demands (environmental
Switch cabinet
machine module n
conditions, EMC) in industrial surroundings. Networking to additional stations at the machine or in the factory building, however,
must be solved with the help of additional components. Panel
feed through and connectors with a high degree of protection (IP
65/67) are used on the switch cabinet for this purpose. The disadvantage of this solution is that there is no status or diagnostic
information concerning the
Line/star networking in automation technology
with HARTING switches with a high degree of protection
data link available outside
the switch cabinet (for exam-
The In-between Ethernet Switch supports both line structures in
ple, when the switch cabinet
distributed systems (such as conveyors) and star/line structures
door is locked). This is
that, starting at a switch cabinet, connect the other components
where the newly developed
directly in or at the machine.
In-between Ethernet Switch
from harting comes in.
DIAGNOSIS
The integrated display area allows status information concerning
NEW SOLUTION
In-between Ethernet Switch
24
the data communication to be viewed from outside by the machine
A 5-port Ethernet switch
operator during the production process. If there is a malfunction,
is integrated into a rugged
these LEDs signal important information, which accelerates fault
metal housing with an IP
location within the plant.
65 / 67 degree of protection.
In addition, malfunctioning can be communicated directly to
The compact housing, with a
the control room or center via the alarm contact integrated in
base area of 105 x 105 mm
the switch.
SUMMARY
The In-between Ethernet Switch ESC 67-30 from harting closes
the gap between the switch cabinet (IP 20 version) and hostile
industrial environments (IP 67 version). The switch guarantees
networking with other stations at the machine, both in line and in
star/line structures, thereby connecting the two worlds.
Heiko Frese
Product Manager Devices
[email protected]
25
S p e c i a l
INTERNATIONAL
t o p i c
Kai Nurmenniemi
OBSAI – Enabling an open Market
for Base Station Modules
Traditionally, mobile network manufacturers have developed
MMS (Multi-media Messaging Service), presence, transactional
proprietary modules for Base Tranceiver Stations (BTS). The
services and video-streaming, not only add to infrastructure com-
key challenge in the future is to create cost effective prod-
plexity, but will create growth in network traffic (see figure 1).
ucts for base station manufacturers in order to facilitate
Large numbers of base stations will need to be deployed, initially
the production of new base stations that will allow telecom
to provide coverage as next generation mobile technologies come
operators to roll out new services, cost effectively and rapidly.
on line, and then to provide sufficient capacity to meet the rising
The Technology Group harting and several other companies
market demand.
support this approach.
COMPLEX TO COST EFFECTIVE
Greater complexity almost invariably leads to higher capital and
operational costs. In an increasingly competitive market, mobile
Monthly data consumption per subscriber (MB)
70
operators will not be able to sustain the potential increase in costs
60
that these developments will bring. The cost of base stations and
50
their implementation will also have a critical impact on an opera-
40
tor’s profitability. As next generation networks are deployed and
30
the number of subscribers rises, more and more base stations will
Mobile data
20
be needed to provide the coverage and capacity that the market
10
will demand.
Voice
0
2001 '02
'03
'04
'05
'06
'07
'08
'09
New and more cost-effective ways to design infrastructure equip-
'10 2011
Source: OBSAI
ment must be found in order to reduce the higher costs that would
otherwise occur with conventional development methods.
Fig. 1: Monthly data consumption per subscriber (MB)
With large numbers of base stations being deployed, even a
small improvement in the cost-effectiveness of each BTS can
The Open Base Station Architecture
Initiative (OBSAI) has developed a comprehensive set of open specifications for
key module interfaces within the base
station architecture. This development
System Software
will enable an open market to become
reality.
A key challenge facing cellular op-
Open
interfaces
erators and other mobile telecommu-
Radio
RP3
future will be the rising cost of the
RP2
Power System
WCDMA GSM/EDGE CDMA2000
Processing
Transport
Mechanics
…
Control
nications service providers in the near
infrastructure needed to provide suf-
Antenna Line
Base Band
IP
ATM
E1
T1
…
ficient capacity for advanced mobile InRP1
ternet services. Recently launched and
forthcoming services such as content
download, location based applications,
26
Fig. 2: OBSAI Base Station Overview
have a large impact on the overall investment that an operator
control, transport, baseband and radio. The OBSAI architecture
must make.
provides a clear functional split and detailed internal interface
MAKING INROADS IN THE INDUSTRY
that are truly compatible in all OBSAI compliant base stations.
The Open Base Station Architecture Initiative (OBSAI) is a con-
OBSAI provides the springboard for a new, competitive market
stantly growing group of over 63 members from industry, span-
for interoperable modules, where economies of scale will result
ning leading base station vendors, module and component manu-
in significantly lower costs.
specifications which then allow companies to create modules
facturers. The members of OBSAI have created a complete set of
open specifications for the base station architecture. By defining a
HARTINGs COMMITMENT TO OBSAI
basic modular architecture and the detailed specifications for the
harting has been a supporter member of OBSAI since September
internal interfaces between modules (see figure 2), OBSAI aims
2003.
to create an open market for cellular base stations.
The company’s activities in the wireless market are in line with
those of OBSAI. The OBSAI specifications allow harting the
OPENNESS AND BENEFITS
opportunity to support a large group of wireless base station
An open market will substantially reduce the development effort
manufacturers and module manufacturers with unified, state of
and costs that have been traditionally associated with creating
art interconnection solutions. harting has utilised its extensive
new base station product ranges. The availability of off-the-shelf
technology and service capabilities available to provide signifi-
base station modules will enable manufacturers to focus their
cant contribution to OBSAI towards the definition of their inter-
development efforts on creating further added value within the
connection specifications.
base station, encouraging greater innovation and more cost-effec-
The har-bus® HM Signal and HM Power connectors meet OBSAI
tive products. Furthermore, as product development cycles will
specifications and provide a reliable and cost effective solution for
be reduced, new base station functions will become available on
connecting plug-in units to the backplane. The connector solution
the market more quickly.
available from harting will offer full compatibility and intermate-
Not only will operators benefit from greater competition among
ability with base station modules.
base station vendors, but they will also have the opportunity to
bring new and advanced services to market earlier.
End-users will benefit too, by having access to mobile services at
the price levels they are prepared to pay and earlier than would
otherwise be possible.
COMPLETE SET OF INTERFACE SPECIFICATIONS
OBSAI has now defined a complete set of detailed interface speci-
Kai Nurmenniemi
Application Engineer
HARTING Oy Finland
[email protected]
fications to cover the functions of all key base station modules:
Fig. 3: har-bus® HM Signal and HM Power connectors
27
S p e c i a l
t o p i c
STANDARDS
Jörg Hehlgans
PICMG-AMC –
HARTING parecon® Technology leads the Way!
You may not be familiar with the name PICMG, but if
you have used a PC since this organization was founded
in 1994, then you will almost certainly have had firsthand experience of their work.
28
PICMG (PCI Industrial Computer
Manufacturers Group) is a consortium of over 600 companies
who collaboratively develop
open specifications for high
performance
Appendix A covers a total of 6 modular connector designs mounted
within 3 housing variants. The designs are all 85 contacts wide and
cover up to 340 contacts. Of these between 15 and 84 are differential pairs capable of operating above 12.5 Gb/s.
telecommunica-
tions and industrial computing
applications. The members of
the consortium, which include
module cards will connect to the main boards through a small
leading corporations such as
family of surface mounted z- pluggable connectors.
Intel, Motorola, Lucent, Nortel
harting EO, along with Molex, Samtec, Tyco and Yamaichi all
and Nokia have a long history of
submitted draft proposals for the layout of this connector for
developing leading edge prod-
consideration by the PICMG members. Thanks in no small part
ucts for these industries. PICMG
to Intel’s open support, the harting parecon solution won the
specifications include Compact-
subsequent vote. In fact all the potential users voted for harting®
PCI® for Eurocard, rackmount
parecon, while only connector suppliers voted against.
applications and PCI/ISA for
passive backplane and standard
format cards.
Subsequently harting has been a driving force in the developAssembly of 3 carrier blades
with each 8 AMCs
ment of this connector family, actively suggesting modifications
and improvements as well as trying to accommodate as many user
In line with harting’s policy of
requirements as possible. Hundreds of drawings and 3-D views
early involvement in design-in activities, harting Electro-Optics
have been generated and harting EO also stepped in to take over
have been actively involved with PICMG for the last 2 years.
the related mechanical design of the card guiding structure when
Their latest development, Advanced Telecom Computing Architec-
the original supplier dropped out. This mechanical design has
ture (AdvancedTCA® or ATCA) is the largest specification effort
demonstrated novel solutions to requirements in an area outside
in PICMG’s history, with more than 100 companies, including
the normal scope of harting’s activities and may provide added
harting, participating. AdvancedTCA is a new series of PICMG
revenue for the Group that was not anticipated at the start of the
specifications (3.X), targeted to the requirements of the next
program.
generation of carrier grade communications equipment. This
The Appendix A document covering the specifications of this con-
series of specifications incorporates the latest trends in high
nector family has been prepared by harting EO and was officially
speed interconnect technologies, next generation processors and
adopted by the PICMG working group in mid December 2003.
improved reliability, manageability and serviceability.
In telecommunication networks to date, each of the current sys-
This is an ambitious project as the standardization involved goes
tems has been engineered and put into production separately and
much deeper than in previous generations. Systems suppliers
at great expense. The same problems have been solved in at least
who have had to severely trim their own R&D resources can look
four different but very similar ways. Each system will fail unless
900
mercial Off-The-Shelf) components that will al800
low them to build systems with the minimum
of clean-paper design effort.
ture, the Advanced Mezzanine Card (AMC)
connector. The high-capacity z- pluggable
connections are needed by hot-swap capable
processor or transceiver modules realized on
mezzanine cards. The rear edges of these
800
700
700
600
600
500
500
Units (K)
of the key components of this new architec-
Non-Server Blades Forecast
Wireless Access
Units (K)
harting EO’s involvement is related to one
Server Blades Forecast
Source: RHK Inc.
forward to a pool of interoperable COTS (Com-
400
Wireless Edge
400
Wireline Access
300
300
Edge
200
200
New Access Edge
100
100
0
0
Core
Signaling
2003
2004
2005
2006
2007
2003
2004
2005
2006
2007
Market forecast for carrier blades
29
customers can be convinced that all their potential interfaces
The adoption of the ATCA standard is expected to match the con-
can perform as a compatible system within a reasonable period
vergence of the computer, telecoms and CATV networks. Today
of time.
each of these industries have their own standards and their own
One major reason is the lack of compatibility. Each of these sys-
specialized processing equipment which makes integration com-
tems comes from a different industry – computer, fixed telecoms,
plicated. As well as offering cost-effective bandwidth increases,
cellular telecoms, cable TV, and each industry already had its own
the ATCA standard will allow existing signal protocols from each
infrastructure and way of thinking. Their independent solutions
of these industries to be handled and combined within a single
are conceptually similar but not interoperable.
rack.
Currently chip development significantly outpaces the 5 – 10
This means that ATCA will arrive at just the right time to be
year typical life-cycle of telecoms systems. Adoption of any new
adopted for some of the potential applications. This is just one
architecture is more likely to happen when an existing system
small example of the challenge facing the broadband industry.
approaches the end of this cycle and/or has reached the limit of
It also high-lights the opportunities for future business as it has
its upgradeability.
been forecasted.
Envisaged Network architecture with AdvancedTCA
Jörg Hehlgans
Market Development Manager
HARTING Electro-Optics GmbH & Co KG
[email protected]
30
3D model of the demonstrator for AMC
Differential lines’ conduction
HARTING parecon®
Introduced to the world markets as recently as 2003, harting’s
parecon technology for high speed connectors has not only
generated broad customer interest across an extensive range of
applications, but has also made its way into standardizations, a
development promising extensive utilization of parecon based
Eye diagram
solutions.
harting is developing a set of technology design rules, thereby
enabling rapid response to customer inquiries. For example,
there are simulation models for the mechanical properties of the
flexible PCB, as well as electronic SPICE models that enable the
development of the desired high frequency transmission parameters to a high degree of precision.
The simulation predictions are continuously enhanced by meas-
Insertion loss
urements. A testing set-up of this type featuring the high-speed
demonstrator from the new AMC connector family was presented
at the Bus and Board trade fair. With the help of the demonstrator
a range of key parameters can be displayed for customers.
In cooperation with the Zentrum für Aufbau- und Verbindungstechnik (ZAVT) in Lippstadt (“Center for Packaging and Interconnection Technologies”) verifications of proper solderability are
compiled. Soldering tests under industrial conditions have shown
Return loss
that the parecon’s flexible PCB can be handled just as easily as
conventional, standard components.
Dr. Jens Krause
Head of Development
HARTING Electro-Optics GmbH & Co. KG
[email protected]
31
S p e c i a l
t o p i c
INTERNATIONAL
Christian Ruque / Alain Thevenon & Nicolas Mallet
Cab Radio Systems, easy to use, easy to maintain
Responding to rapid technology advances, including new
TYPICAL HARDWARE ARCHITECTURE
train control techniques, French National Railways (SNCF)
The mechanical design offers
has decided to revamp its entire cab radio operation in col-
the same level of flexibility.
laboration with harting. The cooperation focuses on back
The product housings range
panel connectors.
from tiny mobile units to complex configurations enclosed
Train-borne communication func-
in a 6U21 rack. Moreover, all
tions are generating increasing
boards have the same standard
interest throughout the railway
format of 3U x 160 mm.
community since they extend the
possibilities of embedded informa-
MECHANICAL INTEGRATION
tion systems and offer a seamless
Agate Cab Radio mechanical
and reliable link to the ground.
design is based on Alstom’s
In terms of implementation, the combination of the railway-
extensive experience in em-
specific version of the global system for mobile communications
bedded electronics for rolling
(GSM-R) and the global positioning system (GPS) offers high value
stock and the particularly
added to systems builders designing reliable radio communica-
harsh environments involved.
tions between trains and the ground. Moreover, it also enables
Since a number of years, the
precision positioning.
patented EasyPlug™ racking
SNCF decided in 2000 to upgrade its cab radio
fleet, encompassing several dozen different
types of trains. Alstom Transport Information
Solutions provided its Agate onboard electronAntenna Coupling Units
ics platform, which includes a complete range of
cab radio products.
GSM-R
AN EXTENSIVE PRODUCT RANGE
ALSTOM’s Cab Radio solutions cover client re-
EVC
(voice, ERTMS
& data)
1 to 4
module(s)
Analog
radio
GPS
(positioning)
(voice, data)
Central unit
processing MMI management
I/Os, serial links TDMA config.
maintenance
quirements from the basic GSM-R radio through
to the full ERTMS-ready, voice and data comTDMA bus
munication system including analogue radio
compatibility.
architecture. In fact, all products are based on a
Power supply
MMI
(redun
(redudant
dantin
inoption)
option)
Audio
TDMA (Time Division Multiple Access) internal
LV & serial
communication bus allowing fast data and voice
Train network
transfer between the modules, and total freedom
in terms of configuration design.
32
Interfaces
This diversity is enabled by the given product
technology has established itself as a proven standard thanks to
A piece of Zamac is ensuring the centring of the floating posi-
its unique feature: the harting connectors (located on the rear)
tion.
can be plugged and unplugged in one move. As connectors are
Both power and coax contacts needed 3,3 mm mating security
not handled during maintenance operations, the reliability is
minimum, through contact’s resistance measure.
dramatically enhanced.
The right angled coax contact is mounted by force on the male
body to exclude any potential mismatching.
A HIGHLY MAINTENANCE FRIENDLY PRODUCT
l
l
10 minutes max. are required for in line unit replacement
THE CABLE CONNECTION
thanks to the EasyPlug with harting specific connectors.
Depending on applications, the cable connection is made by crimp
Maintenance data are available on the train network thanks to
or flat cable technologies.
the Cab Radio network connection
In collaboration with the Alstom packaging manager Christian
Ruque and the Alstom Product Manager Alain Thevenon, the
harting Technology Group developed this specific Easy Plug
MAJOR REFERENCES:
l
SNCF (France)
l
SBB (Switzerland)
l
CD / Pendolino (Czech Republic)
l
Euro AVE / HSL (Spain)
l
West Coast Main Line (UK)
DIN project in 2 years from the conception phase through to
realization.
Christian Ruque
Alstom Packaging Manager
Alain Thevenon
Alstom Product Manager
THE HARTING DIN MH 21+4 CONNECTORS
Based on the MH 21+5, a specific female body has been designed
to mixed 21 power contacts with 4 coax contacts.
Nicolas Mallet
Sales engineer – Electronic division
HARTING France
[email protected]
Contacts have to be designed to make up for an axial residual
play of the contacts of ± 0.25 mm when floating housing plugged
with centring pegs.
33
S p e c i a l
t o p i c
INTERNATIONAL
Jan Cerny & Bohuslav Tryzna
Han-Modular® Inserts in Train Coupling Devices
34
Apart from other sectors of its production range such as com-
by its volume, the device size was reduced by some 30 % to 35 %
plete DC-substations for different kinds of public transport
compared to the original. In series production the coupling head
(railways, metro, trams, etc.) Sécheron Tchequie produces an
contains nine Han E®-modules with male contacts and nine Han
extensive range of electrical apparatuses for railway vehicles
E-modules with female contacts (a total of 108 contacts); these
for the world market. In addition to various types of discon-
contact types can be used to connect various conductor cross-
necting, selecting and earthing switches, contactors, pulse
section sizes (from 0.5 to 4 mm2). The use of harting elements
generators and other components, the company also produces
is advantageous because of their modularity – it is possible to
several types of devices for the mechanical or electrical cou-
use various existing combinations of Han-modules with a differ-
pling of traction vehicles.
ent number and type of contacts. If necessary, by coupling-head
Intensive cooperation between Sécheron Tchequie and harting
size modifications, the number of modules can be increased /
Czech, which started in 1997, was necessitated by Sécheron’s
decreased, which provides a solution that offers a wide range
need to develop a new automatic electric coupling device for one
of possibilities to match the best the requirements of potential
of its customers, where the design was limited by the maximum
customers. Even though the coupling types produced so far con-
permissible dimensions that excluded any use of normal standard
nected only communication, video-signal and control conductors
equipment. The customer’s requirements then resulted in the
(up to 40 A/750 V), there is a possibility of connecting some
miniaturisation of the device and the development of a new range
power conductors, air pressure connections, optical cables, etc.
of coupling devices. The use of Han-Modular series connectors
Another advantage, compared to the earlier solutions, is the ease
proved to be the best option.
of repairing or replacing damaged contacts or modules. With the
USAGE IN HELSINKI METRO
placed at ‘the other end’ of the device, i.e. connecting the cables
The first type implemented using Han®-modules was the automat-
to the vehicle cable channel; however, this design is now being
ic coupling device for the Cobra-Tram, which was later followed
used by other traction vehicle manufacturers as well and, together
by the automatic-pneumatic coupling device for the Helsinki
also with other connectors, they have become standard on all the
Metro. At the very beginning, there were some doubts about
coupling devices supplied by Sécheron Tchequie.
new range of electric coupling devices the connectors can be
the mechanical life of the contacts (the generally required life
The new range of coupling devices has been developed due to
for automatic electric coupling devices is at least 20,000 cycles)
the active cooperation of Sécheron Tchequie and harting CZ,
as well as the contact engaging motion (the ‘sensitive’ manual
where the representatives of the latter provided Sécheron with
coupling of standard connectors is replaced by ‘hard-pressing’ of
all the development support, including the test model samples.
modules by either electric or pneumatic drive). Bearing this in
This cooperation continues in a development project for a new
mind, there was designed and manufactured a coupling prototype.
higher capacity disconnecting switch (in the order of 650 A/4000
This prototype was tested in the Sécheron testing plant for the
V), which will be another specific example for the application of
mechanical resistance of modules and electrical characteristic
harting solutions in the instrumentation for traction vehicles
of contacts. The test results were remarkably successful: about
manufactured by Sécheron Tchequie.
32,000 connecting cycles were carried out with satisfactory mechanical and electrical parameters on all the tested modules. It
has been noted that the use of harting components in applications
of this type is both possible and suitable. So the customer has
Jan Cerny
Head of the construction department
Sécheron Tchéquie, spol. s r.o.
approved this solution.
THE NEW COUPLING DEVICE
This development project resulted in a coupling device, the
Bohuslav Tryzna
Product Manager EL & EC
HARTING s.r.o. Czech Republic
[email protected]
external dimensions of which have been significantly reduced;
35
S p e c i a l
t o p i c
TECHNOLOGY
Hans-Günter vom Bauer & Thomas Heckmann
Wind Power Plants see the Light
The development of wind power has produced resolute system
modularization for the series production of modern plants.
With the building block principle, manufacturers and system
suppliers achieve not only efficient manufacturing processes,
but also greater flexibility for implementing special customer
demands. In industrial management and operations, modularization also proves to be advantageous for tasks in service and repair work, where simplified exchangeability of the
subsystems leads to greater technical availability in terms
of the overall system.
The so-called “W, red” (German: W, rot) hazard beacon from the
REETEC Company in Bremen, Germany, is a typical example of
a modern system area in a wind power plant. Most wind power
plants are equipped with hazard beacons, among other features,
for reasons of air navigational safety. Day and night identifiers
are prescribed for aircraft objects with a total height of 100 m or
more. A high degree of operational dependability was reached
in the development of “W, red” by means of component selection
36
and design (such as LED technology). Furthermore, the compact
ternal seal, locking elements of non-rusting steel and housing
signal bodies offer sufficient assembly options with regard to
material made of a corrosion-resistant zinc die casting alloy.
specific customer wishes – even when the unit is not assembled
By using the appropriate adapters, it is possible to choose be-
until it is outside.
tween cable clamps with a universal clamp for the upper part
The harting connectors used for the electrical connection of the
of the housing with strain relief and special cable clamps with
“W, red” hazard beacon were not only selected for their primary
bend protection or anti-twist protection. The EMC cable clamp is
mechanical and electrical functions. It was more important to
a further option for providing a conductive connection between
design in a high protection class, surface quality and – in those
the cable screen and the housing.
places that call for it – electromagnetic compatibility with the
Together with REETEC, harting is ensuring that “W, red” hazard
combination of the cable and connector components, thereby ena-
beacons make wind power plants easy to recognize.
bling them to meet the high demands of a wind power plant.
The currently enhanced Han® HPR housings that are used, offer
very tight sealing increased pressure tightness (protection class
IP 68). They comply with tough climatic demands, such as found
in wet areas, which allow the use of sensitive interfaces that must
be protected. The identifying features are the black coloring, in-
Han® 3 HPR
Hans-Günter vom Bauer
R&D / Support Engineer for Special Components
REETEC GmbH
Regenerative Energie- und Elektrotechnik
Thomas Heckmann
Market Manager Renewable Energy
[email protected]
37
S p e c i a l
t o p i c
INTERNATIONAL
Davide Bozzini & Rolf Baumann
Technology Group supports Technology Activities – Han®Connectors used by CERN for their Large Hadron Collider (LHC)
A TeV is a unit of energy used in particle physics. 1 TeV is about
the energy of motion of a flying mosquito. What makes the LHC
so extraordinary is that it squeezes energy into a space about
1012 times smaller than a mosquito.
The LHC is the next step in a voyage of discovery which began a
century ago. Back then, scientists had just discovered all kinds of
mysterious rays, X-rays, cathode rays, alpha and beta rays. Where
did they come from? Were they all made of the same thing, and
if so what?
These questions have now been answered, giving us a much
greater understanding of the Universe. Along the way, the anThe Large Hadron Collider (LHC) project is another step for-
swers have changed our daily lives, giving us televisions, transis-
ward to prove CERN’s ability to be in front of the relevant re-
tors, medical imaging devices and computers.
search activities. The approval for the LHC construction was
On the threshold of the 21st century, we face new questions which
given in 1994 and the LHC will go live in 2007. The Technol-
the LHC is designed to address. Who can tell what new develop-
ogy Group harting has traditionally worked very closely with
ments the answers may bring?
the CERN engineers. The interconnection solutions in many
cases are responsible for reliable connections of important
power and datastream systems. The below presented project
again demonstrates harting’s ability to cope with CERN’s
high needs of quality, support and product versatility.
CERN is the European Organisation for Nuclear Research, the
world’s largest particle physics center based in Geneva, Switzerland. Here physicists come to explore what matter is made of and
what forces hold it together. CERN exists primarily to provide
the physicists community with the necessary tools. These tools
are accelerators, which accelerate particles to almost the speed
of light and detectors to make the particles visible. Founded in
1954, the laboratory was one of Europe’s first joint ventures and
includes now 20 Member States. The organization is designed for
the very specific needs of a scientific community.
The prototype LHC full cell during test
WHAT IS LHC?
The Large Hadron Collider (LHC) is a particle accelerator which
will probe deeper into matter than ever before. Due to switch on
HARTING WITHIN THE LHC PROJECT
in 2007, it will ultimately collide beams of protons at an energy
For the LHC particle accelerator, 1232 dipole magnets (for the
of 14 TeV. Beams of lead nuclei will be also accelerated, smashing
bending of the beam) and about 400 quadrupole magnets (for
together with a collision energy of 1150 TeV.
beam focusing) are needed, all operating at a cryogenic tempera-
38
ture of 1.9 K. Each cryo-magnet assembly comprises the main
the above mentioned CERN acceptance tests/specifications. The
magnet and several small corrector magnets. Each assembly is
Han family diversity in terms of contact configurations, mechani-
equipped with instrumentation for the protection of the supercon-
cal layout as well as ease of integration and robustness makes it
ducting electrical circuits and for the control of the accelerator
a powerful and multifunctional connectivity solution. Because of
components. The total number of instrumentation wires routed
its compatibility with industrial standards, it is also suitable for
out from the cryo-magnets is around 120 000. The routing of the
cost-efficient upgrading of existing systems and industrialization
instrumentation wires from the magnet to the corresponding
of the manufacturing and assembly process.
electronic has to satisfy several requirements in order to grant
a high degree of reliability for the entire 25 years lifetime of the
machine. Above all, the connectivity technique shall make possible a simple integration, an easy handling and manipulation
during test and commissioning phases and shall be mechanically robust and compatible with the different voltage and current
withstand levels.
LHC Dipole Magnet Instrumentation Box
Cryogenics for the LHC test facility
TECHNICAL SPECIFICATIONS FOR CONNECTIVITY
The need to group and distribute different types of instrumentation wires led to selecting a family of connectors suitable to
cover all the envisaged configurations. More than 15 different
configurations of connectors are needed, differing on the type of
instrumentation and on the number of wires. The most complex
case consists of three assorted types of instrumentation wires
LHC Beam Separation
Dipole Magnet Instrumentation Box
with different functionalities such as: 1000 V DC voltage pickup point, 75 A peak capacitor discharge carrier and a 8000 A,
200 ns peak current pulse carrier, on a single connector.
HARTING’s HAN®-CONNECTORS SELECTED
During the development phase, in total 15 different configurations
have been evaluated and the Han family has shown to comply
fully with the CERN technical requirements. The Han-Modular®
including “Axial-screw-module”, “C-module” and “EE-module” has
Davide Bozzini
LHC Project Engineer
CERN, European Laboratory for Particle Physics
Geneva, Switzerland
Rolf Baumann
Managing Director
HARTING AG Switzerland
[email protected]
been retained as a possible solution and has successfully passed
39
S p e c i a l
t o p i c
APPLICATION
Hervé Yves Herman / Antonio de Diego & Pere Joan del Valle
Automated Baggage Handling with intelligent Connections
In 2000, Siemens Dematic undertook what is globally its most
The process of automated transport developed by Siemens Dematic
important project and embarked on the biggest project in
in the extension to Barajas Airport includes all the stages of lug-
Europe: the extension of the Madrid-Barajas airport. In this
gage processing: from the arrival of the luggage at check-in, to
extension, Siemens Dematic is carrying out the automatic
labeling, weighing, inspection and classification, right through
baggage handling system (BHS) encompassing four phases,
to its final destination within the airport.
with a budget of 300 million Euros, which will be completed
in 2005.
The BHS project, which is highly automated, includes, among
other elements, about 12,000 monitors which are controlled by
The BHS will have a total circuit of 91.3 kms divided between
some 15,000 detectors.
conventional belt conveyors and high-speed conveyors. One of
the most important new features incorporated by Siemens De-
CONNECTION APPROACH
matic into this project is the use of the high-speed system (ITBS)
The development of this important project required careful con-
characterized by a belt conveyor speed of more than 10 m/s.
sideration of points crucial to the efficiency of the system: rapid
Madrid-Barajas will be the first airport in the world to use this
and secure connections, practical installation and assembly and
groundbreaking solution developed by Siemens Dematic.
uncomplicated maintenance. These same considerations have
been applied to all the electrical and electronical components
The BHS will process more than 16,500 pieces of luggage per hour,
supplied by the Technology Group harting:
controlled by 174 check-in desks together with an early baggage
store for 2,000 pieces of luggage. Simultaneously, it will manage
l
Quintax connectors – used in peripheral cabinets to connect
the inspection of 100 % of the baggage, using 30 X-ray machines
touch panels and carry out the motor control in manual mode.
in Level 1 and 4 tomographic scanners in Level 3.
The connection is made by crimp contact.
40
l
HARAX® M12-L connectors: these PROFIBUS-DP connectors
link the INDRIVE motors and the read/write stations of inductive identification. The connection is made by means of axial
insulation displacement.
l
Han® 10 E connectors: installed in the connection box of the
motors. The connection is made by crimp contact.
l
Han® 3A connectors: used to connect the photocells of the vertical classifiers by means of extra flexible cables. The connection
Han Quintax®
is made by screws.
To achieve all this, Siemens Dematic has invested a great deal
in terms of human resources and technical knowledge in order
to offer integrated solutions based in state of the art systems
Hervé Herman
SATE-NAT Project Manager
Siemens Dematic
and equipment to meet the requirements of AENA (Aeropuertos
Españoles y Navegación Aérea).
Antonio de Diego de Castro
Electrical Engineer
Siemens Dematic
With all of these innovations, improvements and BHS solutions,
the new Area Terminal will service more than 35 million passengers a year.
Pere Joan del Valle
Product Manager & Marketing Industrial Markets
HARTING Iberia S.A.
[email protected]
41
S p e c i a l
t o p i c
TECHNOLOGY
Rainer Schmidt & Simon Seereiner
Converging Office and industrial Networks
Effective communication is increasingly becoming an es-
HISTORY OF STRUCTURED BUILDING CABLING
sential part of everyday personal life, as well as a decisive
While cabling was developed and set up on an application-by-ap-
competitive factor in business life. Communication technolo-
plication basis during the 1970’s and 1980’s, the idea of univer-
gies geared to increasing efficiency in all business processes
sally usable cabling in the LAN area took hold at the beginning
are particularly evident in the constantly growing number
of the 1990’s. This generic cabling, not tied to any specific ap-
of PCs in companies. Genuine efficiency was only attained,
plication, was meant to offer a cost-effective infrastructure for
however, with the advent of LAN technology (LAN = Local
all existing information services and protocols within buildings
Area Network).
or building complexes.
A LAN not only includes servers, PCs, protocols and programs, but
In 1995 the first internationally coordinated standard on struc-
also the corresponding cabling, which more or less represents the
tured building cabling (ISO/IEC 11801) appeared; essential sec-
transport paths for the data packets to be sent.
tions of this standard were adopted by the European EN 50173.
In the same year, the German standard titled “Generic Cabling
Systems” (DIN EN 50173) was published.
The current standards for structured building cabling are:
42
l
ISO/IEC 11801:2002 (international standard)
l
EN 50173-1:2002 (european standard)
l
TIA/EIA 568:2002 (american standard)
CABLING STRUCTURE
Defined outlets are needed in order to reliably connect the large
IN ACCORDANCE WITH ISO/IEC 11801, EN 50173
number of already existing office networks to industry’s machine
There are three distinct areas:
networks. Therefore, user demands for defined standards have
l
Primary area (also called the campus area)
l
become increasingly vocal in recent times.
Secondary area (also called riser area or, more frequently, backbone)
CONNECTING THE OFFICE WORLD
l
Tertiary area (also called the horizontal area)
WITH INDUSTRIAL ENVIRONMENTS
There is a central theme in the international standardization of
Today’s structured building cabling systems essentially use only
generic cabling: How does the IT network enter into industrial
two cable types: fiber optic cable for the campus and backbone
applications? The TO (Telecommunication Outlet = junction box)
areas and twisted-pair copper cable for the horizontal area.
already known from the office, is of essential significance. The
so-called InO (Industrial Outlet) represents the interface between
In the horizontal area, a maximum length of 100 m is assumed.
building cabling and plant cabling.
Cable and connector are organized into categories, which simultaneously define the components’ performance.
The locations for the Industrial Outlets are already defined during
network planning for the factory building. The building network
cables terminate at outlets positioned on columns or at manufac-
The categories are defined as follows:
l
Category 5 for bandwidths up to 100 MHz,
turing cells. These industrial outlets represent the point where
l
Category 6 for bandwidths up to 250 MHz and
plant or facility specific cabling commences. In order to ensure
l
Category 7 for bandwidths up to 600 MHz.
smooth interaction from the top (office) to the bottom (machine),
the harting Technology Group developed a product family that is
While the SC and Duplex SC connectors are predominant for
optimally adapted to the machine network and still compatible
fiber optic cabling, the RJ 45 connector is the standard for copper
with common office standards.
cabling. This connector is used as a socket in distribution panels
and junction boxes and, in plug form, it is employed on patch and
The harting RJ Industrial® connector simultaneously conforms
connection cords.
to the specifications of the Profibus Nutzerorganisation (PNO
2
3
1
1: Campus
2: Backbone
3: Floor area
Organization of the cabling levels in a building complex
43
– Profibus User Organization) and is RJ 45 compatible, which
ISO/IEC
118
Structure 01
d network
industrial
for
building
Productio
means that it supports the global office standard according to ISO
IEC 11801. The PNO has defined this interface for PROFInet, the
Ethernet-based automation network, which optimally corresponds
n area
to industrial cabling requirements.
The InO is the data handover point between the factory building
Field cab
and the office network, which is usually a part of the company-
ling
PROFInet
Structure
d
Field cab
network
wide IT infrastructure.
ling
Field cab
for mach
ling
ines
INDUSTRIAL OUTLET FROM HARTING
In the interest of providing users with technical continuity, the
Outlet from office cabling to industrial cabling
InO from harting has adopted proven LSA-PLUS® termination
technology for the building network cable. Consequently, users
encounter something that they are already familiar with and can
therefore install. The development of this InO was driven forward
in close cooperation with the experts for building and in-house
cabling in the office area at KRONE. KRONE’s cabling solutions
and components for equipping buildings (office cabling) are used
in building cabling around the world.
harting presented a plastic housing version of the Industrial Outlet, which combined the expert knowledge of the two companies,
as an absolute innovation for the first time at the SPS/IPC/Drives
2003, in addition to the metal InO, which is already very successful in the market.
Merging a wealth of functions and practical qualities with award
deserving design, the InO Push Pull is setting new standards.
Preparing the KM8 jacks without tools
Guiding the cable with the help of the
cable manager
PROPERTIES OF THE INDUSTRIAL PUSH PULL OUTLET
Connecting the cable in the InO was simplified, as the prescribed
terminal lengths are clearly marked inside the housing. This allows the installing technician to determine the cable length for
the specific case even faster, spelling a considerable reductions
in installation times as a result.
The RJ 45 jack connection in the housing was optimized by using
KM8 jacks from KRONE, which can be harnessed without tools.
The office-proven RJ 45 terminal blocks KM8 with LSA-PLUS®
termination technology allow cabling with AWG 22-24 industrial
cables. These terminal blocks have 360° screening and comply
with IEC 11801, not only in their link performance, but also in
the strict component requirements in accordance with Cat. 6. This
Cable entry from top and bottom
44
guarantees reliable transmission of data signals according to the
standard, in addition to further reducing the connection time as
Task Group (IPTG) – a work group within the ISO IEC for revis-
no tools are required for the preparation.
ing the 11801 cabling standard – as the possible mating face for
connecting industrial cabling to the office network.
The integrated cable manager ensures that the cable is guided
correctly inside the housing. The geometry of this innovation
These developments outlined demonstrate, close cooperation
enables the creation of a defined bending radius, allowing
among experts from office and industrial cabling can produce
smooth installation of Cat. 6 performance. When the InO is con-
the greatest possible advantages for end users. Thanks to this
nected and the cover has been closed, it is always ensured that
approach harting is able to offer reliable solutions today that fully
the cable is guided inside in just the right way, as HF lines work
meet the requirements of crucial applications in building cabling
like a water hose:
in industrial surroundings.
Nothing gets through if the line is kinked.
This resulted in an extreme reduction in the housing’s overall
dimensions, as it was possible to minimize the standard bending
Rainer Schmidt
Manager, Marketing/Product Management
PremisNET®
KRONE GmbH Berlin
radius since the cable is precisely guided into the cable manager.
At the same time, this cable guide facilitates the installing technician’s work, because he/she can be sure that the cable is fed
in the housing correctly, thereby patting the error ratio and the
Simon Seereiner
Strategic Market Manager Industrial
HARTING Electronics GmbH & Co. KG
[email protected]
error propability to zero.
Another advantage of this cable manager is the cable feed into the
InO from two sides. By simply shifting the cable manager, it is
possible to rotate the lower housing by 180° and thereby connect
the cable coming in from the top or from the bottom. This allows
the widest possible application range for the InO.
As an inserted connector cannot always be assumed, the InO Push
KRONE
Pull is fitted with automatic flaps. This guarantees permanent
KRONE has been involved in the development of struc-
IP 65/67 degree of protection – whether plugged in or not. The
tured cabling systems right from the initial stages, and
subsequent insertion of cover flaps can be dispensed with.
is a member of international and many national standards
In order to realize unique port identification in the network,
passive infrastructure solutions. KRONE cabling solutions
committees. The company ranks as a leading provider of
even under unfavorable environmental conditions, the InO from
and components for buildings systems (office cabling) are
harting has an integrated transparent protective glass, which
marketed globally under the PremisNET® name.
allows the box to be labeled, even in an IP 65/67 environment.
Cabling components from KRONE show up in all telecom-
This ensures that even after many years of use in a hostile en-
munications companies, providers and in cabling in large
vironment, the box identification does not yellow and become
office buildings, airports and financial service providers.
illegible.
KRONE has responded to constantly growing market
THE RJ 45-BASED CONNECTION
Consequently, KRONE was the first company to put a 100%
The harting RJ Industrial Push Pull is used as an interface in
component-compliant Category 6 system based on the KM8
machine cabling. This connector beats the space requirements
on the markets. The company is dynamically advancing the
of all other IP 65 and IP 67 RJ 45 connectors by 50 %. Given user
development of de-embedded test methods and is leading
requirements by increasing its capacity for innovation.
demands for miniaturization, harting also resolutely follows this
in the development of copper cabling systems capable of
path in international standardization. The harting RJ Industrial
10 Gigabit Ethernet.
Push Pull connector is currently seen by the Industrial Premise
45
S p e c i a l
t o p i c
TECHNOLOGY
Michael Grätz
Success with the small and fine: Micro Packaging Solutions
from HARTING are strengthened by Cooperation with LPKF
Decreasing size and increasing
opens the metal complex, and the metal seeds for the subsequent
performance – harting Electro-
metal-plating process are exposed.
Optics is meeting these market
demands by way of micro pack-
STRUCTURING PROCESS
aging solutions. The solutions
The structuring process allows processing times in the seconds
are offered as project services.
range; thanks to batch processing (or also production run process-
The LPKF LDS (Laser Direct
ing) it is possible to reduce the average processing time per piece
Structuring) process plays a key
even further. The data for the structuring is generated directly
role here by enabling the cost-efficient mass production of
from the CAD data and processed immediately in the laser system,
3D circuit carriers that are tailored to individual customer
which allows structuring without the need to produce any masks.
requirements.
After a cleaning step to remove the ablation products (ablation:
removal of material using a high temperature process and crea-
COOPERATION AGREEMENT
tion of a clean surface), the metal layers that form the later circuit
In the course of the productronica 2003 trade fair, a cooperation
structures are applied in a multiple-step wet-chemical process.
agreement between harting Electro-Optics and the LPKF Company in Garbsen was signed on November 10, 2003, that focuses on
LAYER BY LAYER
the joint development and qualification of the LDS process. LPKF
The starting layer plays a crucial role here; it essentially deter-
is an established equipment manufacturer and service provider in
mines the adhesion properties for the entire metal setup. This
the field of laser microprocessing. Some of the operations covered
starting layer is always generated using purely chemical deposi-
are micro-drilling, structuring, cutting and surface treatments
tion. In an adequate process the starting layer only grows in those
in the micrometer range, based on laser equipment and serving
areas at which the metal seeds were previously already exposed,
the widest range of application fields. Thanks to the new coop-
so that the deposited metal represents an exact image of the pre-
eration agreement and associated equipment base, harting now
vious structuring. The layers applied subsequently ensure the
has access to patented, leading-edge technologies offering high
appropriate surface properties, which allows further processing
application flexibility.
with typical electronic assembly technologies, such as SMD sol-
WORKING WITH THE LPKF LDS PROCESS
technologies. A typical layer combination used in this context is
The LPKF LDS process is an additive procedure for creating 3D
copper-nickel-gold, with a total layer thickness of approximately
circuit structures on a plastic carrier. The principle of the proce-
8 – 11 µm. The chemical deposited structures can be reinforced
dure is based on laser activation of a metal complex. To this end,
by electroplating. This presupposes the existence of contacting
the metal complex, in a finely distributed form, is added to the
possibilities for the electroplating process. Such contacting pos-
dering, conducting adhesives, chip and wire bonding or flip chip
plastic material (LCP, PBT and PP are currently available).
sibilities must already be
The blanks for the circuit carrier are injection molded from these
taken into consideration dur-
special plastic materials by way of a conventional injection mold-
ing the development of the
ing procedure. The blanks may typically measure in the range
parts. Furthermore, it must
from 2 x 2 x 1 mm to 100 x 100 x 30 mm.
be noted that while a layer
In the subsequent structuring process in the laser structuring
applied with electroplating is
system, the circuit structures are “written” onto the blank with a
considerably thicker and less
laser beam, in a 3D structuring process. This process destroys, i.e.
rough, when the electroplate
46
Figure 1 shows a part manufactured with the LDS method.
layer grows, the track conductor image is also considerably
of micro packaging. The advantages of the procedure are prima-
changed horizontally.
rily based on its flexibility, permitting subsequent adjustment
The comparison with the match in Figure 1 impressively demon-
of the circuit structure design without any tool changes at all.
strates the achievable structure sizes that are currently in the
Just as important is the possibility of interlacing mechanical and
range of 200 µm. Further work is directed at advancing down to
electrical functionalities, as a mechanical carrier simultaneously
the region of structure sizes around 100 µm. The procedure also
serves as the carrier of a three-dimensional conductor image, and
enables the creation of vias, i.e. the connection between 2 sides
therefore allows a further step in component miniaturization. The
of the carrier.
cooperation project with the LPKF Company merges the strengths
of the two companies to deliver maximum customer benefits,
SUMMARY
combining LPKF’s equipment knowledge and first procedure
In summary, it can be stated that the procedure outlined above is
results with harting’s technology experience and qualification
opening up new potentials for the harting Company in the field
procedure knowledge.
The products created with this new method are finding use in
the fields of medical technology and sensor technology, among
others.
Figure 2 shows a cross-section through a 300 µm through-plating
(via), magnified 100 times, before and after the metal coating.
Michael Grätz
Manager Production Technology
HARTING Electro-Optics GmbH & Co KG
[email protected]
47
S p e c i a l
t o p i c
TECHNOLOGY
Frank Quast
No halfway Measures
It’s only been around for some 50 years, but there are few
These operations must be performed manually, and are time and
products that have asserted themselves and spread through-
cost- consuming, depending on the cable’s flexibility. This was
out the industrial arena as quickly as the rectangular con-
the background for the development of a housing impressing
nector. Its diversity is primarily found inside the protecting
with new, unconventional approaches, in order to offer optimized
metal housing. The range of different inserts is gigantic and
cabling convenience for interfaces with unwieldy cables or high
covers virtually any requirements that may arise.
pin count cables.
Sectional view of a standard connector
Viewed against this backdrop, it is all the more surprising that
Industrial connector with separable hood
there have been only very few changes in the appearance or function of the metal housing until now.
CURRENT SITUATION
FIFTY-FIFTY
On the cable side, the entire industrial connector design in protec-
The fundamental innovation is the vertical separation of the
tion class IP 65 consists of three components.
housing. The two half-shells make it possible to open the hood,
which has been closed until now. The work paths in the assembly
l
Connector insert
l
Hood
l
Cable clamp
consequently move out of the axial level and into the horizontal.
This affects the logistics during the wiring process, because
the cable and insert can be conveniently connected at different
Regardless of the termination technology used for the insert, the
work stations and then inserted into the hood later. This makes
assembly of an industrial connector requires five basic steps.
assemblies easier and more reliable, because the housing interior
1. Guiding the cable through the cable clamp and through the
can be viewed and inspected. In order to completely implement
opening in the hood
the “divided” principle of the hood, the “cable clamp” components
2. Connecting the insert
must also be considered. The pressure screw, mostly of brass, is
3. Feeding the insert with cable back into the hood
completely eliminated for this housing model, and the clamp’s
4. Screwing in the insert’s fixing screws.
elastomer moves completely into the housing. Along with IP 65
5. Tightening the cable clamp.
tightness, this principle offers an optional strain relief clamp,
48
which guarantees high-quality function protection when the
conductive pressure spring system, which is also the connection
cable is subjected to a tensile load. Housing and “cable clamp”
to the hood’s ground potential. The insert is no longer screwed to
become a single unit.
the hood. This time-saving fastening system has been designed
for all harting contact inserts and consequently allows maximum
FIRM SEATING EVEN WITHOUT SCREWING
application flexibility.
Another feature for reducing the assembly time is the insert
receptacle. The contact insert is based on a patented electrically-
TIGHTNESS UNDER TOUGH CONDITIONS
Vertically separated housing places high demands on the housing
seal. The area of the hood’s vertically running cord seal is the
most sensitive; it borders the lower part of the housing’s horizontal profile rubber gasket. In order to quickly and effectively reach
reliable sealing contours, these “bordering spots” were digitally
modeled on computer by a specialized company. Using FEM analyses (FEM = Finite Element Methods), it was possible to optimize
volume compaction, so that IP 65 dust and water jet tightness in
accordance with IEC 60 529 can be guaranteed throughout the
product’s entire lifetime.
Housing shell with contact insert for voluminous wire packets
UNDREAMED-OF POSSIBILITIES
All of the details mentioned result in an industrial connector that
allows new ways of assembly thanks to its separated construction.
The product offers expanded cable room and improved packing
density, while retaining insertion compatibility with existing interfaces. It is possible to look into the cabling, which considerably
increases the connector’s reliability. Assemblies can be completed
up to 25% faster and, thanks to the horizontal working method,
automation approaches are possible for assembly operations.
Non-linear static simulation of the volume compaction in the area
of the cord and rubber profile gasket
Frank Quast
Product Manager Connectors
[email protected]
49
S p e c i a l
t o p i c
INTERNATIONAL
Steve Richardson & Paul Atkinson
Pressing Arguments: Backplane Assembly
as next Module for Technology Approach
Traditionally, converting soldered backplane assemblies to
2. Where the backplane is heavily populated on two sides with
pressfit technology really pays dividends when certain intrin-
connectors necessitating slow and potentially unreliable hand
sic conditions are present in the design of the unit.
soldering of one side.
HARTING INTEGRATED SOLUTIONS
In a recent high-volume application encountered by harting Integrated Solutions (HIS) in the UK, a family of four backplanes had
been designed using flow solder as the assembly process.
harting were chosen for the main interconnect, with cable-toboard connectors from a variety of manufacturers – all solder
pin contacts.
Interestingly, none of the aforementioned conditions were present
in this application, all connectors were mounted on the same side
of the PCB and all were short ‘pc tail’ contacts, so at first glance, a
‘flow solder’ approach to assembly seemed the best solution.
Double-sided assembly – pressfit connectors both sides
However, on further investigation, several factors emerged that
brought the prospect of transitioning to pressfit more into focus
These fall into two main categories.
1. Where there is a requirement for ‘feed-through’ interface on the
– and on discussion with the design authority, HIS was awarded
a contract to investigate this option.
backplane, using connectors with long spill contacts whereby
The HIS team proceeded to look at all aspects of the four assem-
either a second daughter card or I/O cables are plugged-up to
blies to see where more cost-effective solutions could be offered
the rear. In this instance pressfit provides clean gold plated
against the current designs.
pins for reliable connection, a condition that cannot always be
Conversion of the main interconnect was quite straightforward,
guaranteed by other assembly methods.
as pressfit versions were part of harting’s existing connector
Backplane with feed-through contacts and shrouds
50
M3 nut swaged into reverse of board
also able to bring to bear influence in other aspects of the board
assembly process, with experience of “design for manufacture”
principals extensively used within other products made at the
harting UK facility.
HIS’s Production Engineers looked at cost-effective process solutions in respect of both production and test, eventually submitting proposals that reduced manufacturing time of the individual
boards from eleven minutes down to as little as five minutes per
assembly, including electrical test. These proposals included utilization of harting CPM machines, with a pressing cycle of three
minutes per board.
Jack sockets fixed through connector, board and into M3 nut
Finally, HIS submitted their proposal, highlighting all the technical and cost advantages on offer and not surprisingly with such
portfolio, but finding cost-effective pressfit solutions to the cable
compelling arguments, the business was won via a world-wide
connectors presented more of a challenge and after extensively
CEM, even in direct competition with their own in-house back-
searching the market-place, good quality pressfit options were
plane manufacture.
selected, submitted to the design authority, and approved.
As ever, the most expedient means of manufacture may not
Reliable retention of jack sockets, cable retention brackets and
always maintain the levels of quality compliance demanded. Ini-
bail locks in the cable connectors was a key concern for the
tially, through the use of FMEA (failure mode and effect analysis)
designers, due to the fact that when the backplane is mounted
techniques, the cross-functional team employed manufacturing
in the sub-rack, any loosening and spinning whilst securing the
techniques based upon Poke-Yoke (fool-proof) assembly methods
mating cable half “in the field” would cause a major problem. HIS
to ensure “right first time” product conformity.
provided the solution with a pressfit M3 nut swaged into the re-
This approach ensured a rapid and reliable production cycle that
verse side of the PCB. This secure solution had the added bonus
engendered customer confidence in HIS’s ability to deliver large
of eliminating time-consuming washer and nut handling, simply
quantities of product, on-time and to high levels of quality.
leaving any hardware to be fitted down through the connector,
A production cell was instigated across two shifts, with flow line
PCB and into the M3 nut.
principals employed to ensure immediacy of feedback along the
The original solder design also required fixings for the DIN 41612
production line – using pre-defined performance metrics. This
connectors. With 16 to 24 DIN connectors per board, huge savings
ultimately enabled the team to meet the exacting requirement
in assembly time would be possible if fixings were completely
discarded. HIS were able
to quadruple the throughput within the first four weeks of
manufacture.
to prove to the customer
using sample assemblies
and pull test data, that
with 64 or 96 pressfit pins
retained in the PCB, the
need for further fixing was
indeed unnecessary.
THE BOARD ASSEMBLY
PROCESS
In providing cost effective
solutions to the customer in
the field of pressfit applicaHARTING 2001/s press in action
tions, the HIS team were
Drop-on connector check
51
Test fixture. Simple and fast, checks all connector orientation again,
exercises all contacts and electrically tests backplanes
Re-useable packaging
Finally, always aware of its environmental responsibilities, the
HIS proposal for shipping the backplanes in re-useable, collapsible boxes avoided the use of expensive disposable packaging,
Each stage is verified as correct before the board is moved on
whilst also dramatically simplifying the handling of the product
within the cell. After pressing and before test and hardware as-
both at HIS and the Customer’s premises.
sembly, the orientation of all connectors is checked on a simple
This was not only a welcome cost-saving initiative, but the cus-
‘plug-on’ fixture.
tomer was sufficiently impressed to adopt the idea themselves for
Boards then move on to electrical test, which is simplified as far
the handling of their own PCB assemblies and metalwork.
as possible, using a purpose-made fixture that suits all assembly
In true harting style, the framework of the continuous improve-
styles. Four multi-connector plug-in cards are mounted horizon-
ment philosophy as part of The harting Way, ensures that HIS
tally, the backplane is easily located in a drop-down, hinged rear
constantly strive for better and more cost effective ways of
panel and locked in position as
responding to today’s ultra reactive market environment by
shown.
accommodating fluctuating demand curves, whilst ensuring
The cards are then plugged up,
complete compliance with the customers’ requirements and
the test programme run and the
specifications.
board is moved on to the final
stage of fitting hardware.
The fitting of the various hardware requirements is completed
using
automatic
dispensing
equipment, torque-set electrical screwdrivers and Poke-Yoke
fixtures that only allow the
right part to be fitted to the
Hardware fixture
52
Steve Richardson
Sales & Marketing Manager (HIS) HARTING
Integrated Solutions, HARTING Ltd. UK
[email protected]
Paul Atkinson
Manufacturing Manager (HIS)
HARTING Ltd. UK
[email protected]
right place.
S p e c i a l
t o p i c
TECHNOLOGY
Heinz-Wilhelm Meier
Applied Technologies – Projecting the Future
The term “Applied Technologies” stands for the company
The following examples provide an overview of how the techno-
in the harting Group that for years has worked directly on
logical basis is transformed into concrete solutions:
transforming what is technologically possible into products
delivering practical benefits and meeting customer requirements.
This is where technologies, in the sense of the practical application of knowledge, ability and skills, are harnessed to create
products and processes. Technologies assume concrete form as
actual products and create value.
The activities of harting Applied Technologies revolve around
engineering in the fields of tooling, special purpose machines
and assembly systems. This entails covering a wide range of
Fig. 1
technologies that meet the needs of today’s applications, while
also pointing the way to new, innovative applications.
Stepped insulating sleeve for high-frequency contacts. Outer diOn the one hand, the know-how acquired in theory and practical
mensions: Ø 1.1 / n 1.8 mm x 8.9 mm length. Parts weight: 20
operation in plastics processing (precision and micro injection
mg (Fig. 1).
molding), metal processing (precision stamping and die cast-
Demands made on the tool: minimized metering and miniature
ing), the necessary assembly, adjustment and inspection to suit
core for producing elongated bores with a diameter of 0.47 mm,
industrial demands and professional application of 3D CAD/CAM
with additional slide switch cross-slot cores that seal along the
systems is used to conduct the continuous, innovative, ongoing
elongated cores.
development of existing products and processes in the harting
Technology Group; on the other hand, this know-how opens up
completely new markets.
THE MICROTECHNOLOGY TREND
One of these markets is determined by rigorous miniaturization
in the field of mobile communication, medical technology and
automotive engineering. It is not enough simply to manufacture
microstructures of plastic and metal – they also have to be assembled industrially, meaning in an automated process. Today the
handling technology for microstructures or for the microsystem
technology necessary for this generally represents a weak link
Fig. 2
in the overall value chain. The manufacture of precision tools for
microstructures and assembly technology, however, are exactly
the core competence of harting Applied Technologies. Synchro-
Molded contact (Fig. 2) for high-performance connectors. Part
nizing the necessary and available technologies with the market’s
weight = 42 mg, plastic weight = 22 mg.
emerging applications and needs is the greatest challenge and
Demands made on the tool: minimized metering and sealing of
opportunity here.
round contacts.
53
Insulating carrier for connectors (Fig. 3). Dimensions: 13 x 7 mm,
Structural height = 1.1/1.6 mm, weight = 137 mg. The contact
cavities are set off and partially tapered.
The tool is designed for direct injection molding and does not
produce a protruding injection point.
Fig. 5 + 6
Handling technology (Fig. 7) for the automatic assembly of
micro-components (from the component parts to the complete
assembly).
The carrier covers are separated and the bridges are fed in
the form of a magazine tape to the assembly unit. This unit is
Fig. 3
equipped with an integrated bending tool. After they pass the
bending phase, the bridges are separated and mounted onto the
Carrier cover (Fig. 4) with intricate contours for electronic switch
carrier covers. In the final step, the machine ejects the finished
connectors. Parts weight = 20 mg. Dimensions: 6.7 mm x 2.4 mm
parts.
x 4.8 mm.
Demands on the tool: multiple slide-action tool for producing
cutouts and undercuts on the part.
Fig. 7
PERSPECTIVE
harting Applied Technologies is drawing on innovative power
precisely in this critical field of tension between the technically
feasible and the market’s future needs – to the benefit and profit
of the company’s customers. Against this background, the terms
tool and assembly system engineering open up a completely different perspective, pointing ways towards the future.
Fig. 4
Mold insert (Fig. 5 + 6) for an MID component with domes for
bores.
Die dimensions: wall thickness = 300 µm, structural width = 250
Heinz-Wilhelm Meier
Project Management / Marketing
HARTING Applied Technologies GmbH & Co. KG
[email protected]
µm, bore diameters = 100 µm.
54
S p e c i a l
t o p i c
FAIRS
HARTING Fair Attendances 2004
30.03. – 02.04.
USA, San Francisco, electronicaUSA
30.03. – 02.04.
Czech Republic, Prague, AMPER
19. – 24.04. Germany, Hanover, Hannover Messe
21. – 24.04.
Italy, Genova, Venditalia
29.04. Belgium, Leuven, M & R
04. – 06.05.
USA, Las Vegas, Electronic Distribution Show
11. – 14.05.
Germany, Hamburg, Windenergy
11. – 14.05.
18. – 22.05.
25. – 28.05.
Denmark, Odense, EL 2004
Brazil, São Paulo, Mecânica 2004
Russia, Moscow, Expo-Electronica
15. – 17.06.
Germany, Nuremberg, SMT
31.08. – 04.09. Switzerland, Basel, go. Automation days
01. – 02.09. USA, Boston, Arrow Fest
20. – 24.09.
Czech Republic, Brno, MSV Brno
21. – 24.09. Germany, Berlin, InnoTrans
21. – 23.09.
Norway, Oslo, e04
22. – 24.09. Spain, Zaragoza, Power Expo
01. – 02.10.
USA, San Jose, Arrow Fest
28. – 30.10. Brazil, São Paulo, Negócios nos Trilhos 2004
09. – 12.11. Germany, Munich, electronica
23. – 25.11.
Germany, Nuremberg, SPS/IPC/Drives
55
Austria
Germany
Russia
HARTING Ges. m. b. H.
Deutschstraße 3, A-1230 Wien
Phone +43 1 6162121, Fax +43 1 6162121-21
E-Mail: [email protected]
HARTING Deutschland GmbH & Co. KG
Postfach 2451, D-32381 Minden
Simeonscarré 1, D-32427 Minden
Phone +49 571 8896-0, Fax +49 571 8896-282
HARTING ZAO
ul. Tobolskaja 12, Saint Petersburg, 194044 Russia
Phone +7 812 3276477, Fax +7 812 3276478
Internet: www.HARTING.ru
Belgium
Great Britain
HARTING N.V./S.A.
Doornveld 8, B-1731 Zellik
Phone +32 2 4660190, Fax +32 2 4667855
HARTING Ltd.
Caswell Road, Brackmills Industrial Estate
GB-Northampton, NN4 7PW
Phone +44 1604 766686, 827500
Fax +44 1604 706777
Internet: www.HARTING.co.uk
Brazil
HARTING Ltda.
Av. Dr. Lino de Moraes Leme, 255
Pq. Jabaquara
CEP 04360-001 - São Paulo - SP - Brazil
Phone +55 11 5034-0073
Fax +55 11 5034-4743
HARTING (HK) Limited
Regional Office Asia Pacific
4208 Metroplaza Tower 1, 223 Hing Fong Road
Kwai Fong, N. T., Hong Kong
Phone +85 2 2423-7338, Fax +85 2 2480-4378
Italy
HARTING (HK) Limited
Shanghai Representative Office
Room 2302 Hong Kong Plaza South Tower
283 Huai Hai Road (M)
Shanghai 200021, China
Phone +86 21-6390-6935, 6390-6936
Fax +86 21-6390-6399
HARTING SpA
Via Dell‘ Industria 7, I-20090 Vimodrone (Milano)
Phone +39 02 250801, Fax +39 02 2650597
HARTING spol. s.r.o.
Mlynská 2, 16000 Praha 6
Phone +42 02 20380450
Fax +42 02 20380451
Internet: www.HARTING.cz
Finland
HARTING Oy
Hakamäenkuja 11 A, FIN-01510 Vantaa
Phone +35 8 9 350 87 300, Fax +35 8935087320
France
HARTING France
ZAC Paris Nord II, B.P. 60058
181, av. des Nations
F-95972 Roissy Charles de Gaulle Cédex
Phone +33 1 49383400, Fax +33 1 48632306
HARTING Singapore Pte Ltd.
No. 1 Coleman Street, #B1-21 The Adelphi
Singapore 179803
Phone +65 62255285, Fax +65 62259947
Spain
Hong Kong
China
Czech Republic
Singapore
Japan
HARTING K. K.
Yusen Shin-Yokohama 1 Chome Bldg., 2F
1-7-9, Shin-Yokohama, Kohoku-ku, Yokohama
222-0033 Japan
Phone +81 45 476 3456, Fax +81 45 476 3466
Internet: www.HARTING.co.jp
Korea
HARTING Korea Limited
14/F FKI Building, 28-1 Yodo-dong
Youngdungpo-Gu, Seoul 150-756, Korea
Phone +82 2-784-4614, 784-4615
Fax +82 2-3776-0070
Netherlands
HARTING B.V.
Larenweg 44, NL-5234 KA ‚s-Hertogenbosch
Postbus 3526, NL-5203 DM ‚s-Hertogenbosch
Phone +31 73 6410404, Fax +31 73 6440699
HARTING Iberia S.A.
,
Josep Tarradellas 20-30 4o 6a E-08029 Barcelona
Phone +34 933 638 475, Fax +34 934 199 585
Sweden
HARTING AB
Fagerstagatan 18 A, 5 tr., S-16353 Spånga
Phone +46 8 4457171, Fax +46 8 4457170
Switzerland
HARTING AG
Industriestrasse 26, CH-8604 Volketswil
Phone +41 19082060, Fax +41 19082069
Taiwan
HARTING R.O.C. Limited
Room 6, 10 Floor, No. 171
Sung-Te Road, Taipei, 110 Taiwan
Phone +886 2 2346-3177, Fax +886 2 2346-2690
USA
HARTING Inc. of North America
1370 Bowes Road, Elgin, Illinois 60123
Tel. 877 741-1500 (toll free)
Fax 866 278-0307 (Inside Sales)
Fax 847 717-9430 (Sales and Marketing)
Internet: www.HARTING-USA.com
Eastern Europe
Norway
HARTING A/S
Østensjøveien 36, N-0667 Oslo
Phone +47 22 700555, Fax +47 22 700570
HARTING Bauelemente GmbH
Vertrieb Osteuropa
Bamberger Straße 7, D-01187 Dresden
Phone +49 351 4361760, Fax +49 351 4361770
HARTING KGaA
Marienwerderstraße 3 | D-32339 Espelkamp
P.O. Box 11 33 | D-32325 Espelkamp
Phone +49 5772 47- 0 | Fax +49 5772 47- 400
E-Mail: [email protected] | Internet: www.HARTING.com

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