AUTOMATION & DRIVES
VOL 07 | AUG-SEP 2014 | ` 100 www.AandD24.in
A U T O M AT I O N & D R I V E S
Engineering design
AUG-SEP 2014 I VOLUME 07
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FOCUS Semiconductors & electronics A&D - Interview
P. 36, 42
ROUND-TABLE Ushering in the robo era
P. 30
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Managing Director, VDMA Robotics + Automation Association (p.24)
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The next big disruptive technology Robotics is said to be the next big disruptive technology in the manufacturing sector with increasing demand for both industrial and service robotics. Although automotive industry has emerged as the biggest customer for industrial robotics, there has been a growing demand for robots from sectors like electronics, machine tools, plastics, pharmaceuticals, food & beverage, etc. According to a recent market report, the global demand for industrial robots reached an all-time-high of about 1,68,000 units in 2013 and the global industrial robotics market revenues are expected to cross US$ 37 billion by 2018. According to industry experts, the basic reason for the continuous growth in the use of robotics is its continuous technological development in relation with market and industrial requirements, accounting for product quality and competitiveness as well as safe processes. Also, the software to work with and run robots and automation cells has developed rapidly over the last few years and the ease of use has transcended into more applications under a very demanding and dynamic manufacturing landscape. This has enabled manufacturers to provide products to the market quicker and with flexibility of variations to meet consumer demand and at the same time ensure the quality required and the performance demanded. Check out the Round-table feature in this issue that highlights the market dynamics, technology trends, innovations and new application areas in the global industrial robotics sector. Please do write to us with your feedback.
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editorial advisory board
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net
Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari President Honeywell India
Repeatibility <1µm Diameter, gap, width and position measurement
Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India
Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant
Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants
Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A&D India | Aug-Sep 2014
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www.micro-epsilon.in Phone contact: +91 20 2674 1009 Email: pragnesh.mori@micro-epsilon.de 3
8/18/2014 8:01:08 PM
CONTENTS
Market
Management
Focus
Semiconductors & Electronics 10 NEWS
24 “We are looking at professional
36 MEMS vibration monitoring
A read into the inertial MEMS technology which is ushering in a new era of vibration monitoring
service robotics”
Interview with Patrick Schwarzkopf, Managing Director, VDMA Robotics + Automation Association
18 “Creating trained resources across India”
Interview with Subash Nambiar, Country Manager, PTC
42 Semiconductor test system
An application story on how IDT lowered test cost by using NI semiconductor test system
ROUND-TABLE TRENDS 26
30
Strategic approach to global sourcing activities
An article on how TÜV SÜD Chemie Service ensures the implementation of quality-assurance measures for global sourcing
Ushering in the robo era
Industry experts in discussion on technology and market drivers in industrial robotics sector
Technology
EVENT REPORT 88
Creating information driven digital enterprises
Cover Story
A post-event report on ARC Advisory Group’s 12th India Forum
20 Enabling flexible design experience
The article focuses on the latest functionalities added in Synchronous Technology, ST7 – the latest version of Solid Edge
CONTROL & REGULATION 48
Open core engineering
The article on open core engineering that increases application flexibility and engineering efficiency across value chain
54
Evolution of switching interfaces The article details on ultra-slim relay interface modules that provide a low-cost, space-saving solution for a host of industrial applications
ULTRA FAST AUTOMATION 1μs RESPONSE TIME www.br-automation.com/reACTION Phone: +91-20-41478999
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Email: sales.in@br-automation.com
8/18/2014 8:52:26 PM
CONTENTS
Advt
Technology
WIRELESS AUTOMATION
58
Applying wireless to Ethernet/IP
76 FIELDBUS & NETWORKS
Remote eavesdropping
An article on the use of wireless technologies in Ethernet/IP based networks for industrial automation systems 66
Wireless technology for utility monitoring
An application story on how an American manufacturer of equipment for concrete pipe production added remote maintenance capability 80 M2M COMMUNICATION
Transforming industrial & energy systems with IoT
A feature on how wireless technology from Emerson helped Hindustan Zinc improve visibility in real-time
MOTORS & DRIVES
68
Out-of-the-box ideas
The article highlights on how Universal Robots aims to establish the flexibility of articulated-arm robots in industrial production 70
72 ROBOTICS & HANDLING
Designing cable management systems for 6-axis robots
An article on designing cable management systems for 6-axis robots
93
A feature highlighting the challenge in translating intelligence in connected embedded devices to new products
MACHINE VISION
83
Keys to successful multicore optimisation
A read into how to optimise machine vision application for multicore PCs through field-testing
Intuitive engineering
A read into how thermoforming machines can be equipped with efficient synchronous motors
New Products
86
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Revolutionary simple & ingeniously fast
Article on the new 3D vision automation for greater flexibility & higher productivity
OPC Unified Architecture for industry 4.0; Signal conditioners; Screw clamp fuse terminal blocks; Heady duty encoder Intelligent earth leakage relay; Data portal; Relay interface modules; Pressure transmitters & sensors made of titanium IT powered automation; Linear modules; Handheld barcode readers; Eddy-current measuring system
Columns
92 TECH TALK
Cable trolley solution
An insight into cable trolley system used to support, protect and manage flat & round cables for the transfer of electrical energy & data
07 08 96 96
Editorial Contents Highlights - Next issue Company index Advt
< Replaces dedicated hardware < Freely programmable < IEC 61131, Function Block Diagram < Reduces CPU load < Reduces machine cycle time
content page_Aug-Sep14.indd 7
reACTION TECHNOLOGY
Find out more.
8/19/2014 3:36:05 PM
market | news
Manufacturing PMI rises to 17-month high in July
Providing modern automation solutions for the Indian market
According to HSBC Purchasing Managers' Index (PMI), manufacturing activities in India in July 2014 was the maximum compared to the past 17 months on increased orders. PMI was up by 53 points in July 2014 from 51.5 in June 2014. As per Markit Economics, which co mpiles PMI data, output grew at the quickest rate in line with the headline indicator, in the past 17 months (since Feb 2013), marking a 9-month period of increased production. Among the monitored sub-sectors, makers of intermediate goods raised production at the sharpest pace. The eight core sector industries, which have a combined weight of 38% in the IIP, increased by a 9-month high of 7.7% in June 2014, signalling that IIP and manufacturing could see better recovery in the month.
SPS Automation India will take place on February 5–7, 2015, in Ahmedabad, Gujarat. The show will be organised by Messe Frankfurt Trade Fairs India. Focused on modern automation solutions for the Indian market, SPS Automation India will cover a wide range of topics from automation products to services and solutions, in The trade fair, will represent a leading order to meet India’s demands platform for advancements in automation as one of the fast growing and their cost optimising and latest automation markets in the technologies in factory and process world. The trade fair, will automation represent a leading platform for advancements in automation and their cost optimising and latest technologies in factory and process automation. Commenting on India’s high-growth path over the next decade, Raj Manek, MD, Messe Frankfurt Trade Fairs India, says “India, has established itself as an economic powerhouse and has the potential to become the world’s 5th largest consumer market by 2025.”
> MORE@CLICK ADI03514 | www.AandD24.in
> MORE@CLICK ADI03515 | www.AandD24.in
Siemens PLM software used at Toyota Toyota Motor Corporation has expanded its vehicle safety information management system based on Siemens’ Teamcenter® software. The system has been in use since January 2013 as part of a comprehensive initiative to produce safe vehicles for its customers. Teamcenter was selected based on its widespread usage throughout the global manufacturing industry. Market requirements regarding safety compliance for vehicles are The company’s successful deployment constantly increasing. In 2011, the of Teamcenter has allowed it to International Safety Organisation (ISO) enhance collaboration between published the ISO 26262 Functional multiple divisions and significantly Safety standard which defines functional improve traceability management safety for automotive equipment applicable throughout the lifecycle of all automotive electronic and electrical systems. In order to ensure compliance with ISO 26262, Toyota decided to implement a new safety information management system based on PLM that would standardise processes across multiple divisions. After evaluating several PLM software systems, Toyota selected Teamcenter. Toyota cited the widespread adoption of Teamcenter by the global manufacturing industry and Siemens’ open policy for PLM technology as important factors in its decision. > MORE@CLICK ADI03516 | www.AandD24.in
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Turck opens assembly line in Pune Turck India Automation recently inaugurated a new warehouse-cumassembly line at Hinjewadi industrial area and shifted to a new office at Baner – Balewadi Link Road, Pune. Announcing the new facility, Pradeep Arora, MD, Turck India, said, “The assembly line is a small start for Turck’s manufacturing footprint in India. This has been possible with the able support of our customers, vendors and the Turck officials announcing the channel partners”. He also launch of its India manufacturing thanked Ulrich Turck for showing operations confidence in Turck India operations. On the occasion, Ulrich Turck, MD, Hans Turck GmbH, shared the company’s technological vision for the growing needs of factory & process industrial automation. Turck said, “In the expansion mode, apart from sales, we have added expertise in terms of integrated solutions for customers; system integration together with hardware combination, including 3rd party products; and value added solutions on-site. We have also added sourcing of components from the Indian market. As India has a vast engineering talent pool, we are also planning to use India as an engineering pool for our activities.” > MORE@CLICK ADI03517 | www.AandD24.in
A&D India | Aug-Sep 2014
8/19/2014 3:39:10 PM
market | news
Bhadresh Dani Joins Bharat Bijlee
Fieldbus Foundation & HART Communication Foundation join hands
Bhadresh Dani has recently joined Bharat Bijlee as Vice President & Head – Drives & Automation Division. A Power Electronics Engineering graduate, he completed his management education from Henley Management School, UK and IIM - Ahmedabad as well as a leadership development program from the Scandinavian Management Institute, Denmark. Prior to joining Bharat Bijlee he was with Danfoss Bhadresh Dani, Vice President & Head Industries, and he brings with him – Drives & Automation Division domain expertise and rich experience to realise Bharat Bijlee’s ambitious growth strategies in the Drives and Automation segment. Bharat Bijlee is one of the leading professionally managed companies engaged in the manufacture & marketing of transformers, motors, pump sets, industrial electronics products, drives & automation and execution of turnkey electrical projects. The company's manufacturing facilities are located on a 1,93,000 sq m campus, with a working area of approximately 50,000 sq m, in Airoli (Navi Mumbai).
Fieldbus Foundation and the HART Communication Foundation join hands to create a new industry organisation dedicated to the needs of intelligent devices and their integration in the world of process automation. The combined power of both these organisations will serve to protect the investments that end users in process automation have made in HART® and Foundation fieldbus communication technologies. The mission of the combined organisation is to develop, manage, and promote global standards for integrating devices into automationsystem architectures, providing functional solutions for process automation suppliers and end users. Suppliers will also profit from the increased efficiencies in resource utilisation, procedure consistency and member service and support improvements. These two organisations will continue to exist individually, and evolve into the future. Each protocol will retain its own brand name, trademarks, patents, and copyrights. The new organisation will continue development, support, and promotion of the two existing protocols, and will direct the development, incorporation, and implementation of new and overlapping technologies.
> MORE@CLICK ADI03518 | www.AandD24.in
> MORE@CLICK ADI03519 | www.AandD24.in
Republic of Rwanda – the partner country for AUTOMATION-2014 IED Communications Ltd in its continual endeavour of promoting Indian East Africa, ranked 3rd in African countries as per the Global Competitive Index Report 2013-2014. In Rwanda, new special automation industry on the global platform, has now economic zone has been developed and operational. reached African countries. Republic of Rwanda, one of More zones are planned on the districts level. Rwanda’s the rapidly growing countries on economical and workforce has demonstrated increasing capacity for infrastructural levels is the partner country for knowledge-based industry. “The Govt of Rwanda is very AUTOMATION-2014 exhibition. The 9th edition of AUTOMATION-2014 will be held on 15-18 October 2014 investor-friendly and committed to market the economy, at the Bombay Exhibition Centre, Mumbai. Other African which is very inspiring for Indian industry and especially developing countries are also expected to come on the for the automation industry. Indian industry should grab board as bilateral partner countries for the event. The the potential opportunities for investment abound, Govt of Rwanda and other African countries will have a particularly in the sectors such infrastructure, energy, strong presence at the event with participation from the information and communication technology, mining, Govt representatives and business delegations. “We are M Arokiaswamy, MD, IED manufacturing, real estate and construction & financial proud to serve Indian industry for its economical growth Communications suggests that services & agriculture,” added Arokiaswamy. through business development on the platform of India should grab the potential AUTOMATION-2014 will also be organising knowledgeAUTOMATION-2014”, said M Arokiaswamy, MD, IED opportunities for investments based technical conferences, in-depth discussion with abound Communications. experts on various subjects like innovations in Republic of Rwanda is an attractive destination for technology, Foundation Fieldbus technology, safety and foreign investments. There is a great opportunity for Indian industry to security, tank automation & metering. > MORE@CLICK ADI03520 | www.AandD24.in develop business in Rwanda, the most competitive place to do business in
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Shaping the future of embedded design
MathWorks conducts MATLAB EXPO 2014
National Instruments recently announced NI SOM, the first global product Mathworks recently conducted MATLAB EXPO — the 5th edition of its launch from India, with the company introducing a major transformation in annual user conference in Bengaluru and Pune to cater to a growing embedded technology for the world at Chennai. It combines the Xilinx Zynq customer base in the country. The two-city event welcomed more than All Programmable system on a chip (SoC) with supporting components such 1000 participants from the commercial, as memory on a small PCB and features a complete middleware solution government and academia sectors. and ready-to-go Linux-based real-time operating system (RTOS) already Design engineers, professors and integrated. With this industry experts were in attendance from launch, it is paving across the aerospace & defense, the way for its automotive, computers, electronics and e m b e d d e d semiconductors, industrial automation technology to be a and machinery and technology services game changer for industries. Jason Ghidella, Product The two-city event welcomed With this launch, it is paving the way for its embedded the future. “The NI Manager — Simulink platform & controls, more than 1000 participants from technology to be a game changer for the future System on Module MathWorks, delivered the keynote the commercial, government and (SOM), combined address titled ‘Behind today’s trends: The academia sectors with powerful LabVIEW libraries, enables engineers to transform their ideas technologies driving change.’ The into embedded products faster than any other tool available on the market. highlights of the two-city event included Simulink and LEGO MINDSTORMS Healthcare devices, smart machines and other applications that require NXT workshops that demonstrated the potential for project-based learning embedded technology will benefit as the NI SOM not only speeds up, but techniques while teaching undergraduate technical courses. Participants also bridges design, prototyping and deployment with a single platform,” worked through lab modules with examples of sound tone control, linesays Joel Shapiro, Leader for Marketing, Emerging Markets Region. following robots. > MORE@CLICK ADI03521 | www.AandD24.in
> MORE@CLICK ADI03522 | www.AandD24.in
Frost & Sullivan to host a forum on enhancing manufacturing competitiveness Frost & Sullivan’s Industrial Automation & Process Control (IPC) Practice tracked the manufacturing sector in India for more than a decade, Frost & will host Industrial Technologies summit 2014 Sullivan is confident that the current slowdown titled, “Enhancing manufacturing in the Indian manufacturing sector is a competitiveness: Reality of adopting global temporary phenomenon. India has the trends and technologies in the Indian context”, potential to be a manufacturing powerhouse on October 8, 2014, in Mumbai. The summit of the world”, says Niju V, Director, Automation will highlight the mega trends in the Indian & Electronics, Frost & Sullivan. He further manufacturing industry and the evolving adds “Advanced automation and control imperatives that enable companies capitalise solutions are expected to play an important on short term growth opportunities. The part in this transition.”Apart from knowledge summit will focus on sharing best practices gathering on future prospects for the market and ideas on how to leverage innovative and evolving dynamics, the event is poised to technologies and best-in-class solutions as a facilitate business interactions that can evolve resource to address the evolving challenges Representational image from the last edition of enhancing into long term rewarding relationships. for a better tomorrow. It will examine the manufacturing competitiveness event hosted by F&S Participants would benefit from insightful and reality of adopting global technologies and strategic discussions involving industry following international trends in the unique context of India. Success stories experts and the opportunity to meet and network with peers and potential will be showcased and key challenges will be examined with respect to customers. The event will also have an awards evening and witness the implementing state-of-the-art technologies and solutions. It will bring coronation of the industry's best-in-class companies at the Excellence in together solution providers and solution adopters in a true meeting of Industrial Technologies Awards, India banquet. minds, to collectively deliberate on the key steps to be taken to catapult the > MORE@CLICK ADI03523 | www.AandD24.in process, discrete, and batch industries into a new growth era. “Having
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8/19/2014 3:39:15 PM
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“Creating trained resources across India” Subhash Nambiar, Country Manager, PTC, discusses Indian manufacturing industry and how companies are looking at creating and delivering smart, connected products to their customers, during an interview with Srimoyee Lahiri. Excerpts… How crucial is the Indian market for PTC? University Academy program supports this initiative and many India is a very important market for PTC. We offer products customers are enjoying the benefit of the product through this in CAD, Application Life Cycle Management (ALM), Service knowledge. Lifecycle Management (SLM), and Product Lifecycle Management (PLM) and now, we also have a platform for As the new leader at PTC India, what are your strategies to Internet of Things (IoT) to meet customer expectations. We enhance performance during this fiscal year? have customers in India who have invested in our flagship 3D I am excited to join PTC which owns a long history of product and Pro E for the past 20 years. Like any other industry, technology innovations and is the leader in technology manufacturing industry, particularly automobile, faces a lot of solutions that transform the way companies create and service competition from both domestic and international companies. products. India is one of the fastest growing markets in the Most of the companies look at reducing their manufacturing world with a significant customer base for us. As a strategy, we cost and India is no different. In the last three decades, we have always looked at changing environment and industry needs grown from a CAD company to a software and offered products and services to help our product and service solution provider for customers achieve competitive advantage. manufacturing companies. Many Indian The company has pursued an aggressive companies are using our products for meeting strategy of acquisitions and rapid organic their industry transformation. development to expand its offerings into fastgrowing markets. We currently have huge What are your views on cloud computing in focus on creating well-trained resources CAD space? across India. There are mixed responses from the customers on cloud computing due to What are the latest technology & demand security, bandwidth, uptime, dependency, trends in your domain? etc. At present, based on the customer Indian manufacturing industry contributes requirements, we have been offering Creo more than 50% of export revenue and is software in CAD space on our perpetual 15% of India’s GDP. All the manufacturing license model. If customers are looking at a companies are looking at how they can managed service, we are in a position to offer them a private create smart, connected products. In the IoT era, customers are instance model, offering a better performance and uptime at a bringing to market increasingly smart and connected products lower cost compared to the customer hosting the solution in which can generate value in new ways as streams of real-time their infrastructure. operational data are captured, analysed, and shared to deepen a company’s understanding of its products’ performance, use, How is PTC pursuing its service strategies in India? and reliability. We have been encouraging our partners to imbibe enterprise Acquiring ThingWorx will allow us to accelerate and help consulting using our service advantage program to drive value our customers capitalise on the market opportunity that the based selling to enterprises. The customer gets a complete IoT presents. The opportunity, however, goes well beyond this solution either directly from PTC or through partners immediate pragmatic application. Industries of all types are from consulting, product positioning, implementing and poised to see disruption from the Internet of Things and the getting the solution advantage - meeting/exceeding customer expanding networks of connected sensors and devices, and expectations. a growing ecosystem of ThingWorx partners is forming to Apart from consulting and implementation, we also capitalise on this growth. ☐ provide high-end training to adopt our e-learning tools > MORE@CLICK ADI03524 | www.AandD24.in supported by trainers in precision learning programs. Our
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c o v e r s to r y | t e c h n o l o g y
Engineering design
Enabling flexible design experience
For manufacturers to realise more profitable innovation, they need to consider opportunities to optimise & accelerate designs, improve validation earlier in the development process, enable faster product to market, reuse 2D & 3D at maximum, and improve visibility to program execution and risk management. Siemens PLM Softwareâ&#x20AC;&#x2122;s Solid Edge has been able to address these needs, and ST7 - the latest version of Solid Edge with Synchronous Technology brings in breakthrough innovations in this area. 20
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
A&D India | Aug-Sep 2014
8/18/2014 6:58:59 PM
t e c h n o l o g y | c o v e r s to r y
Blank body functionality
Manufacturers have to rely on a combination of design innovation, more electronics and embedded software content to meet the demands of the marketplace, today. They are also required to demonstrate and provide increased responsibility for the design, development, prototyping and final production of parts. Siemens PLM Software was able to respond to these challenges with Solid Edge, a hybrid 2D/3D CAD system that uses Synchronous Technology (ST) for accelerated design, faster revisions and better re-use of imported geometry to help companies design better. Packed with over 1,300 userrequested enhancements, the latest version of Solid Edge – ST7 has grabbed the attention of its existing as well as new adopters worldwide. With its remarkable attention to detail, newlyadded functionalities and ease of use, ST7 was introduced in May, this year during the Solid Edge University 2014. Based on four major pillars of development – accelerated 3D modeling, streamlining design management, powering up with new apps and amazing user experience – ST7 features some standout enhancements such as patent pending duplicate components command, blank from a 3D model, powerful photorealistic rendering using KeyShot®, and enhanced Microsoft Surface Pro functions, among many others. Dan Staples, Vice President, Solid Edge Product Development, Siemens PLM Software, while focusing on the product development strategy behind the new upgrade, asserted, “The key thing in development is to ensure that with every function added, complexity is kept to the minimum. There is saying, if I had more time, I would have written less. Similar is the trend in user-based design. It is very easy to cover everybody’s needs, but to do that elegantly where it is simple to use, and caters to everybody’s requirements is quite hard. But we have successfully achieved this in ST7.”
Enhancing users’ experience A great deal of attention in ST7 has been applied to streamlining the interface and trimming areas of the workflow
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that were possibly unnecessary or redundant. This was the principle applied when Dynamic Dimensions were added. This allows users to key in dimensions as they sketch without stopping to click an icon. In the case of a rectangle, users can apply multiple dimensions, just by using Tab to move between fields. If they don’t want to use the Dynamic Dimensions, one can ignore them without the need for extra steps (or turn them off altogether). Part of focusing on the user is certainly making the interface more intuitive with more “heads-up” functions. Heads-up interface elements have enabled the user to keep focus on the work area while helpful cursor symbols or other visual feedback help to indicate items such as selections or automatic sketch relations. One of the new enhancements where this is most evident is in the Quick View Cube, displayed in the lower right corner. One can select from dozens of view orientations directly from the cube. Select a corner for an isometric, or a face for a primary named view. Rotate with the arrows. New document templates have been organised by drafting standard as well as units, and document type (part, assembly, draft, sheet metal). Using units in this way is new, and enables users to have templates set up in various units for different purposes rather than needing to do this at the time of creation. During installation of the Solid Edge software, templates are created and saved based on the language specified in a user’s Operating System, and all templates for all standards are saved for later access. This allows multinational companies to easily work with multiple standards. Along with the new startup screen comes a new File Open. Solid Edge has implemented the Microsoft File Open standard interface. This allows the user to reuse knowledge from other Office applications such as Word, Excel, or PowerPoint, also enabling tasks such as copy/paste, delete, rename, sorting, and previews. Providing a consistent experience across the entire technical computing environment leverages shared skills and saves time.
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c o v e r s to r y | t e c h n o l o g y
Users can publish their designs to GrabCAD Workbench for collaboration with team members, suppliers and customers
Drawing views of parts and subassemblies coexist with views of the top level product
ST7’s user experience features an intuitive user interface which informs users’ work
Tool tips have been enhanced to include short video clips for simple actions. This is not only good for users migrating from other CAD packages, but has been singled out by CAD managers of larger organisations as being helpful in training and in reducing support inquiries.
allows users to continue to work that way. But in ST7, users can now fence-select objects, and then select the sketch relation which they want to apply. This is essentially Object-Action. What’s new here is the ability to do it either way. If a user has different types of geometry selected, for example, lines and circles, Solid Edge automatically filters the entities for valid types (for example, circles cannot be made parallel). Accelerated 3D modeling 3D sketch is a new function, and is available for all types of First things first. In most cases, designers start off by entities. This used to be only available for pipe/wiring functions. applying/choosing a relevant material for a part. ST7 has Making this available for general modeling (consistent in Part, brought big changes to material tables. Users can now group Sheet Metal & Assembly environments), most specifically materials, Table Primitives select them from a visual interface. wireformed products, will be a big time saver. Material data can be imported from sources such as Matlab. 3D measure tool: A new and comprehensive 3D Measure tool com using an Excel file. Materials include mechanical and is also part of ST7. The results of 3D Measure are visual, and visual properties that are reused downstream by mass the window stays available until the user dismisses it. The text calculations, stress analysis and even rendering applications. from the results can be copied to be used in other dialog boxes or dimension entry boxes, which will save a great amount of time. Quick Shapes / Primitives Sheet metal: In ST7, sheet metal has got a fair bit of attention. Quick Shapes are a set of primitives for box, cylinder and The “part to sheet metal” enhancement, which enables to wrap sphere. For example, to create a sphere in ST6, one would have a sheet metal part around (outside or inside) a solid body, is a to sketch a semi-circle on a plane and revolve it. In ST7, users remarkable feature. In fact, in one example, creating a particular can click a keypoint or any point on a plane and drag a radius. sheet metal part has been found to be 5X faster than doing so According to Dan Staples, this results in four times fewer in previous versions. clicks. Blank body: Also noteworthy is the Blank Body functionality, which flattens a punched, drawn or formed sheet metal shape. This tool can also be used on lofted shapes, for example, on a Intelligent relationship filters fabric seat cover. This tool replaces separate third-party Another ease of use enhancement aimed at easing migration software that would cost thousands on its own. from other CAD systems comes in the sketch environment. In Standards-based holes: One of the most exciting of the ST6 and prior, to assign sketch relations to multiple sketch revamped Solid Edge ST7 tools is the Holes tool. In the past, a elements, a user would have to click on each element user would need to have their Machinery’s Handbook available individually, and use the Action-Object workflow. There was to reference hole sizes for particular bolts correctly, ST7, nothing wrong with working that approach, so Solid Edge however, incorporates all of this information in an editable
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t e c h n o l o g y | c o v e r s to r y
3D Sketch provides the users a fast creation method for components bent in more than one plane
Streamlined, graphical and intuitive design management bought to you by Solid Edge SP
database, and enables one to select hole sizes based on screw size. Users can also specify edge breaks and bolt head clearance. This is a big step forward in automating machine design parts. Comprehensive material definition: A more intuitive, visual interface for storing, categorising and applying material specifications is also available with ST7. The interface has enhanced material appearance preview capabilities and users can add their own properties. Material information can be imported from external sources and stored in multiple libraries to support the needs of different departments. Duplicate component tool: This functionality is “Patent Pending”. Turning to assemblies, a duplicate component tool has been added to ST7. This is like a pattern, but it works where there are no identifiable regular patterns. For example, if there is a set of parts that fit into every bracket in the assembly, Duplicate Component will take the original set of parts and duplicate them in every situation where it finds that bracket, orienting the parts to match the original occurrence. Early trials found this to be 10X faster than doing the work manually, and results in fewer assembly relations. ST7’s new ability to rename a family of assembly (FOA) member is another enhancement that’s sure to be a huge time saver. In draft enhancements, the automatic placement and arrangement of coordinate dimensions on parts is a new tool. For this, the amount of time saved is a function of how many dimensions of this type are used. This new function actually makes coordinate dimensions feasible. Enhanced Microsoft Surface Pro support & Keyshot: The Microsoft Surface Pro offers full support for Solid Edge design tasks and expanded support for finger gestures is now included. For example, a single finger drag enables a pan operation in 2D and a rotate operation in 3D, and a two finger pinch enables a zoom-in operation. ST7 also features a significant inclusion of Luxion’s Keyshot software available with Solid Edge Keyshot
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Material selection is made easy with an intuitive interface presenting multiple libraries utilised by different departments
Classic and Premium versions. A single click will take a Solid Edge model with its visual properties into the Keyshot environment. The Live Link function enables updates to the Keyshot geometry directly in Solid Edge, so users never have to start over again after re-importing. Improved productivity for working with massive assemblies: Users now have more control over the extent to which an assembly is recomputed during open and save operations using the Limited Update option. This option speeds response times when working with large assemblies. Users can also check for out-of-date components within an assembly and update & save them using the Component Tracker command. Users can also insert reference assemblies from a higher level of the assembly into the current level, enabling this data to be used as part of the design process while maintaining correct bill of materials (BOM) generation. They can also designate assemblies as simplified assemblies that are treated as leaf parts and are not automatically expanded. This improves performance when working with large assemblies, while users can still expand these assemblies as needed.
ST in the future? With patent pending innovations & breakthrough tools already included in the ST7, what should users expect in ST8 next year? Answering this, Staples affirmed, “Some years ago, we saw traction in direct modeling in ST, but then it was just not adequate. We thought that direct modeling needed to be addressed in a completely new way and we have been successful in achieving it. We think there is a lot more potential in ST in the future and we will continue to explore it in unique ways for all industry models.” ☐ > MORE@CLICK ADI03525 | www.AandD24.in
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management | interview
â&#x20AC;&#x153;We are looking at professional service roboticsâ&#x20AC;? Patrick Schwarzkopf is the new Managing Director of VDMA Robotics + Automation Association, which has nearly 250 member companies. In this exclusive interview with Megha Roy, he stresses on the growth prospects in the industry, foreign markets focus and development opportunities for newer applications What are the recent developments in VDMA Robotics + exports. Naturally, we are supporting our member companies Automation in terms of new managing board, new initiatives, in becoming more global through our VDMA representative international activities, global strategies, standardisation offices in India. plans, etc? This year, we focused on the AUTOMATICA Fair in Munich, How do you look at the performance of the robotics & which presented the latest trends in robotics and automation. automation sector, in Europe as well as globally? How are The latest development is the direct cooperation between the the growth prospects in 2014? industrial robot and the human worker. VDMA Robotics + The robotics and automation sector has been receiving a lot of Automation has published a position paper that helps users attention recently. The European Commission has just launched ensure that such solutions are absolutely safe. Another topic SPARC, the worldâ&#x20AC;&#x2122;s largest civilian research programme for that is high on our agenda is sustainability. We provide many robotics. AUTOMATICA 2014, the leading trade show of the solutions for increased safety, the more economical use sector, concluded with record results. There is great demand for of material and saving energy. We are also looking at new robotics and automation technology from high-wage as well as application areas, such as professional service robotics. The low-wage regions across the world. Therefore, we expect the robotics and automation sector is also expanding exports global turnover of the German robotics and automation sector every year. Currently, some 55% of business is made through to grow by 7% in 2014.
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i n t e r v IE w | m a n a g e m e n t
“Industry 4.0 will be the next leap development that will bring a paradigm change” Patrick Schwarzkopf
Besides automotive industry, what are the other major industries being targeted globally? Do you plan to come up with any new application in the near future? For robotics and assembly technology, automotive industry accounts for some two third of sales. For machine vision, the situation is much more diversified, with approximately one quarter of turnover going to automotive. Electronics is a major application field. We believe there is a big growth potential in the food and pharmaceutical industries. In machine vision applications “outside the factory” are the big growth drivers, such as intelligent traffic systems, surveillance or precision farming. How do you look at the business potential in India for the robotics & automation sector? Any new initiatives/activities planned from VDMA India office? The technology is indispensable for many products that are miniaturised, safety-critical and of particularly high quality. If an economy wishes to play a major role in the high-tech segment, it needs to apply robotics and automation in production. Currently, the so-called robot density (the number of industrial robots applied per 10,000 employees in the manufacturing sector) is still very low in India. Thus, there is still a very big potential which will gradually be tapped over the coming years with time. In the meantime, we will monitor the Indian market, provide information services and organise a management meeting later this year. What are the technological breakthroughs expected in the robotics & automation sector in the coming years, for example, Industry 4.0, Big Data, Cloud Computing, Digital factory, human-robot collaboration, etc? Industry 4.0 will be the next leap development that will bring a paradigm change: If production systems are currently centrally controlled; in the new scenario, the workpieces will find their
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way through production and will book certain “services”, e.g. robot. The devices will communicate with each other, everything will be a network, all players uniquely addressed (e.g. with an own IP address) and the production will become much more flexible and efficient. This integration will pave the way for new business models, in which the customer’s order will trigger the manufacturing of an individualised product that need not be more expensive than today’s mass produced off-the-shelf item. Robots will come out of their protection cages and will collaborate directly with human workers. Each side will focus on their specific strengths and the outcome will be increased productivity. To reach this goal, the robots must be made safe to work with in a shared work space. Our members are developing the necessary solutions. According to you, where will be the focus of technical developments for the next few years? The application of robotics and automation will be made a lot easier and more intuitive. The result of it will look simple, but the technology behind it is complex. This requires new ways of communication and collaboration between humans and machines through gestures or speech recognition. How important is the networking of different areas of industry as well as different countries so as to make a globalised technology approach? To employ robotics and automation to the benefit of the companies, the workers and the customers, a thorough knowledge is needed on the technology, specific market requirements, skills of the workers and many more factors. Those who are good communicators and networkers and those who share knowledge will be taking the lead and producing the best solutions. ☐ > MORE@CLICK ADI03526 | www.AandD24.in
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market | trends
Strategic approach to global sourcing activities For global sourcing in the chemical and process industries, quality assurance schemes embracing the whole supply chain are imperative. This article highlights how TÜV SÜD Chemie Service points out such weaknesses and ensures the implementation of quality-assurance measures. Kurt Schumacher Global sourcing expert & Member of Managing Board TÜV SÜD Chemie Service GmbH kurt.schumacher@tuev-sued.de
For companies in the chemical and process industries, reducing the cost of materials is one of the essential strategies to stay competitive. Known as ‘global sourcing’, medium-sized enterprises are increasingly joining large multinationals in engaging in procurement management at international level, to identify lower-cost sources. The construction of world-scale plants, for example, is moving over to emerging markets, a trend accompanied by increasingly networked international supply chains. Manufacturers purchase plant components – including process-engineering equipment and pressure vessels for the European market – at attractive prices in, say, India. Conversely, complex high-tech equipment such as processengineering devices made of special materials or processcontrol systems are imported to the Asian market from countries such as Germany. While the share of third-party costs in revenue has been rising for years and numerous studies have raised awareness of sustainable purchasing, practice shows that there is a common trend towards “Best cost sourcing”, which can involve
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considerable risk factors. Globally sourced products do not always reliably fulfil the relevant legal, regulatory and standard requirements in the country of destination. Ultimately, quality or delivery issues may use up the forecast savings. When quality-assurance aspects are not examined individually and in detail but only across the board, opportunities and risks may become distorted. A one-sided focus on purchasing prices may consequently become expensive; all the more if extensive rework becomes necessary in a country with high labour costs before a plant or piece of equipment can be placed into service.
Approaches Against this backdrop, a more strategic approach to global sourcing activities by purchasing departments makes good sense. Such an approach must include all relevant types of costs, e.g. investment costs, life cycle costs and total cost of ownership, in the purchase decision. To do so successfully,
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COMPETENCE IN COMMUNICATION
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market | trends
A systematic and complete purchasing strategy that extends along the entire supply chain is of critical importance
quality assurance along the supply chain must cover the entire manufacturing process up to shipping from the country of manufacture. The devil is frequently in the detail when problems arise later on. In these cases, statutory and singular tests will not be enough to identify and eliminate critical issues before they turn into problems. Furthermore, many purchasing experts underestimate supply chain dynamism, which renders adequate process design next to impossible without in-depth familiarity with the local market situation in the country of origin. Given this, a systematic and complete purchasing strategy that extends along the entire supply chain is of critical importance. This strategy must consider economic and technical aspects, but also supplier relationship management, including monitoring of production conditions. First and foremost, this means thorough selection and evaluation of manufacturers, watertight specification of product characteristics and differentiated control of implementation.
End-to-end quality management The central element of an optimised procurement strategy is quality assurance that primarily aims at ensuring that the design of the purchased systems or components is in conformity with the rules. Project specifications, too, must be comprehensively clarified to ensure end-to-end quality management. This includes, for example, the traceability of materials and the completeness of the required documents such as drawings, plans and documentation. At what point does TÜV SÜD Chemie Service support global sourcing? Originating from the former user inspectorates
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Success factors in global sourcing • Systematic and complete overall strategy • Individual opportunities and risks analysis, cost-effectiveness, empirical values • Comprehensive project specifications (design, materials, manufacturing, testing, quality assurance, documentation) • Manufacturer selection and evaluation • On-site quality assurance (in-line and pre-shipment inspections) • Familiarity with the local situation (language, culture) • Flexibility in supplier management (high dynamism in some supplier countries)
of Bayer, Dow Olefinverbund and Hoechst, the specialists are on-site at all major chemical and industrial centres in Germany and accompany their clients to international markets, expanding their worldwide presence. This ultimately created the Team of Global Networking, a group of specialists dedicated to intensive exchange of know-how and experience. To ensure that the materials used will also meet the ambitious requirements, the experts combine conventional and innovative non-destructive testing procedures. Based on decades of experience in the chemical and process industries, the experts have adopted the indispensable high level of quality as a core value, supporting purchase decisions in global sourcing to ensure far-sighted planning and keep the risk of service interruption to a minimum. ☐ > MORE@CLICK ADI03527 | www.AandD24.in
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m a n a g e m e n t | r o u n d - ta b l e
USHERING IN THE ROBO ERA With the number of robots in the world crossing well-over 1,000,000 mark, this feature aims at analysing the various technology & market trends emerging in industrial robotics while assessing the key challenges the industry is facing globally As per a recent report by International Federation of Robotics (IFR), in 2013, about 1,79,000 industrial robots were sold worldwide, an all-time high and 12% more than in 2012. Robot sales have reached record levels in Asia/Australia, Americas and Africa. Almost 1,00,000 new robots were installed in 2013 in Asia/Australia, 18% more than in 2012. The European market also increased by 5% to more than 43,000 units almost reaching the all-time-high of 2011. With this in the backdrop, A&D India analyses the views of industrial robotics experts – Arturo Baroncelli, President, IFR; Rajesh Nath, Managing Director, VDMA India; Sunil Raibagi, Managing Director, GÜDEL India; and Raj Singh Rathee, Managing Director, KUKA Robotics India – to gauge the
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
emerging technologies, market drivers and understand the issues faced by manufacturers in this industry.
Market drivers The use of industrial robots has increased steadily in the recent years. In the past, industrial robots were used almost exclusively in the automotive sector and in series production. Rathee notes, “The continuous on-going development of robot and control technology has enabled robotics to establish itself across a broad spectrum of different markets in sectors outside the automotive industry. In the general industry, the primary objective of development work is to tap into new markets,
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m a n a g e m e n t | rou n d - ta b l e
particularly in the fields of foodstuffs, plastics, metalworking, foundry, electronics, medical technology and the entertainment industry.” As per Nath, “Automotive and metal industries are the main drivers of growth in industrial robotics. The automotive industry increased robot investments continuously and considerably between 2010 and 2013, by 22% on average per year. The main countries involved were China, Germany and the United States. In 2013, robot sales to the automotive industry increased by 5%. Also, the metal and machinery industry had an average annual growth rate of 22% in the same period. In 2013, robot sales to this industry were up by 17%. The food industry as well as the pharmaceutical industry increased robot investments substantially in 2013. The electrical/electronics industry - which had reached a peak level in 2013 - increased robot orders by 9% in 2014.” Quoting statistics, Nath adds, “The trend towards automation fuels further growth in robotics. The main drivers of automation are energy-efficiency and new materials, e.g. carbon-composites, requiring new productions; global competiveness requiring increased productivity and higher quality; growing consumer markets requiring expansion of production capacities; decreasing life-cycles of products and increasing variety of products requiring flexible automation; and robots improving the quality of work by taking over dangerous, tedious and dirty jobs that are not possible or safe for humans to perform.” Sharing a similar thought, Baroncelli points out, “The incentives to automate are forcing manufacturing industries worldwide to improve their production processes continuously to be competitive in a global market. This is true for traditional, emerging markets and low-wage countries. The demand for consumer goods is increasing especially in the emerging markets; and the life-cycles of many of these products are decreasing.”
Demand trends With huge demand for industrial robotics, let’s analyse the latest demand trends in articulated robots, SCARA(Selective Complaince Assemby Robot Arm) robots and gantry robots. Nath elaborates, “The global SCARA robot market is expected to witness moderate growth during the period 2013-2018 at a
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CAGR of 4.38%. One of the major drivers in this market is the increased automation across industries. The growing need to reduce human effort and errors in the production process has led to the adoption of SCARA robots across industries. In many industries, workers performing repetitive tasks cause errors in the production process. However, the adoption of SCARA robots that can perform repetitive tasks with unmatched efficiency can lead to a drastic reduction in production errors. Another major growth driver is the low maintenance cost of SCARA robots.” As per a recent study, the global SCARA robot market is witnessing an increase in the adoption of articulated robots as a substitute for SCARA robots. Nath stresses, “The market is witnessing the replacement of SCARA robots with articulated robots in the automotive industry. Further, the integration of artificial intelligence with articulated robots has led to the high demand for such robots globally.” With the demands growing for all kind of robots, Raibagi highlights, “As we manufacture more gantry robots, we are seeing that articulated robots are mounted on gantry systems to increase work envelope and reach. These combi robots are giving lot of application functionality and reduce overall costs.” Increasing demand for robots with higher speed and advanced vision system for pick & place applications has also been seen in the food and pharmaceutical industries. Identifying major demand trends in such sectors, Baroncelli states, “Increasing demand for robots used in hygienic areas such as in the food and pharmaceutical industries; in the assembly of cars; increase of multi-axis-robots, i.e. robot arms with 7, 8 axis instead of 6 for better maneuverability; increase of riveting technology in the automotive industry; increase of welding for high tension and zinc coated material, because the automotive customers try to use lightweight and rust proof material, among others, have emerged.”
Emerging technology trends The new industries are built around areas of robotic automation cells. Due to this, there are new requirements for the development of robots and industrial production benefits
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rou n d - ta b l e | m a n a g e m e n t
“The biggest challenge today is the possibility that human operators and robots cooperate” Arturo Baroncelli, President, IFR
“Automotive & metal industries are the main drivers of growth in industrial robotics”
Rajesh Nath, Managing Director, VDMA
from these recent technological trends in robotics. Raibagi use of robots. Therefore, emerging technologies are in general explains, “Robots, and even the control units, become smaller oriented towards this issue: capability of robots to react to and more compact. That minimises the required floor space unexpected collisions, definition of interference regions where and offers opportunities to integrate more robots and increase robots can choose automatically max kinematical parameters, the productivity.” sensors to detect the presence of operators and so on.” Multi-functional robots and combi robots can take over With multiple evolving technologies, which influencers are additional tasks which are needed for a complete robot-based affecting the innovation roadmap of industrial robotic automation solution, such as process control, motion control technologies? Answering this, Baroncelli elaborates, “Software of additional axis, NC-motion, logic control, safety control. and man-machine interface, besides being a key part of a robot, Integrated solutions reduce investment costs, reduce the are obviously influenced by key trends in information communication effort between the different components, lead technology. Main issues in this perspective are: more intuitive to an improved process quality (since motion and process programming, easier operator interface, interaction with smart control are optimally synchronised), and facilitate configuration devices, image recognition. Anyway, when applications of such and diagnosis since the operator has only one user-interface. general trends are to be when applied to industrial robotics, Identifying key innovation drivers like fast performance very specific issues are to be considered: safety and reliability.” growth, alterations in classical fields and enhanced product diversity combined with reduced product life cycles manifest Challenges themselves in specific innovation trends, Nath elaborates, The global trend towards adoption of robotic automation is “Some major trends in industrial robotics are increased adaptability of robot cells and robot periphery; vanishing increasing in India, but is still in early stages. Nath explains, boarders between simulation and reality; smart robot “Automation still being in its infancy in several sectors is a controllers; advanced Human Machine Interfaces (HMI); reflection of being in the ‘low value-addition’ zone. India is redundant kinematics and cooperative robots; advanced sensor required to leap-frog to ‘higher value-addition’ manufacturing performance and sensor fusion; energy efficiency; service processes. The real drive for automation started only in 1997 robotics becoming innovation motor for industrial robotics and India is lagging behind in comparison to the world growth in automation sector. The factors affecting automation sector and human robot collaboration.” Commenting on the future technology developments, in India is the political scenario, the economy conditions Rathee says, “Technological trends, such as robot-robot prevailing and the social & technological challenges.” As per cooperation, human-machine cooperation, production Baroncelli, “The biggest challenge today is the possibility that assistants or modular, interactive robot generations, will all human operators and robots cooperate. Traditionally industrial serve to secure the market of the future. Cooperating robot robots have always worked in operating areas protected by systems, for example, are modifying and optimising fences and safety devices which separated them from human beings. Now, all the robot producers are trying to solve this in manufacturing processes.” Adding on the safety front of industrial robotics, Baroncelli different ways but all with the same objective: man and robots stresses, “The most important challenge is connected with safe working together in a safe way.” While for Raibagi the main
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“The continuous on-going development of robot & control technology has enabled robotics to establish itself across a broad spectrum” Raj Singh Rathee, Managing Director, KUKA Robotics India
“The end-customer-friendlyintegration of robots in machine tools provides an enormous potential for new robot installations” Sunil Raibagi, Managing Director, GÜDEL India
challenges lie in achieving energy-efficiency and lightweight construction to reduce energy costs. He avers, “The potential of the use of industrial robots in the general industry will substantially grow when robots will collaborate with workers and when the integration of the robot will become easier. Especially, the end-customer-friendly-integration of robots in machine tools provides an enormous potential for new robot installations.”
from the ones having found solution for service robots can be usefully employed in factories. Frankly speaking, it is difficult to forecast today the limits of robotics, but the direction is clear towards technical developments and new fields of application.” Building a technology roadmap, Raibagi asserts, “Even with primitive intelligence, robots have demonstrated ability to generate good gains in factory productivity, efficiency and quality. Beyond that, some of the “smartest” robots are not in manufacturing; they are used as space explorers, remotely Future outlook operated surgeons and even humans – like Asimo. In some With robotic intelligence, artificial intelligence, the need ways, some of these other applications show what might be for increased factory productivity, efficiency, safety and quality possible on production floors if manufacturers realise that resulting in many technology breakthroughs in the robotics industrial robots don’t have to be bolted to the floor, or sector, how does the technology outlook for the industrial constrained by the limitations of yesterday’s machinery robotics sector in the next decade? Replying to this, Baroncelli concepts.” affirms, “Robotics has, among others, the fantastic feature of Indeed with rapidly increasing power of the microprocessor being a synthesis of many technologies: mechanics, material and artificial intelligence techniques, robots have dramatically science, electronics, mathematics, software, control…all these increased their potential as flexible automation tools. Raibagi disciplines, at various paces, are naturally evolving bringing notes, “The new surge of robotics is in applications demanding sound innovation to the market: the combined effects of such advanced intelligence. Robotic technology is converging with improvement would result in an overall better and better a wide variety of complementary technologies – machine performance of a robot.” Moreover, robot has the feature of vision, force sensing (touch), speech recognition and advanced being able to interface with other equipment, in turn subject to mechanics. This results in exciting new levels of functionality technological evolutions: sensors, vision systems, inspection for jobs that were never before considered practical for robots. systems. The integration of these technologies with the robot Additionally, the introduction of robots with integrated vision can create new performing systems to be applied in more and and touch dramatically changes the speed and efficiency of more segments, therefore, populating areas where robotics is new production and delivery systems. Robots have become so not applied yet. Adding further, he says, “Finally, there can be accurate that they can be applied where manual operations are a cross fertilisation of technologies between industrial robotics no longer a viable option. Semiconductor manufacturing is and the younger discipline of service robotics. Service robotics one example, where a consistent high level of throughput and is a relatively younger branch having as a target to use robots quality cannot be achieved with humans and simple (of different kinds) in environments different from factories, mechanisation.” ☐ such as, for example, at home with people with no specific > MORE@CLICK ADI03528 | www.AandD24.in training. I am sure that technologies and approaches deriving
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MEMS vibration monitoring The inertial MEMS technology is ushering in a new era of vibration monitoring and enabling a wider user base for this type of instrumentation. Through functional integration and ease of adoption, MEMS devices are gaining increasing attention in new vibration monitoring applications as well. New adopters of vibration sensing are also finding that quick deployment and the reasonable cost of ownership are good reasons to evaluate fully integrated MEMS devices. 36
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Mark Looney Senior Applications Engineer Analog Devices - Greensboro, North Carolina mark.looney@analog.com
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F o c u s | S e m i c o n d u c to r s & E l e c t r o n i c s
Inertial MEMS(micro-electro-mechanical system) sensors play a significant role in the massive expansion of todayâ&#x20AC;&#x2122;s personal electronic devices. Their small size, low power, ease of integration, high level of functionality and superb performance encourages and enables innovation in gadgets such as smartphones, gaming controllers, activity trackers and digital picture frames. In addition, inertial MEMS sensors have substantially improved reliability and reduced cost in automotive safety systems, allowing them to be deployed in most automobiles. The continuous advancement in functional integration and performance has also helped MEMS accelerometers and gyroscopes find their way into many different industrial systems. Some of these applications offer lower-cost alternatives to present products and services, while others are integrating inertial sensing for the very first time. Vibration monitoring is emerging as an application that has both types of users. Traditional instruments that monitor machine health for maintenance and safety often use piezoelectric technology. High-speed automation equipment monitors vibration to trigger feedback control of lubrication, speed, or belt tensionâ&#x20AC;&#x201D; or to shut down equipment for quick attention from maintenance staff. Although piezoelectric devices have a mature user base, MEMS accelerometers offer easy integration and reduced cost to an emerging group of new users. In addition, their advanced functional integration allows devices such as the ADIS16229 digital MEMS vibration sensor with embedded RF transceiver to provide a complete solution including signal processing and communications. This type of programmable device can wake itself up periodically, capture time-domain vibration data, perform a fast Fourier transform (FFT) on the data record, apply user-configurable spectral analysis on the FFT result, offer simple pass/fail results over an efficient wireless transmission, provide access to data and results and then go back to sleep. New adopters of vibration sensing are finding that quick deployment and the reasonable cost of ownership are good reasons to evaluate fully integrated MEMS devices.
Vibration monitoring applications When using vibration to observe machine health, the objective is to correlate observable vibration with typical wear-out mechanisms, such as bearings, gears, chains, belts, brushes, shafts, coils, and valves. In a typical machine, at least one of these mechanisms require regular maintenance. Figure 1 shows three examples of the vibration v/s time relationship
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for a normal wear-out mechanism. Although it takes time and experience to develop this type of relationship, a wellcorrelated vibration signature can be a cost-saving alternative to regular maintenance that follows short cycle times. Using actual observations, such as vibration, provides an opportunity to take quick action when warning conditions are detected (red curve), while avoiding premature maintenance on machines that have more life remaining (blue and green curves). Sometimes, these three zones of operation (normal, warning, critical) can correlate to the three stages of a machineâ&#x20AC;&#x2122;s maintenance cycle: early life, midlife, and end-of-life, in which case they may influence the vibration monitoring strategy. For example, during early life, an instrument might only require daily, weekly or monthly observation of key vibration attributes. As it moves into midlife, this might change to hourly observation, and as it approaches end-of-life, vibration monitoring might occur even more often, especially in cases where people or the asset are at risk. At this stage, machines that monitor vibration using portable equipment will accumulate recurring costs that might become prohibitive when compared to the cost of maintenance. While major assets can justify special attention, many other instruments cannot bear the recurring cost. To complement manual measurements, embedded MEMS-based sensors provide a more cost-effective approach for equipment that requires real-time vibration data. Nature of vibration:Vibration is a repetitive mechanical motion. A number of attributes are important for developing a vibration-sensing instrument. First, an oscillating motion often has both linear and rotational components. Most vibration-sensing relationships tend to focus on the magnitude of the oscillation, not on absolute position tracking, so linear sensors such as MEMS accelerometers are sufficient for capturing motion information. When the motion is mostly linear, understanding the direction can be important, especially when using single-axis sensors. Conversely, a 3-axis sensor can offer more mounting flexibility, as the orthogonal orientation enables pickup on one or more axes regardless of the vibration direction. Since vibration is periodic, spectral analysis offers a convenient way to characterise the vibration profile (the relationship between vibration magnitude and frequency). The profile shown in Figure 2 has both broadband and narrow-band components, with primary vibration at ~1350 Hz, four harmonics, and some low-level wideband content. Every piece of moving equipment will have its own vibration profile, with the narrow-band response often
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S e m i c o n d u c to r s & E l e c t r o n i c s | F o c u s
Figure 1: Example of vibration v/s time
representing the natural frequencies of the equipment. Signal processing: The sensor selection and signal-processing architecture depends on the application’s objectives. The manufacturer’s insight into the mechanical design aids with the band-pass filter design, specifically with the start frequency, stop frequency and pass-band roll-off rates. Rotation speed, natural frequencies of the mechanical structure, and faultspecific vibration behaviours can all influence the band-pass filter. While this type of approach is simple, vibration monitoring requirements can change as historical data from a particular machine becomes available. Changes in monitoring requirements can lead to changes in the filter structure, which can present a recurring engineering cost. Developers can trade complexity for flexibility by digitising the sensor response, implementing key signal processing functions such as filter, rms computation, and level detectors, and leveraging auxiliary I/O outputs to control indicator lights or provide a numerical output. Core sensor: The core sensor for either approach can be a MEMS accelerometer. The most important attributes for selecting a core sensor will be the number of axes, package/ assembly requirements, electrical interface (analog/digital), frequency response (bandwidth), measurement range, noise and linearity. While many triaxial MEMS accelerometers support direct connection with most embedded processors, capturing the best available level of performance might require single or dual-axis solutions that have analog outputs. For example, the ADXL001 high-performance wideband iMEMS® accelerometer leverages its 22-kHz resonance to provide one of the widest available bandwidths, but it is only available as a single-axis, analog-output device. Analog outputs can enable a quick interface in systems that have an available analog-todigital channel, but the present trend of development seems to favour those sensors that have digital interfaces. The core sensor’s frequency response and measurement range determine the maximum vibration frequency and amplitude that it can support before saturating the output. Saturation degrades the spectral response, creating spurious content that can cause false alarms, even when the saturation
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frequency does not interfere with a frequency of interest. The measurement range and frequency response are related by Ap-p=Dp-p × ω2 where D is the physical displacement, ω is the vibration frequency, and A is the acceleration. While the frequency response and measurement range place upper boundaries on the sensor’s response, its noise and linearity place limits on the resolution. The noise will establish the lower limit of the vibration that will cause a response in the output, while the linearity will determine how much false harmonic content is generated by a vibration signal. Analog filter: The analog filter limits the signal content to one Nyquist zone, which represents one half of the sample rate in the example system. Even when the filter cut-off frequency is within the Nyquist zone, it is impossible to have infinite rejection of higher-frequency components, which can still fold back into the pass band. For a system monitoring only the first Nyquist zone, this fold-back behaviour can create false failures and distort the view of the vibration content at a particular frequency. Windowing: Time-coherent sampling is often not practical in vibration-sensing applications, as nonzero sample values at the start and end of the time record result in large spectral leakage, which can degrade the FFT resolution. Applying a window function before calculating the FFT can help manage the spectral leakage. The best window function is dependent on the actual signal, but in general, the trade-offs include process loss, spectral leakage, lobe location and lobe levels. Fast fourier transform (FFT): The FFT is an efficient algorithm for analysing discrete time data. The process transforms a time record into a discrete spectral record, where each sample represents a discrete frequency segment of the Nyquist zone. The total number of output samples is equal to the number of samples in the original time record, which in most cases represents a number in the binomial series (1, 2, 4, 8 … ). Spectral data has both magnitude and phase information, which can be represented in either rectangular or polar form. When in rectangular form, one half of the FFT bins contain magnitude information, while the other half contains phase information. When in polar form, one half of the FFT bins
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Figure 2: Vibration profile, natural frequency ~1350 Hz
contain the real result, while the other half contains the imaginary result. In some cases, both magnitude and phase information are helpful, but the magnitude/frequency relationship often contains enough information for detecting key changes. For devices that offer only magnitude results, the number of FFT bins is equal to one half of the samples in the original timedomain record. The FFT bin width equals the sample rate divided by the total number of records. In a way, each FFT bin is like an individual band-pass filter in the time domain. provides an example of an actual MEMS vibration sensor, which samples at 20480 samples per second (SPS) and starts with 512-point records. In this case, the sensor only provides the magnitude information, so the total number of bins is 256 and the bin width is equal to 40 Hz (20480/512). The bin width is important because it establishes the frequency resolution as the frequency shift from one bin to an adjacent bin, and because it determines the total noise the bin will contain. The total noise (rms) is equal to the product of the noise density (~240 μg/√Hz) and the square root of the bin width (√40 Hz), or ~1.5 mg rms. For low-frequency applications, where noise tends to have the most influence on resolving vibration, a decimation filter prior to the FFT process can help improve the frequency and magnitude resolution without requiring a change in the ADC’s sample frequency. Spectral alarms: One of the key advantages of using an FFT is that it enables simple application of spectral alarms. The warning and critical levels correspond to the levels in the machine-health vibration vs time profile. The start and stop frequencies complete the process variable definition represented by this relationship. When using an embedded processor, the spectral alarm definition variables (start/stop frequencies, warning/critical alarm levels) can be in configurable register locations that use digital codes for configuration. Using the same scale factors and bin numbering scheme can greatly simplify this process. Record management: One of the key functions associated with process variable relationships is record management. Storing FFT records from different stages of each machine’s
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lifetime enables analysis of a variety of behaviours that may lead to a wear-out curve, which contributes to maintenance and safety planning. In addition to compiling historical vibration data, some will find value in capturing condition data associated with parameters such as power supply, temperature, date, time, sample rate, alarm settings and filtering. Interface: The interface depends on the existing infrastructure in a particular plant. In some cases, industrial cable-ready communication standards such as Ethernet or RS-485 are readily available, so the interface between a smart sensor and the communication system might be an embedded processor. In other cases, that same embedded processor might be used to interface the smart sensor with an existing wireless protocol, such as Wi-Fi, ZigBee, or a system-specific standard. Some smart sensors, such as the ADIS16000 wireless gateway node for remote sensors and the ADIS16229, come with a ready-todeploy wireless interface that is available through common embedded interfaces such as SPI or I2C.
Conclusion Inertial MEMS technology is ushering in a new era of vibration monitoring and is enabling a wider user base for this type of instrumentation. Performance, packaging, and familiarity may contribute to continued use of piezoelectric technology, but vibration monitoring is clearly growing and evolving. Through functional integration and ease of adoption, MEMS devices are gaining increasing attention in new vibration monitoring applications. Convenience, through advanced signal processing at the point of sensing, reduces the monitoring burden to a simple state (normal, warning, critical) for most situations. In addition, remote data access through convenient communication channels is creating new applications for vibration monitoring instruments. Future advances in key performance metrics (noise, bandwidth, and dynamic range) and the high level of functional integration will help this trend to continue in the near future. ☐ > MORE@CLICK ADI03529 | www.AandD24.in
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8/14/2014 8:21:02 PM
S e m i c o n d u c to r s & E l e c t r o n i c s | F o c u s
Semiconductor test systems An application story on how IDT lowered cost of test by adopting the NI semiconductor test system. The solution creates a wide range of mixed-signal semiconductor solutions from low-power to high-performance devices.
Glen E Peer Director of Test Engineering Integrated Device Technology Inc
IDT faced a major challenge in keeping pace with continuously increasing test performance requirements in a fast moving environment where device performance is constantly pushing the limits of ATE system capabilities and thereby, accelerating tester obsolescence and driving test costs higher.
Test System (STS) to achieve flexibility and the ability to reconfigure and grow its test platforms in parallel with their rising performance needs. They also built on their original investment rather than throw it away like with traditional ATE systems, which generally require major costly reboots of the test floor as generations of test systems advance.
Solution
Project details
IDT used the open PXI architecture of the NI Semiconductor
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IDT creates a wide range of mixed-signal semiconductor
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S e m i c o n d u c to r s & E l e c t r o n i c s | F o c u s
Figure 1: Combination of a low-cost commercial ATE system with IDT’s enhancement system
This methodology worked well, but IDT eventually faced solutions from low-power to high-performance devices. A worldwide leader in timing devices (clock ICs), IDT offers a hardware obsolescence that required replacing its chosen ATE broad portfolio for networking and communications, and, therefore, a system redesign. Secondly, though the company’s hybrid approach was successful from an engineering consumer, and computing applications. As the performance of IDT’s devices increases, it becomes and performance perspective, it was not always production more difficult to maintain the pace in the production test friendly. In general, as novel engineering enhancements get environment. Traditional ATE systems capable of meeting “bolted” onto ATE systems, the systems become more difficult IDT’s high-performance measurement requirements are to support in high-volume manufacturing. Adding cables, expensive and often include extra capabilities that are not hardware, and sometimes device under test boards with used but add to the cost. Additionally, within the traditional extravagant electronics to ATE systems increases the potential ATE environment, upgrading a tester to improve its for possible failure points in high-volume manufacturing performance often requires upgrading to the next-generation environments. The most ideal solution is to create or find a test platform test platform and phasing out the current platform. This is both expensive and wasteful because a large portion of the with an open architecture that allows users to build on their engineering investment made during previous generations investments from within the tester rather than through bolton enhancements or reinvestments in high-dollar big iron can be lost. To combat this, IDT typically engineers its own solutions ATE. The company needed an architecture that was resistant on top of the installed base of test systems. Having used to hardware obsolescence and could be reinvented as various models from nearly every ATE vendor, the company technology improved. The NI STS provided this architecture. STS’s PXI platform is perfectly suited to solve these have become proficient at extending the useful life span of these ATE platforms while controlling costs and enhancing its problems. The system offers multiple PXI chassis inside a tester mainframe to offer expansion capabilities so the user measurement capabilities. can add enhanced test features within the tester itself. The PXI open standard gives users the flexibility to select instruments Evolution of test from a variety of vendors based on their needs instead of from The evolution of test within the timing business unit at the limited choices of a single ATE hardware vendor. IDT is the perfect example of this approach. The company STS works well for IDT as the natural extension of the began with an off-the-shelf, high-dollar ATE system. Soon company’s tester evolution. With it, IDT can continue to build they realised that this approach was too expensive, so the high-performance, low-cost test platforms using only the company built its own internal test system(s). These modules and components we need to meet our performance homegrown systems met the high-performance requirements targets. The open architecture of the NI STS makes this even but sacrificed some of the benefits of using a commercial easier. platform such as high parallelism and external support. The During the past year of STS deployment at IDT, the company therefore migrated to a hybrid of these two company already enhanced the systems from their original approaches and combined a low-cost commercial ATE system configuration to meet its evolving test needs. Through careful with its own performance enhancement system as shown planning during the startup phase, the company ensured that in Figure 1. despite these enhancements, these systems maintained 100 %
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STSs running production test within IDT’s manufacturing facility
backward compatibility with the initial target solution(s). All of the company’s initial investment was preserved as it expanded the testers to enable a broader usage base throughout IDT.
NI STSs provide high-performance measurement features across multiple test sites with true parallel test capabilities to further reduce the cost of test. The NI STS is a scalable tester family with models available using one (STS T1), two (STS T2) and four (STS T4) internal PXI chassis. IDT designed its NI STS beginning with the T2 Benefits of using an NI solution model with upgrades and enhancements in mind. The ability IDT took advantage of many benefits to using NI solutions. to grow the test platforms in response to the company’s own First, unlike its previous hybrid approach, IDT could needs is one of the strongest selling points of these systems. consolidate the test head, which reduced the number of Previously, it was difficult or impossible to share test systems potential failure points within manufacturing, downtime for across internal business units, but the company now have maintenance and repair, and floor space requirements. The other teams evaluating its NI STS. These groups’ test needs company also increased its ability to test a wide range of are different from those that the company’s systems are devices with the same configuration because the system has currently configured to handle, but with the open architecture interchangeable interface boards, and IDT can use the same of the PXI platform, these users can add capabilities to the tester configuration for different device types. The multisite original IDT system definition, which have been already system allows for higher test throughput because it is a true proven in production. parallel test system with high-accuracy performance Though no single ATE platform is ideal for all situations, parameters for hardware optimisation. Lastly, this solution for the first time the company saw the possibility of maintaining was lower in cost compared to alternative integrated solutions an ATE platform that can be reconfigured and reused across because the company needed to build only one set of multiple business units through the simple swapping of instrumentation and had fewer individual systems to interface boards or internal instrumentation modules. With maintain. the NI STS, IDT believes that it can define one or two system configurations and use these systems on its production test floor to satisfy the different needs of all the businesses within Growing for the future IDT. The company designed its NI STSs so that they can STSs installed on IDT’s production test floor run 24/7. simply swap interface boards to enable various hardware The company has experienced test time reductions in the 10% configurations as required. This ability will greatly simplify to 25% range, enhanced measurement capability and accuracy, overall test operations and help further drive down the total and cleaned up footprint on the test floor, which made its cost of test. testers much more production friendly. Using the NI STS, the Finally, the company can break away from the big iron company not only increased its test performance but also ATE vendors and their hardware obsolescence cycles and reduced its overall cost of test by retiring older, difficult to determine the best test strategy based on their own overall support and maintain test systems. Some of these older needs. The current and future investments in test hardware systems had expensive power and cooling requirements, but and software are preserved and reusable for the foreseeable the NI STSs simply plug into any 110 V outlet with no extra future. ☐ facilities required. Hourly test costs per unit on these older > MORE@CLICK ADI03530 | www.AandD24.in systems were as much as twice that of the NI STS. Additionally,
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Open core engineering A read into open core engineering that combines a high degree of engineering efficiency and future-readiness, which increases the applicationâ&#x20AC;&#x2122;s flexibility and engineering efficiency along the entire value stream Machinery manufacturers and users require more engineering efficiency for a faster time to market and futureproof automation solutions in order to protect their investments. At the same time, they are looking for possibilities to customise their machines economically with new automation ideas for machine processes and functionalities to meet the needs of individual customers. This is how they can set themselves apart from the competition. As a result, the wish for more flexibility to implement these customised concepts rounds out the list of new requirements. Rexroth meets these requirements with open core engineering, which represents the companyâ&#x20AC;&#x2122;s comprehensive package of solutions that increases engineering efficiency along the entire value stream for all drive and control technologies. Users benefit from accelerated engineering at
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K R Raghunandan Application Dept Bosch Rexroth India raghunandan.kr1@boschrexroth.co.in
lower cost and increased future-readiness based on open industry standards. At the same time, it also provides new degrees of freedom for customisation and flexibility for various programming languages and device classes. This engineering uses the Open Core Interface to connect previous engineering that is based on the newest IEC standards.
Engineering efficiency Open core engineering accelerates engineering efficiency decisively with software tools, function packages and multitechnology solutions. It makes contributions at every step, from project planning to programming and parameterisation, commissioning to service. The engineering framework IndraWorks provides all required tools for the engineering of
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
Open core engineering replaces timeconsuming programming of complex machine processes through simple parameterisation of customised technological functions
all technologies. In complex projects and tasks, innovative function packages accelerate the work processes. For example, the â&#x20AC;&#x153;Generic Application Templateâ&#x20AC;? (GAT) creates the optimal requirements for the development of modular machine software. Based on templates, GAT uses wizard support to automatically generate an executable machine program to match the specifications of the project planner, thereby significantly increasing engineering speed. Interfaces such as the Automation Interface further increases engineering efficiency. With this interface, engineering tasks can be carried out in an automated manner according to a script, and interfaces to eCAD systems. Open core engineering replaces time-consuming programming of complex machine processes through simple parameterisation of customised technological functions. For example, the FlexProfile: with this function, machinery manufacturers can easily fulfil their customersâ&#x20AC;&#x2122; requests for more flexibility and retrofits at the push of a button. Based on two analytical motion profiles, it automatically adapts all drive movements to changed parameters in the production process.
Future-proof solutions Choosing an automation system means big investment for machinery manufacturers. Open core engineering protects this investment through the consistent use of open standards and uses the IEC 61131-3 and PLCopen standards for open PLC programming. The automation bus Sercos can be homogeneously integrated into all solutions to this end. With its high performance, application flexibility and the number of available field devices on the market, a highly functional and more future-ready Ethernet field bus is available as the backbone for state-of-the-art machine concepts. Open core engineering continues to integrate the newest standards such as FDT/DTM for tool integration or OPC UA for M2M communication. Through multi-Ethernet interfaces, Rexroth drives can also be integrated into heterogeneous automation
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topologies, which allow machinery manufacturers to create customised versions with regionally preferred communication systems without additional effort. Thanks to the library concept in engineering and the scalability of the automation portfolio, machinery manufacturers can reuse entire programs or individual program modules on larger or smaller versions of their machines with a control unit that complies with the requirements. They can place the corresponding content into the new project via drag and drop, hence saving time. Today, open core engineering safeguards major investments in modern, software-based solutions and in the future too.
Individualisation In the past, applications requiring access to all functions of the control core, could only be accomplished by the drive manufacturer. With the Open Core Interface, Rexroth opens the door into a new world of automation and offers machinery manufacturers entirely new degrees of freedom, with room for individual solutions. In order to increase productivity, increasing amounts of information from various sources at the production and control system level must be exchanged quickly. By adapting Ethernet-based communication for fast production processes and integrating it into automation systems, as happened with Sercos, the data network stemming from the IT environment has become the current backbone of modern machines. The Open Core Interface also expands the software tools and function packages of open core engineering and creates additional degrees of freedom in the engineering of machines and systems. Rexroth opens its drives down to the core and provides methods for economically creating individual functions oneself. With the Open Core Interface, applications based on high-level programming languages on external devices receive flexible access to all control and drive functions down to the core. Applications become executable based on
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Save time, save energy, save resources™ HMS Industrial Networks India Pvt. Ltd. “Corporate Plaza”, Unit 1A & 1B, Ground Floor, Senapati Bapat Road, Near Chaturshrungi Temple, Pune – 411016 (M.S.), INDIA. Email: sta@hms.se, Mobile No:+ 91 83800 66578 URL: www.hms.se Netbiter_building_HMS_India_11_8_5_inc.indd 1
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
With the Open Core Interface, Rexroth opens the door into a new world of automation and offers machinery manufacturers entirely new degrees of freedom, with room for individual solutions
C/C++ directly in the real-time environment of the drives. Machinery manufacturers can use the Open Core Interface to implement firmware expansions of the Rexroth motion logic drives by themselves.
Flexibility
calculated in which the lubricants are to be renewed or topped and warnings are displayed. All these functions can also be simulated, so this app can also be used to show the functionality without a connected control. Apps for smart devices also increase the efficiency of maintenance work in the production arena. Unlike in the past, the user needs no special consoles with a physical connection to the control unit. For example, a technician can simply use his/her smart device to scan a QR code on the machine. The app immediately provides the user with wireless access to this control unit and allows him or her to call up all diagnostic data. With the appropriate infrastructure and authorisation, diagnosis can be performed from any desired site. In the event of a malfunction, for example, the control unit can send error messages directly to the smart device per SMS or email and allow the technician to access the control unit directly for remote troubleshooting. For commissioning, diagnosis and operation, in the long term, smart devices will therefore replace the HMI devices that were necessary in the past. For example, users will be able to use a tablet PC to operate several machines, which in turn no longer need their own dedicated HMI devices.
The penetration of smart devices into the consumer world has also opened up new communication channels between humans and machines. In the future, intelligent control systems will adapt even more easily to human communication, thereby making interaction at the user level faster, more intuitive, more intercultural and more flexible. The Open Core Interface is already turning such innovative machine concepts into reality. The wide support for open programming and data interfaces in the IT world enables a high degree of flexibility in the selection of programming languages and device platforms. Hence, the user is free to choose between C/C++, C# (.NET), Visual Basic, VBA (Office), LabVIEW G, Objective-C, Java as well as all programming environments that support the integration of Microsoft COM libraries. The Open Core Interface supports Apple® iOS and Google® Conclusion AndroidTM, currently the two most important operating Open core engineering combines a high degree of systems for smart devices such as smartphones and tablets. Machinery manufacturers can, therefore, implement native engineering efficiency and future-readiness with same degrees apps for Apple iPhones®, iPads® or Google Android smartphones of freedom available with modern high-level languages and and tablets. Users can simultaneously connect to several IT-based technologies in new production machines. This control units or access a control unit from various user combination enables the customisation of machine concepts and increases the application’s flexibility. For commissioning, applications at the same time. With the Operation App for Handling, one can operate a diagnosis and operation, in the long term, smart devices will machine using tablet PCs. Setting up and commissioning the therefore replace the HMI devices that were necessary in the system is possible via functions for teaching, jogging and past. For example, users will be able to use a tablet PC to referencing. There exist manual functions to execute user operate several machines, which in turn no longer need their specific switching functions of the system. Machine specific own dedicated HMI devices. ☐ programs can be selected, started, stopped and debugged. With > MORE@CLICK ADI03531 | www.AandD24.in maintenance functions for linear systems, the cycles are
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
Evolution of switching interfaces This article briefs on a number of interface relay modules that are made available to provide the bridge between the industrial controller and the increasing number of real-world control scenarios As processes, machine control and automation become ever more complex, industrial controllers have become more of a commodity item, offering an amount of ‘control power’ sufficient to handle most applications. However, controllers invariably provide fixed and inflexible electrical interfaces. This inflexibility is almost inevitable since no single interface can satisfy the disparate needs of switching both thermocouples and high power contactor coils. And since the provision of optimised plug-in interfaces is seen as too costly a feature for the standard industrial controller, no ‘easy fix’ exists within the controller. This point, combined with the need for quick and easy replacement of worn or damaged interfaces, has
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Dr Ashish Manchanda Managing Director Finder India
meant the use of external interface relay modules that has become the de facto solution.
Concern The common concerns of the system integrators and end users these days are of different nature when it comes to relay interfaces. An end user has a need for easy diagnostics, faster uptime, redundancy/standby features for easy replacements and above all longer electrical life under the harsh industrial environment. Whereas an integrator apart from the above also looks forward to solutions which are able to save costs directly
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C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
Relay interface in control panels
or indirectly by saving space, less wiring, faster installation & commissioning, etc. The relay boards as a concept thus got initiated almost two decades ago and later got spread in the nooks and corners of the industry due to its easy availability at local assembly units near to the cabinet builders. At one time the most common style simply incorporated multiple PCB relays on a single board, which was in turn mounted on a 35 mm rail. This was helpful where an enhanced current rating was needed across a block of outputs, but it tended to hinder the tailoring of outputs from channel to channel and be inflexible & bulky. However, lately, some more of the concerns with these relay boards have come to light. Some of these issues are nonavailability of a common industry standard on the quality of the PC board design & soldering, PCB insulation strength, electrical creepage, temperature withstand capabilities, MTBF values, behaviour under failures, consistency of components used, international test standards for finished product and last but not the least the compatibility of the soldered sockets with respect to the requirement of the relays.
Evolution To overcome these elements of doubts, a number of interface relay modules were made available to provide the bridge between the industrial controller and the increasing number of real-world control scenarios. Today, the preferred solutions are of an ultra-slim single pole module type, particularly those equipped with a replaceable relay element. Different versions can be selected channel-by-channel to match the particular requirements of the load, without any kind of over or under-specification.
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The replaceable relay type also offers quick and easy maintenance for those applications where exceptional longevity is paramount. Development of this approach has led to further benefits in cost and time-saving through innovations such as multi-way jumper links for simple common circuit interconnection between adjacent interface relay modules, and the inclusion of identification labels to aid commissioning and maintenance.
The new approach By identifying a relatively limited number of relay/socket/ module combinations, the technology has now advanced to a level where the designer of the control panel has even better flexibility for selecting and using a combination of single part numbers. The new technology Ultra Slim Relays in Solid State (SSR) as well as Electro Mechanical (EMR) has now provided the design engineer access to a range of ideally matched components that are assembled and ready to accept wiring â&#x20AC;&#x201C; offering the additional benefits of reduced inventory, purchasing time, wiring time, space inside the cabinet and cost. However, there are small but significant differences in the ideal feature set of an interface relay, depending on whether the device is on the input or the output side of the controller. Until now this aspect of design had not been fully addressed, but of-late new solutions have even made the life easier by reducing control cabinet foot print, wherein the regular set of terminal blocks can be avoided which saves a lot of space and wiring cost too! â&#x2DC;? > MORE@CLICK ADI03532 | www.AandD24.in
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T e c h n o l o g y | W i r e l e s s a u t o m at i o n
Applying wireless to EtherNet/IP An article on the use of Ethernet which is growing rapidly in factory automation, process control and SCADA systems. The ODVA EtherNet/IP network standard is gaining popularity as a preferred industrial protocol. Plant engineers are recognising the significant advantages that Ethernet-enabled devices provide such as ease of connectivity, high performance and cost savings While EtherNet/IP has many advantages, cable installation is often expensive, and communications to remote sites or moving platforms may not be reliable or cost-effective. Wireless Ethernet technologies have emerged that can reduce network costs while improving plant production. However, applying these technologies is not a simple matter as industrial Ethernet systems vary greatly in terms of bandwidth requirements, response times and data transmission characteristics.
Features Ethernet Industrial Protocol (EtherNet/IP) is a network protocol defined by Open DeviceNet Vendor Association (ODVA). As an open standard, vendors may implement EtherNet/IP communications in their devices without licensing fees. Many vendors have adopted EtherNet/IP including Rockwell Automation, who selected the protocol as one of three preferred networks on their popular Logix controllers (DeviceNet and ControlNet are the other two).
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An important part of the EtherNet/IP standard is definition of Common Industrial Protocol (CIP) messaging. CIP defines the information packet with recognition that the message attributes will vary as applications do. Thus CIP message definition takes into account a wide range of applications including programming/diagnostics, data collection, PLC data exchange and I/O communications.
Wireless as an alternative to cable installation The cost of installing cable in industrial plants is a function of the material costs plus the labour charges. Cable installation costs have been estimated as ranging from $20 to $2,000 per foot depending on installation challenges (distances, obstacles), environment and local labour costs. Factors that impact total cable installation costs include distance and number of locations; conduit design and installation; trenching; fibre optic cable & infrastructure and hazardous location regulations. Once the total cost of cable installation is calculated, a comparison can be made to wireless. Similar to cable installation
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W i r e l e s s a u t o m at i o n | T E C H N O L O G Y
Festoon and slip ring communication systems
though, the total cost of wireless should be examined. This not only includes the wireless hardware (including wireless nodes, antennas and cables), but also antenna installation (if applicable) and personnel training. However, even when factoring in these additional costs, the savings realized by wireless is often dramatic and significant. Additionally wireless (when implemented properly), offers better reliability than cabled systems because there are fewer mechanical connections to fail. If the cable is broken by moving equipment, severed during construction or damaged by vibration, production may be down for hours until the problem is located and corrected. Wireless also offers electrical isolation as fiber optics do, eliminating potential surge damage from ground plane transients. Finally, a significant benefit of wireless is reducing project time. Wireless systems are typically much quicker to install than wired systems. This is especially beneficial in systems that move over time such as mining operations or the reconfiguration of production equipment on the factory floor.
Wireless in motion Where wireless can significantly benefit production is in processes using motion such as material handling systems where controllers and I/O are on moving platforms. Examples include overhead cranes, transfer cars, stacker/reclaimer cranes, automatic guided vehicles (AGVs), conveyor systems and rotating packaging machines. Mechanical methods of Ethernet communications (Figure 2) such as festoon cable systems, flex cable, slip rings and rails are prone to frequent maintenance and sudden failures. These systems are often relatively expensive, especially when supporting Ethernet. Wireless may be less expensive and, if implemented correctly, significantly more reliable. Today, many of these mechanical systems are being retrofitted with wireless as production
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Wireless Automation - Prosoft.indd 59
shutdowns become more frequent. Designing wireless into the system upfront could have reduced installation costs and increased plant production.
Industrial Wireless Considerations TCP/IP or UDP/IP: Before selecting the wireless technology, it is important to consider the EtherNet/IP application and determine if it will be based on TCP/IP, UDP/IP or a combination of the two. This is important because TCP and UDP protocols behave differently over wireless networks. UDP/IP is typically used in implicit messaging systems where controllers communicate to I/O blocks over Ethernet media. TCP/IP is much more common as it is the basis for explicit messaging between controllers, HMIs, remote programming and data collection. Ultimately the automation architecture will determine the EtherNet/IP protocol type and appropriate wireless technologies. Proprietary FHSS v/s 802.11 DSSS/OFDM: The most common approach to wireless Ethernet is RF transmission in the spread spectrum bands. Globally, the 2.4 GHz and 5.8 GHz bands are available for license-free use in most countries. Direct sequence and Orthogonal OFDM offer the fastest spread spectrum data rates as the wide channel permits transmission of complex modulation schemes. OFDM uses a complex modulation technique and is capable of high data rates and low latency (the transmission time a packet takes from one end to the other). OFDM is also significantly more immune to multipath fading, a problem due to RF reflections that high data rate systems frequently have. Direct sequence and OFDM are the methods used by all popular open Wi-Fi standards including IEEE 802.11b, 802.11g (both transmitting in the 2.4 GHz band) and 802.11a (transmitting in the 5 GHz band. The wide band modulation offers high speed, it unfortunately is more prone to noise
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T echnology | W i r e l e s s a u t o m at i o n
Wireless TCP/IP system for HMI connectivity
problems when multiple systems are operating in close proximity. For example, IEEE 802.11b/g has thirteen available channels (eleven channels in North America), but only three channels donâ&#x20AC;&#x2122;t overlap. Due to overlapping channels and the popularity of Wi-Fi systems in plants, band crowding and RF saturation can lead to poor wireless performance. Frequency hopping is a very popular technique for industrial systems because it has outstanding noise immunity techniques. Unlike direct sequence and OFDM, Frequency Hopping uses many smaller channels in the spectrum and rapidly changes channels or hops around from channel to channel. The disadvantage of Frequency hopping is that it is slower than Direct Sequence/OFDM and has longer data latency. Most Frequency Hopping systems are limited to 1 Mbps or less RF data rate. But if the data rate is fast enough for the application, the reliability of frequency hopping is tough to beat especially in high noise environments.
A common error though is assuming that faster technologies are better. If the application can handle slower speeds, then using relatively slower frequency hopping technology may be the best approach. Frequency hopping is the most robust especially regarding communications in high RF noise areas, and easier to implement. As applications demand higher speeds, then more considerations and engineering challenges are typically encountered.
Wireless for explicit messaging between PLCs
One of the most popular uses of wireless is in sharing I/O information between PLCs. Because these messages are unscheduled at the protocol layer, slower wireless Ethernet technologies may be used. MSG blocks in PLC ladder code may be programmed to accept long delays in transmission. If the application (process) is not time-critical, then a slower (but robust) frequency hopping technology may be the best choice. There are many factors influencing how fast an explicit Frequency Band Selection: There are many considerations MSG may be executed. Generally, applications requiring 200 when selecting the frequency band for EtherNet/IP ms response time or slower are a good candidate for FHSS. communications including required data rate, distance, line- Faster response times may require faster technologies such as of-sight obstructions, modulation technique, band availability OFDM available in IEEE 802.11a and 802.11g standards. (government regulation) and band saturation (crowding). There are also spectrum management issues to consider if Wireless for HMI networks wireless is already in place or planned for the future. Another popular application for wireless is connecting The major consideration is band usage and management. Many industrial plants use the 2.4 GHz extensively for IT and Human Machine Interfaces (HMIs) to plant networks or inventory systems. Therefore, the 900 MHz band (for slower machines. HMIs use TCP/IP communications and are not time speed systems) or 5 GHz band (for higher speed) may be the critical other than to meet the needs of the process and, most importantly, the operator. best choice for industrial wireless systems. While HMI screens may look very complex and data intensive, usually the actual data being transmitted (updated) Wireless EtherNet/IP Reliability & Performance is minimal. If programmed efficiently, slower wireless Industrial wireless applications can be divided into two technologies (such as Frequency Hopping) may be used. The broad categories: Those requiring high speed, low latency key consideration is update times and the amount of information performance, and those permitting slower speed with longer actually being transmitted. packet latency. Wireless technologies are available to FHSS may be the best choice if appropriate. However, if accommodate both. portable computers or PDAs are used, then the industrial
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T echnology | W i r e l e s s a u t o m at i o n
EtherNet/IP protocol stack
wireless network must support the standard built into these portable devices. 802.11b and 802.11g (Wi-Fi) are the most common. This technology supports mobile operators while providing high speed, low latency communications.
Wireless for Ethernet I/O (implicit messaging) An emerging application for wireless is communications to distributed I/O blocks using EtherNet/IP. Wireless offers many advantages in these applications including elimination of mechanical coupling methods used in moving systems (e.g. rails, slip rings) and general cost savings due to reduction of Ethernet infrastructure. Communication to EtherNet/IP I/O blocks can also reduce automation costs compared to using remote PLCs. Programming is simpler using I/O instead of remote PLCs because MSG blocks are not required in the main controller’s ladder program. But remember that Implicit Messaging is UDP/IP based, not TCP/IP. Wireless networks must be carefully designed, and the plant RF environment more closely managed to ensure reliable communications. Several factors should be carefully considered before choosing this architecture including: • L ack of remote PLC control (intelligence) in case of communication failure • A mount of I/O and required scan times (network traffic) • P acket handling ability of wireless technology • E fficiency of the RF technology with multicast UDP packets • 8 02.11 clear channel availability However if circumstances are right, wireless EtherNet/IP I/O can be a significant cost saver and actually improve system reliability when correctly implemented, especially in moving systems. Prosoft Technology has performed extensive tests of its Industrial Hotspot technology with EtherNet/IP and has many
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successful customer installations. The following information is provided only as a guideline towards predicting wireless performance and should not be relied upon for any other purpose. Prosoft Technology always recommends field testing to confirm wireless performance and reliability.
Predicting Wireless I/O Performance Because EtherNet/IP I/O messages are scheduled, it is possible to predict scan time performance over industrial wireless systems if the following conditions are met: • Packets per second performance of wireless technology • Wireless behavior in multipoint systems (handling of UDP Multicasts) • Number of CIP connections The first step in designing a wireless EtherNet/IP system is calculating packets per second which determines minimum wireless bandwidth requirements. Start by counting the number of CIP connections. To calculate how many connections are in an I/O system, sum up all direct connections and rack optimized connections. To determine how many packets per second the system will be using, multiply each connection by two. It is multiplied by two because each CIP connection is bi-directional meaning that during every Requested Packet Interval (RPI), a produced packet is sent by each end of the connection. For example, if there are five direct connections and two rack optimized connections (with six digital modules in each) equals 7 total CIP Connections, the total number of packets is then calculated: 7 CIP Connections x 2 = 14 Packets Note that the six modules in each rack that are rack optimized only count as one connection. Rack optimization (if available in the I/O hardware) can significantly reduce wireless traffic. Then multiply the packets by scan time (derived from RPI
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setting) to calculate packets per second (pp/s). Let’s assume that in the above example, the required RPI time is 20 milliseconds (actual RPI time is application dependant), we know that there are 50 packets per second at an RPI time of 20 ms (1 / 0.02). We then multiply the 14 connections by the 50 packets per second to get the over all packets per second rate: 14 Packets x 50 per second = 700 packets per second (pp/s). The overall packets per second rate for 802.11 a/g radios can be in the thousands. However it is best practice to not operate the radio network at maximum capacity. Rockwell Automation suggests reserving 10% of each adaptors bandwidth so it is possible to use its RSLogix 5000 software for remote programming. The next step is to determine a reliable packet per second (pp/s) rate that the wireless technology will reliably support while keeping in mind that at least 40% should be reserved for other applications and RF overhead.
Emerging Wireless Technologies IEEE 802.11n: Not a ratified standard yet at time of this
paper, 802.11n promises several features that are attractive for EtherNet/IP communications including dual band (2.4 GHz, 5 GHz) support, significantly faster packet transfer rates with a reported throughput up to 300 Mbps and RF propagation that actually takes advantage of reflected signals (quite common in industrial plants with lots of metal) using multi-input, multioutput (MIMO) antenna systems. IEEE 802.16 (WiMax): While popularly known as an emerging cellular technology, WiMax technology will soon be available in the spread spectrum (license-free) bands including 2.4 GHz. WiMax offers high speed (up to 70 Mbps) at potentially long range. WiMax technologies may dramatically improve data rates to remote industrial sites and SCADA systems. ISA100.11a: The ISA is working on the ISA100.11a standard for wireless enabled devices, such as sensors. Operating in the 2.4 GHz band, the technology will “sense” existing 802.11b/g systems and work around them. While designed primarily for embedded devices, EtherNet/IP adapters and gateways will likely be supported. ☐ Courtesy: Prosoft > MORE@CLICK ADI03533 | www.AandD24.in
Electric Automation Systems and Components International Exhibition and Conference Nuremberg, Germany, 25 – 27 November 2014
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More information at +49 711 61946-828 or sps@mesago.com
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W i r e l e s s a u to m at i o n | T E C H N O L O G Y
Wireless technology for utility monitoring The article discusses how costeffective measurements based on wireless technology have helped Hindustan Zinc to improve visibility with real time, online, accurate process monitoring and at the same time enhancing flexibility for future needs.
Improving process performance is all about understanding what is happening and being able to respond quickly. There is always a paradigm shift in the manufacturing industry which is periodic in nature. Today, the shifts seem to be towards smart factories where information generated in the virtual world flows into real manufacturing processes to make the production environment more intelligent, flexible and attuned to the necessary specifications and standardisation. This will enable devices and systems to communicate with one another more smartly and exchange information precisely. By introducing cost-effective measurements based on wireless technology has helped Hindustan Zinc to improve visibility with real time, online, accurate process monitoring and at the same time enhancing flexibility for future needs. To remain competitive amid a fluctuating market condition and wobbly economic scenario, utility monitoring is identified an area in the plant with more than 50% of energy consumption. Hence the decision to implement wireless technology in the facility for utility monitoring is a strategic choice as it will help
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to improve visibility, optimise the production cost, reduce energy consumption, congregate real time process variables from the fields, ensure safety and compliance. Moreover, it was first time ever in Hindustan Zinc that it was conceptualised to use wireless mass flowmeters for mass reconciliation at Chanderia Smelting Complex(CSC).
Challenges & issues There was a huge shortfall of High Speed Diesel (HSD) consumption v/s receipt ratio, which was identified in the month of May 2012. Soon after one task force team was formed to find out the various causes for this variance. Also, an external auditor was appointed to assist in finding out the probable causes. As per the outcome of the auditor report as well as the task force, it was recommended to install mass flow meters to measure the HSD consumption at major locations which was one of the implementation part of the report submitted by the
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T E C H N O L O G Y | W i r e l e s s a u to m at i o n
A complete device communication status
auditor. In existing HSD circuit, mechanical type meters were being used to measure the HSD consumption that has lower accuracy levels (upto +/- 2%). There were total 15 such meters in existing scheme. Also wiring the meters would prove to be highly cost prohibitive and time consuming.
Inspired by technology Many industries are deploying wireless networks for targeted applications. Hindustan Zinc thus chose Emerson Process Management’s wireless technology to monitor flow and level of High Speed Diesel (HSD) for mass consumption/ reconciliation at CSC complex. Both the requirements of online accurate and real time monitoring and measurement of main HSD tank is now possible and highly accurate HSD consumption & reconciliation of data for different areas of the plant. The new wireless solution with mass flow meters can deliver accuracy level of +/- 0.1%. A proposal to deploy 10 numbers of highly accurate mass flow meters to bring the consumption and receipt difference within (+/-1.3%) as an overall system accuracy of HSD volume handled has been made. The system needs no site survey or line of sight requirement for deploying wireless & is reliable, safe and secure. The mass reconciliation wireless system at the CSC complex is based on 10 mass flow meters, 1 set of inventory radar gauging system, 1 set of smart wireless gateway and wireless components. It is seamlessly integrated to the system and complete device communication status is available as shown in the above figure. The performance of wireless network after the
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installation and commissioning is excellent in terms of HSD reconciliation at CSC complex from May 2013 onwards.
Technology advantages Wireless technology offers several advantages such as review of historic trend of consumptions; cost savings with no cable laying and associated hardware; faster startup; web/network based secure and safe data monitoring at centralised location; accurate data with accessibility from remote location; fully automated system with no manual intervention; ability to add devices ‘at will’ for future expansions/debottlenecking and predictive maintenance due to availability of advanced diagnostics.
Start anywhere With current wireless network now in place, additional devices can be added anywhere in the plant at much lower cost than if they had to be wired in and without having to worry about the existing cable infrastructure. Potential applications where the benefits of wireless technology can be extended in future could be pump health monitoring, steam trap/relief valves monitoring, temperature profiling, moving/rotating equipments, water intake monitoring, waste water treatment, fire, gas, smoke, spills & leaks, heat exchangers & filters, corrosion and many more. ☐ Courtesy: Emerson > MORE@CLICK ADI03534 | www.AandD24.in
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d r i v e s &&cDRIVES MOTORS o m p o n e| natpsp l| i cat T E C iHon NOLOGY
Out-of-the box ideas The article highlights how Universal Robots aim to establish the flexibility of articulatedarm robots in industrial production by developing UR 5 and UR 10 models for SMEs in particular
Ian Young Key Account Manager Kollmorgen, Ratingen
Universal Robots has developed the UR5 and UR10 models for small and medium-sized enterprises in particular. The handling units lift a payload of five and ten kilograms, but only weigh 18 and 25 kg themselves, respectively. This low weight makes it possible to move the units easily without complex subcomponents. The multi-functional robots are just as flexible in operation given their user-friendly software. It supports the Danish company with a user-friendly piece of software. Using this, the six-axis lightweight robots are ready for new tasks in no time. No special knowledge of robotics is necessary for the programming.
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Modular design The exceptional ratio of dead weight to loading capacity is the result of a sophisticated lightweight construction that does not contain anything that is not required. With the drive technology, this minimalist strategy means integrating the companyâ&#x20AC;&#x2122;s frameless kit motors directly into the articulation axes. In doing so, the robot takes on the function of the motor housing, while the gear unit simultaneously serves as the primary bearing of the rotor. Viewed as a whole, the components used by UR frequently take on multiple functions
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T E C H N O L O G Y | MOTORS & DRIVES
The KBM motors offer a great deal of freedom to configure the servo axes in space-optimised way due to their variable, modular design
and this ultimately reduces the number of mechanical components such as ball bearings, couplings, or shafts considerably, thus decreasing the overall system weight and form factor. In addition, with their high power density, it also increases the lifting capacity of UR5 and UR10 platforms. The KBM motor series offers advanced electromagnetic designs for optimised torque and minimal cogging & harmonic distortion. These benefits are offered over a large operating speed range. The electromagnetic technology with a high packing density in the stator increases torque and keeps thermal losses low. High strength rare earth magnets are used in the rotor, which allow a continuous torque of 1.45 to 3,445 Nm along with a peak torque of 4.91 to 12,812 Nm. “The high quality of these motors was a reason why we opted for Kollmorgen”, explains Esben H Östergaard, Technical Business Manager, Universal Robots.
Operation without noise but high energy efficiency One of the advantages of the robots is its low-noise and energy-saving operation. From a total-cost-of-ownership perspective, the economical use of resources directly increases the efficiency of the overall robots. Thus, the competitiveness of this technology also increases. An additional benefit of high energy efficiency is closely linked to reduced losses in the motors. Since efficiency is high, less heat is produced. This means the motors stay cooler, operate below their maximum ratings and consequently achieve a longer service life.
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The improved temperature behaviour also prevents the entire construction from heating up. “The motors we used in the past became pretty hot when in continuous operation. For the lower losses, the KBM motors simply stay colder. We can therefore run our robots in continuous operation without derating”, says Östergaard. He also refers to test procedures with long operation periods and comparatively high loads. The KBM series is an innovative direct drive frameless motor technology provided by Kollmorgen. The frameless kit motors offer mechanical and plant engineering a wide range of solutions for creating applications with a maximum degree of flexibility, power density, dynamics, and durability. In addition to the technical advantages provided by this product, it includes 14 frame designs and many pre-engineered standard options with competitive lead times. “We can basically order as many motors as we want, when and how we want,” emphasises Östergaard. This aspect is of particular importance because Universal Robots is growing strongly. “We therefore need a partner in drive technology who is a good fit for us.” In this regard, Kollmorgen was able to impress the Danish robot specialists with delivery reliability and has since established a UR-specific production line at the Czech location in Brno. “We can expand our business channels,” says Östergaard. This development is accompanied by the fact that due to sophisticated safety technology both models are even able to be employed without additional shielding. This opens the path to a safe and comfortable cooperation between staff and technology. ☐ > MORE@CLICK ADI03535 | www.AandD24.in
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M OTO R S & D R I V E S | T E C H N O L O G Y
Intuitive engineering The article illustrates how thermoforming machines can be equipped with efficient synchronous motors. These machines are used in food packaging, industrial products and medical pharmaceuticals. The global population is growing and by 2050, the need for also industrial products or medical pharmaceutical products food will double. This means not only the production of food, are packaged and sealed by thermoforming machines. but also transport and storage are the important areas that Although the energy consumption of thermoforming machines will have to be taken into consideration. Even today, an is not particularly high, it is still worthwhile to take a look at enormous portion of food does not reach the consumer this aspect. Due to the tight calculated costs and low profit because it spoils en route or in storage. Approximately 1.2 margins for packaging materials, significant benefits for the billion tonnes of food is wasted worldwide per year. The machine operators can be achieved by small optimisations. packaging industry, therefore, needs to offer solutions that provide better storage and safer transport of food worldwide. Higher degree of effectiveness Thermoforming machines in particular is very important. with synchronous motors Cheese, meat, fresh fruit and vegetables are the food categories Considering these factors, Baum端ller, a Nuremberg packaged by thermoforming machines. Not only food, but
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specialist for automation systems & drive technology, equipped thermoforming machines with efficient synchronous motors. In comparison to asynchronous motors currently preferred for such machines, synchronous motor has a higher degree of effectiveness, and thus more efficiency, due to the use of permanently excited magnets. The DS synchronous motors from the company also offer high torque precision and provides machine builders more flexibility in machine design and decrease the necessary space thanks to their compact structural shape. In conjunction with the energy efficient inverters b maXX 5000, which are also available as feeder and regenerative units and the scalable b maXX controller PLC, the company supplies an efficient and reliable automation system for thermoforming machines. One of them has been installed, for instance, at the Indian manufacturer — Rajoo. The stackable inverter b maXX 5000 offers the benefit of flexibly expanding and modifying entire drive lines without disconnecting the line thanks to the integrated drive-connect system. In addition, pluggable safety modules are available for these inverters, so they can be flexibly adapted to the requirements of the applicable national regulations and the respective application. The safety controls for controlling the respective application and the safety-related programming in accordance with the machine directive are included in the portfolio of the Nuremberg manufacturer.
Faster and more efficient software modules Comprehensive software module kits offer special benefits to machine builders. The technology modules significantly shorten the time-to-market since these provide preprogrammed and validated software modules to the automation technician. The existing library is so comprehensive that the movement processes in thermoforming machines can be executed using pre-programmed modules. These standard modules include modules for automatic roller changes, energy-optimised adaptations of the movement profiles in the machine or for regulating heating elements. The heating elements integrated in the machine, which warm the laminate for processing are controlled centrally or locally via software modules. Here, in particular, significant savings are possible because heating elements are by far the largest energy
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consumers in thermoforming machines. With the most precise regulation possible, this consumption, which is unavoidable in thermoforming machines, can be reduced as much as possible. Using software modules, for precisely recording print marks, can also quickly regulate positions. This saves material since the plastic shells are cut very precisely. Via controls using cam disc technology with a virtual guide axis, sporadic movements in the machine are avoided which in turn protects the mechanisms, reduces wear and tear and, due to the optimised motion control, increases the energy efficiency of the machine. By using EtherCAT, the highperformance real-time ethernet bus system, Baumüller achieves coordinated motion control in real time.
Benefits All software modules are integrated into the ProMaster Engineering Framework. The machine builders can depict the entire machine in this intuitive and comprehensive automation suite. This saves an enormous amount of time as a system diagnosis can be performed during commissioning. In addition, during programming, different machine models can be designed which simplifies the variant handling for the machine builder as the correct version is automatically created for the respective machine type. This is an enormous advantage for the machine builder for designing different machine concepts. In addition, the company has integrated a service and production technology which reduces the system down time to a minimum.
Conclusion When it comes to efficiency in thermoforming machines, there are a number of options for reducing energy consumption and increasing the overall efficiency of the system. The improvements include selection of the right motor, movement optimisation via software and precise control of the heating elements. Such improvements increases energy efficiency and also reduces material wear & tear along with increasing the product quality and productivity. ☐ Courtesy: Baumüller > MORE@CLICK ADI03536 | www.AandD24.in
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R o b ot i c s & H a n d l i n g | T E C H N O L O G Y
Designing cable management systems for 6-axis robots This article deals with designing cable management systems for six-axis robots including cables, hoses, tubing, carriers, and connectors in three separate sections In recent years, cable management has come into the limelight because machine reliability has increased dramatically, even though robots have grown more complex. Unfortunately, the methods used to attach and guide cables have not quite followed suit. While managing cables and hoses is often an afterthought in most designs, it is truly a vital part of any wellfunctioning robot. Since the 1960s, cable management methods for robots have not changed dramatically. Most experts agree that one of the top blunders made is underestimating cable management issues. For instance, during a conference hosted by the Robotic Industries Association (RIA), a group of leading system integrators cited cable issues as the number one reason for downtime in robotics cells. Headaches range from tangled and corkscrewed cables, to complete breaks that cause downtime, lost revenue and damaged reputations. This is why the ways in which robot cables are attached and guided is important. The less is more approach to cable management is a
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Jörg Ottersbach Head of Industry Management, Automotive & Robotics igus GmbH
best practice that robotics engineers and integrators can apply. It centers on designing cable management systems for six-axis robots – including cables, hoses, tubing, carriers, and connectors – in three separate sections.
Overview of industrial robots The term robot is defined as a machine capable of carrying out a complex series of motions automatically. It was first introduced in a Czech science fiction play and then in 1942, the term “robotics” was coined by Isaac Asimov, a well-known American author and professor of biochemistry at Boston University. By 1970s, robotics had made its way into most manufacturing facilities, predominately in the automotive industry, and by 1980, more than 4,000 robots were being used in the US. Fast forward 30 years, and more than 1.3 million industrial robots
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Corrugated tubing is available in a wide range of size and styles
have made their way into manufacturing plants throughout the world. During this robotic evolution, many different types of robots emerged. Some of the most common include cartesian (gantry / linear) that are rectangular arms described as using X, Y or Z axes spherical (polar) 1 linear axis and 2 rotational axes around the vertical shoulder joints. Jointed-arm (6-axis / articulated) that are rotating shoulder and elbow in horizontal axes. SCARA (selective compliance assembly robot arm) the special jointed-arm version and cylindrical (post-type) 3 degrees of freedom, Y and Z linear movements, rotating base. What do all these robots have in common? The cable management system is typically left to the last minute, but without it, unprotected cables are likely to fail. Cable damage can shut down the most important robot on the line, which leads to costly downtime.
This breakdown is the key to longer-lasting cables. Each cable section needs a minimal dress pack, strain relief with service loops, and a junction box that contains and protects the electrical connectors joining the cables. Use of a strain relief mechanism can eliminate stresses and extend the service life of a moving cable. This strain relief may consist of standard elements such as tie wrap plates or clamps. Engineers should ensure the cables are in the neutral axis, not touching the inner or outer radius of the cable management system. From the sixth to third axis • Strain relief cables on the moving end (sixth axis) with a one- to two-foot service loop. • Protect cables and hoses with a modular, multi-axis cable carrier. • Separate cables at the third axis and install a junction box for diagnostics and cable replacement. The less is more approach for six-axis robots From the third to second axis Current systems try to keep the cables on a six-axis robot • Strain relief cables on the third axis with a one- to two-foot service loop. static while everything operating around them is dynamic. Using one, long restrictive cable package prevents movement in • Use a modular, multi-axis cable carrier. sync with the robot. Restrictions stress cables, which accelerates • S eparate cables and install a junction box at the second axis. failure. Often technicians severely bind cables with excessive dress packs (protective coverings on cables), cable ties, and From the second to first axis even duct tape. The goal is to minimise tangling and interference • Strain relief cables on the second axis with a one- to twofoot service loop. with the machine, but these types of solutions cause • Multi-axis, reverse bend radius (RBR) cable carrier, corkscrewing and failure. protecting and guiding rotating cables. Instead, consider a six-axis robot as three separate sections: the sixth to third axis; the third to second axis; and the second • S eparate cables and install a junction box at the first axis. Separating the dress pack into three shorter sections to first axis.
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Robotic cable carriers offers additional benefits not available with other systems
prevents it from wrapping, catching or snagging on machines and minimises stress on cables and hoses. This approach applies to any six-axis robot, regardless of manufacturer or application. While other fixes such as duct tape and ties wraps might cost less and work temporarily, in the long run, properly designed dress packs reduce unnecessary downtime and maintenance costs. Six-axis robots can be found in applications such as robotics / automation, machine tools, handling machines, packaging machines, and many more. In addition to the appropriate dress pack, it is imperative that six-axis robots use dynamic cables specifically designed for continuous flexing. Two important features to take into account are a cable’s torsion-resistance and shielding. Shielded cables face a greater risk of failure because constant movements can easily compromise the cable jacket. Use unshielded, high-flex cables whenever possible to avoid problems. If this is not an option, turn to special “rolling-flex” cables.
Cable management options There are different options available for guiding and protecting cables on six-axis robots. Three well-known solutions include flexible tubing, enclosed dress packs and robotic cable carrier systems.
Flexible tubing Corrugated- or flexible-tubing is one option for protecting cables on six-axis robots and is available in a wide range of sizes and styles. It has superior tear resistance at connection points and a long service life, even with reverse-bend cycles. However, corrugated tubing has its limitations. It delivers
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minimal torsion resistance, and can only be fixed at two points with a defined length. The tubing can also stretch as the robot moves, which puts undue stress on the cables. Tooling interference sometimes occurs because there is no control path for movement.
Enclosed dress pack An enclosed dress pack mounts directly to the robot and is available in multiple configurations. It uses corrugated tubing installed inside a plastic-reinforced housing to protect cables. The system’s spring-loaded design minimises catch and pinch points. Due to the completely enclosed housing, cable maintenance is difficult, and because it is not modular, the entire unit must be replaced if one component breaks. Problems can also arise if the programming or movements of the robot change. This is because an enclosed dress pack does not prevent the cables from exceeding their maximum bend radius.
Robotic cable carriers Robotic cable carrier systems are at the core of the less is more approach, and can be used universally for six-axis robots. The system mounts directly to the robot and is available in multiple configurations. Like an enclosed dress pack, it has a spring-loaded design, which minimises catch and pinch points. However, robotic cable carriers offer additional benefits not available with other systems. They can come equipped with strain relief options to extend the service life of the cables; cables can also be quickly added or removed without dismantling the system. The defined bend radius of a robotic cable carrier protects cables from exceeding their maximum
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T E C H N O L O G Y | R o b ot i c s & H a n d l i n g
bend radius. The limitations of the system include minimal resistance to high-concentration acids and caustic chemicals, and the inability to handle circular movements with heavy loads. Robotic cable carriers are well suited for welding robots in tight areas, multiple-tool applications, material-handling jobs, and de-burring operations. For added flexibility, robotic cable carriers are available in a fully enclosed design, a pullthrough design for easy cable access, or as a lightweight, lowcost system for applications that do not require cables to be completely enclosed.
Additional tips Ideally, a robotic cable carrier system should allow sufficient clearance inside the cable carrier for electrical cables, pneumatic hoses and tubing for other media. This compensates for relative forces between cables and hoses. Cable carrier suppliers typically provide this data. For instance, general rules of thumb for the line of robotic cable carriers from igus® include total cable and hose diameters must not exceed 60 percent of the carrier diameter; leave at least a 10 percent clearance between
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any two cables or hoses and cables and hoses need to move freely inside the carrier. The less is more approach also eliminates some safety concerns within a robotics cell. Cables are able to move more freely, but are protected and guided properly so that they will not injure workers. Ideally, a robotic cable carrier system should guide cables in one continuous path; eliminate loose, unmanaged cables; control the bend radius of cables to avoid pinching; have the ability to quickly add or remove cables and be available as a fully enclosed design for extremely harsh environments. The Triflex® RS robotic cable carrier system from igus® was designed with the less is more approach in mind. It ships and installs as one piece and has an integrated fiber rod that returns cables to a home position after the robot completes a cycle. The system includes mounting plates and brackets, protection links, and a pre-engineered fiber-rod assembly. It is a modular, compact system, but with only one piece to install for complete end-of-arm tooling guidance. ☐ > MORE@CLICK ADI03537 | www.AandD24.in
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Fieldbus & Networks | technology
Remote eavesdropping An American manufacturer of equipment for concrete pipe production added remote maintenance capability for its machines located at other location which enabled a fully transparent information flow of the automation system of the production facility.
C
R
Armin Beck Product Manager, Hilscher GmbH, abeck@hilscher.com
When it comes to servicing and maintaining a production concrete pipes, the others serve to produce the required steel system, speed is of primary importance. For this reason, an reinforcement. “All three systems run with Siemens S7 PLCs American manufacturer of equipment for concrete pipe and offer practically fully automated operation. Manual production wanted to add remote maintenance capability to intervention is limited to minor aspects, such as changing three systems at one of its customers. But in order to be able to recipes and updating software”, said Bob Fehr, an Hawkeye monitor the local data stream all the way down to PLC level, a Pedershaab automation engineer. For process automation of its major communication obstacle needed to be removed. systems, it has opted for the Siemens process control system Fortunately, Hilscher has a solution that was ready out of the SIMATIC S7®. box. HawkeyePedershaab is a world leader in the market of machines for the production of concrete pipes. Safety at a high level In 2011, HawkeyePedershaab installed three fully automatic production systems at a concrete factory in the province of An equipment to produce concrete components represents an Quebec in Canada. One of them is used for the production of assembly of impressive dimensions and handles products
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Red netw
technology | Fieldbus & Networks
weighing several tonnes. So, HawkeyePedershaab uses additional IM151 7F safety PLCs positioned between the individual S7 PLCs and several distributed Siemens ER200 S I/O units used for each equipment.
Translating between protocols The solution is called netLINK (model NL50-MPI) provided by Hilscher. The German-based company is specialised in communications solutions for factory and process automation and operates its own subsidiary in India. It is an intelligent gateway in the form factor of a data bus plug that can be plugged directly into the S7 PLC. It is based upon the versatile netX chip from Hilscher and is able to read practically any
industrial communications protocol and translate it into any other protocol. Power supply is accomplished either directly via the terminal of the device it is connected to or via a separate 24 VDC connection. “The Hilscher netLINK proved to be the perfect solution. It allows us to reach the factory via the Internet and access the IM151 modules via their individual MPI terminals without having to obtain costly S7 Ethernet CP components from Siemens”, adds Fehr.
Remote-controlled safety Due to the netLINK, the complete information flow of the automation system of a production facility becomes fully transparent and is available via a conventional Ethernet
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© 2014 Red Lion Controls Inc. All Rights Reserved.
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Fieldbus & Networks | technology
As a 100% replacement of expensive Ethernet-CP, NL 50-MPI allows control, programming, remote maintenance and connection of visualisations such as WinCC over Ethernet
network. Where Ethernet is available, Internet and VPN also represent no problem. It was therefore rather simple for HawkeyePedershaab to realise the desired remote maintenance for its machines located in Canada. “If access to a machine is required, its MPI terminal only needs to be connected to one of the netLINKs. It only uses one IP address, which makes it easier than using three separate netLINKs, for we do not have to worry about assigning IP addresses. Since we are dealing with a safety issue, we need to be extremely careful. However, the netLINK lives up to our requirement 100 per cent, making it rather easy for us to download and upload data in order to solve problems – just as if the machine would be located right here at our premises.”
company now plans to extend this time and cost saving remote maintenance system to additional manufacturing locations.
Conclusion
As a 100% replacement of expensive Ethernet-CP, NL 50-MPI allows control, programming, remote maintenance and connection of visualisations such as WinCC over Ethernet. As a real highlight, the device allows the Ethernet coupling of Ethernet port less S7-PLCs over their MPI or PROFIBUS interface with automatic DP/MPI baud rate detection. To configure a PLC to PLC connection NetPro in STEP®7 is used as usual. Also routing across multiple and networked PLCs is possible. The protocols RFC1006, DHCP and NTP time distribution to a PLC are part of the comprehensive scope of Small component with far reaching effect services supported. The device is configured either in STEP7® By now, the remote maintenance solution of the three machines with an embedded driver or via a web browser. The driver is HawkeyePedershaab installed in Quebec is live and running Windows 7® and STEP®7 64-Bit compatible and supports for more than two years and works without any problems. Siemens TIA Portal already along with all S7 Engineering tools Sometimes the key to a solution is simply the right translator for full access to Profibus diagnostics and services in STEP7®. to overcome communications problems and add the In addition, Hilscher also provides the DIN rail mountable functionality to a manufacturing system that will save costs at version of NL 50-MPI device called as NT 50-MPI where 16 a considerable level, by eliminating the need to send a service simultaneous Ethernet connections and the access to maximum technician on site. HawkeyePedershaab is fully satisfied with 32 PLCs in parallel are supported. ☐ their new solution, which seamlessly integrates with its > MORE@CLICK ADI03538 | www.AandD24.in Siemens SIMATIC S7 process automation environment. The
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M 2 M c o mm u n i c at i o n | t e c h n o l o g y
Transforming Industrial & Energy Systems with IoT With billions of units generating more than $1 trillion in revenue today, the Internet of Things (IoT) market is already bigâ&#x20AC;&#x201D;and itâ&#x20AC;&#x2122;s growing fast. Analysts predict the market will grow with a doubledigit compound annual growth rate (CAGR), and IDC forecasts that revenues will double by 2015. This feature highlights the challenge to translate the intelligence in connected embedded devices into new products and services that solve customer problems, drive customer engagement and loyalty, and deliver even higher value to the economy. Analysts are unanimous about one aspect of Internet of Things (IoT): the opportunity is huge. Experts predict that there will be anywhere from 20 billion to 50 billion connected devices by 2020. IDC forecasts that the volume for embedded
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Thilak Kumar Regional Engineering Manager Wind River India
systems will outpace any other mainstream system type, reaching 8.9 billion unit shipments by 2015 with 75% of revenue opportunity. Machine-to-Machine (M2M) technology adoption is also spiraling upward. There are already more than
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t e c h n o l o g y | M 2 M c o mm u n i c at i o n
a billion M2M devices at work in sensors, smart meters, industrial control systems, mobile healthcare assets, video surveillance systems, automotive and telematics solutions, smart buildings, and more. Wireless M2M connections alone increased by 37% last year to reach 108 million, according to a report from market analyst firm Berg Insight. The seemingly sudden arrival of IoT and its network of intelligent systems have actually been emerging for years. Innovations in network connectivity, mobile and wireless technologies, multi-core processing, M2M communication, sensor technologies, cloud computing, and data analytics have converged to create an entirely new form of intelligenceâ&#x20AC;&#x201D;and astonishing new capabilities to optimise the productivity of processes and efficiency of decision making. Early adopters of the IoT, sometimes referred to as Industry 4.0 or Machine to Machine (M2M) communication, are the
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industrial and energy markets. These are so heavily mechanised and automated that they very well understand the role that IoT can play in transforming business. These industries have been incorporating sensors and automation into workflows for decades; yet less than 10% of their legacy systems are connected, leaving valuable data localised in devices and equipment, from HVAC sensors to manufacturing robots to building elevators. Once connected this data enables operators to track output based on real-time and trended data analysis to optimise for power efficiency, performance, and operational life. Smart IoT devices can manage the distribution of energy across the smart grid based on real-time data and provide situational awareness. They will also connect once-discrete systems and allow for communication across the factory floor to IT and management. Industrial systems are becoming connected information hubs. From real-time logistics and supply chain management to
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M 2 M c o mm u n i c at i o n | t e c h n o l o g y
Smart devices in the Internet of Things (IoT) will manage the distribution of energy across the smart grid based on real-time data and provide situational awareness
production planning to automated quality control, converged networks deliver visibility across the entire process and enable centralised control. In addition to transforming existing operations through productivity gains and economies of scale, IoT presents entirely new lines of business and services otherwise not possible. Let’s consider some of the key elements within IoT that can transform the way industrial and energy systems are managed today.
operators with connectivity and communication, both within the factory floor and to enterprise IT, to optimise efficiency and reliability. Device-level data aggregation alleviates bandwidth strain by reducing machine-generated data sent to the cloud-based central control systems and back. Algorithms analyse the data to identify factors affecting overall performance. Operators utilise this data to make the adjustments necessary to keep production running smoothly and at optimal capacity while maintaining quality.
Sensor data
Cloud-based central control system
With critical sensor data, operators are able to schedule and manage efficient repairs, performance adjustments and maintenance. New equipment with sensors can alert operators when a machine is not performing properly or showing signs of stress, and maintenance can be scheduled accordingly. With all of the real-time data available, operators rely on data and automation to ensure safety and reduce costs. In the IoT, data is available whenever and wherever required, making planning and spotting potential problems more efficient, triggering preventive maintenance routines, and reducing downtime. Smart devices in IoT will manage the distribution of energy across the smart grid based on real-time data and provide situational awareness. They will also connect once-discrete systems and allow for communication across the factory floor to IT and management. Whether incorporated into your new factory equipment or as a bolt-on solution to a legacy system, gateways provide
A cloud-based central control system provides operators with real-time equipment transparency and visibility to monitor and analyse consumption patterns, predict impending failure risks, and evaluate any piece of equipment at any time. Predictive maintenance capabilities help mitigates outage and downtime. An example on this context is Wind River® that provides industrial and energy customers the tools and technology to meet stringent real-time determinism requirements while taking advantage of the flexibility and cost benefits of open standards. In highly regulated industries and mission-critical applications—where security is paramount and failure is not an option the company delivers intelligence where it’s needed, supplying the foundation that enables IoT networks and connected devices to perform reliably, safely, and efficiently. ☐
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> MORE@CLICK ADI03539 | www.AandD24.in
A&D India | Aug-Sep 2014
8/14/2014 8:36:23 PM
technology | machine vision
Keys to successful multicore optimisation Optimising a machine vision application for multicore PCs can be a complex process with unpredictable results. To achieve best overall system, it is necessary that developers pay close attention. Field-testing under actual conditions is the only way to fully measure system throughput. Machine vision speed increased automatically with increasing microprocessor speeds. However, with multicore PC architectures, it is different, as it requires software design changes to take advantage of parallel processing architecture. A multicore strategy for machine vision can be implemented at multiple levels. Independent high-level tasks — especially those with hardware dependencies, such as acquisition and I/O — can be written to run asynchronously on separate cores, leaving processor free to do those tasks that are not blocked. Individual vision tools can also be parallelised so that they divide their processing task among several cores.
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Didier Lacroix Vice President — International Sales & Marketing Cognex Corporation didier.lacroix@cognex.com
Multicore PC architecture Earlier, to handle bigger and complex application, vision applications depended on advances in PC hardware. However, this requires higher heat dissipation, where cooling has become a limiting factor. Manufacturers like Intel and AMD use multiple processors instead of a single processor. These processors are packaged on a single chip. Each processor is called a ‘core’, and new chips are called multicore processors. Two, four and eight-core processors are now common, while much higher density models are also being designed.
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machine vision | technology
Figure 1: Example of partitioning an image across multiple threads
Optimised software is the key It is not possible to move an existing machine vision application from a single-core PC to a multicore PC and expect performance improvement. Some applications may not run any faster on a multicore machine due to operating system overhead and other inefficiencies. Programmes must be rewritten to speed up their applications, as many algorithms do not lend themselves to parallel processing. Here are four keys to successful multicore optimisation for machine vision applications. These are application optimisation; vision tool optimisation; tuning for overall system performance, and software portability.
Processes & threads PC operating system manages programs as separate processes. Each process has an associated context and when process is blocked the operating system saves current context and swaps in another process. System processes responses to a range of demands, which is invisible to the user. A multithreaded program can be written so that different sections run simultaneously and independently. These are much lighter and share the same address space, allowing it to switch quickly making it easy for them to share data when running in parallel. Multithreaded applications do not require a multicore architecture. They are efficient on a single-core machine, but rely on operating system to manage hardware resources for them. Multithreading is suited for multicore PCs and algorithms that ran sequentially, can be partitioned into separate threads that now run in parallel on separate cores.
Commercial multithreaded software Writing multithreaded application code is not simple and requires underlying machine vision libraries to be written in a re-entrant manner that allows multiple instances of the program to execute in parallel. For this, writing custom
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software at application layer to take advantage of a multicore PC is usually only justified in very demanding applications. Off-the-shelf solutions may not be efficient as custom code, but can provide significant benefits at very low cost. 1. Application optimisation: Application-level software can be optimised for multicore PCs in three ways. Firstly, by creating separate threads for tasks with hardware dependencies, such as image acquisition, accept/reject results, operator interaction and are often designed to minimise unpredictable hardware delays. Secondly, by creating separate threads for each camera in a multi-camera application, allowing each thread to run as soon as its camera is triggered. And thirdly, by creating separate threads for different machine vision tasks within a vision application. However, this works if the tasks are not dependent on each other, and the benefit will be small if one task is much shorter than the other. Some commercial machine vision products have built in these features. For example, CognexVisionProâ&#x201E;˘ software create separate threads for image acquisition and vision processing and can detect number of cores in a PC and create threads based upon it. This type of scalability is advantageous in multicore PCs for applications with multiple image acquisition and vision processing tasks, which need to be performed simultaneously. It is beneficial on single-core PCs, because image acquisition does not use much CPU time and can therefore run in parallel with image processing operations. 2. Vision tool optimisation: In addition to applicationlevel optimisation, it is possible to optimise machine vision tools by parallelising their algorithms so they use multiple cores simultaneously. However, not all vision tools can be easily parallelised. Parallelisation is helpful for image processing filters or other vision tools that run local operations on small regions of the image. Commonly used filters include median, Gaussian and morphology operations can be optimised by dividing image into different pieces and assigning each one to a separate thread (Figure 1). The final speedup depends on algorithm and number of cores. Because of overhead, there will always be
A&D India | Aug-Sep 2014
8/19/2014 12:51:21 PM
technology | machine vision
Figure 2: A vision application divided into
Figure 3: One vision thread per core may
three threads running on a four-core PC
not be the optimum choice. This application finishes later than the one in Figure 2, even though this one has one thread per core. Depending on the application, more or fewer threads may be better
some inefficiencies, so even a well-optimised vision tool may not run eight times faster on an eight-core PC. Many vision applications spend most of their processing on tools that are more complex than simple image processing filters. It is not always possible to parallelise complex vision tool algorithms such as alignment and optimising the tool might only benefit a small portion of the algorithm. The PatInspect™ tool has been redesigned so that inspection steps are divided among available cores. Even when percentage improvement is lower than for simple image processing filters, overall application may benefit more, since complex machine vision tools generally consume large portion of overall application. 3. Tuning for overall system performance: Fastest vision application would be one that control every processor core in the PC and create one thread to run on each core. The PC must also support operating system, machine control and other background tasks. In practice, optimum number of threads for vision application may not necessarily be the same as the number of cores in the PC, and may not make sense to assign each thread to a specific core. The only way to determine optimum number of machine vision threads is to test it under realistic conditions.Cognex’s CVL™ and VisionPro™ software libraries give users a simple method to set the number of threads for multicore-aware vision tools in an application. This top-level ability lets users easily tune the system for best overall performance. 4. Software portability: Another concern is software portability from one PC to another. PC hardware changes quickly that vision applications will be deployed on multiple PC models, either when new vision stations are deployed or needs to be replaced. Machine vision application is usually developed on a different PC than on which it is deployed and replacing PCs deployed in manufacturing lines is a constant maintenance issue. Since number of cores available may change over time, there should be a vision application, which can account for any
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number of cores in the system. Redeploying existing system on a different PC may require recompilation or rewriting application software, which is high cost as development stations are modified and developers move on to other projects. CVL and VisionPro™ libraries can automatically detect number of cores on a PC and dynamically adjust number of threads that they create allowing applications written for a four-core PC to run efficiently on an eight-core PC without touching the source code or recompiling.
Summary Optimisng a machine vision application for multicore PCs can be a complex process. It is clear that developers must pay attention to achieve best overall system performance. Fieldtesting under actual conditions is the only way to fully measure system throughput. To maximise benefits of multicore PC technology in machine vision applications, developers should consider several key questions when evaluating machine vision software products. These should include points such as whether image processing filters have been optimised for multicore, as also other factors that can impact the performance of overall application, including: • Can the software product automatically create separate acquisition and processing threads to speed system throughput and responsiveness? • Does the software allow users to write their own multithreaded application? • Can users tune the number of threads for best overall system performance? • Does the software have the ability to automatically detect and adjust the number of threads, based on the number of cores, without having to rewrite the application? By keeping these points in mind, users can maximise their options (and minimise their work) to take full advantage of multicore PC technology. ☐ > MORE@CLICK ADI03540 | www.AandD24.in
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machine vision | technology
Revolutionary simple and ingeniously fast The new 3D vision automation makes it significantly easier for users to install and integrate them into their systems and processes. The automated processes using 3D robot guidance achieve greater flexibility and higher productivity With its innovative standard product line, ISRA Vision has integrated its 25 years of industry experience, making 3D robot guidance possible without expert knowledge. Production managers on the factory floor are able to quickly and easily integrate ready-to-use sensors into their systems all on their own. In todayâ&#x20AC;&#x2122;s world, 100 per cent monitoring and fully automated processes using 3D robot guidance are key elements to achieve greater flexibility and higher productivity. Machine vision systems make the use of robots even more flexible, which have demonstrated that they can reduce costs and also provide documentation of the manufacturing quality that without them would not have been possible. Until recently, users stayed clear of 3D robot guidance in many industry
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sectors. The technology was too sophisticated and too complicated. We have now passed that stage. For any application, from 2D to 6D, an easy to use product line consisting of sensors and software, scalable in terms of resolution and accuracy and ready for use is now available for 3D robot guidance: install, and connect. Instead of wasting countless hours programming, now you will only need to set a few parameters.
GigE based sensors The GigE based sensors can be used in either stationary or mobile applications and provide the highest rate of accuracy even for large components. For example, MONO3D will make
A&D India | Aug-Sep 2013
8/14/2014 9:14:49 PM
technology | machine vision
Sensor for web-supported robot guidance with structured light from the new range of ready-to-use GigE sensor products for highly precise 3D positioning and orientation determination – with integrated 3D form matching.
it possible to perform 3D measurements of position and orientation with a single sensor. The sensor determines all six degrees of freedom for a three-dimensional object using only three attributes. The lighting is already integrated in the sensor’s enclosure. The stereo sensor uses two sensors for stereoscopic vision and with them determine the object’s 3D coordinates or defined image segments. More areas that are difficult are illuminated using the integrated lighting.
Sensor for web-supported robot guidance SHAPEMATCH 3D makes use of multiple projected lines. Its primary application, when combined with 3D form Matching, is for web-based robot guidance. Robust and highly accurate results are achieved because of the high redundancy of measuring lines. Several single sensors can be combined to a sensor group. The SHAPESCAN3D sensor is designed to allow robots to perform bin picking, meaning to reach into the box. Even in the most difficult lighting conditions, the positions of lower level, randomly distributed objects can be determined threedimensionally in different depths of large bins. The robot can remove unsorted parts directly from the transport bin and without the need for complicated mechanical structures - can then feed them into the production process.
Benefits As compared to mechanical separation, the robot’s ability to directly reach into the box brings with it the benefits of flexibility in the range of parts as well as cost reduction
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advantages, because the need for mechanical feed components is significantly lower. The following applies to all sensors: The standard Gigabit-Ethernet (GigE) interface lets data be exchanged at extremely fast speeds. In addition, many other standard communication interfaces are supported, such as Profinet and Profibus. The robust sensors are supplied quickly and easily via Power over Ethernet (PoE). The sensors are combined with new software technology. It offers a modern graphic user interface that allows the user to navigate intuitively on the touch screen to operate the system.
3D vision automation The new 3D vision automation will make it significantly easier for users to install and integrate them into their systems and processes. “Plug & automate” means that workers will now have the capability to install 3D robot guidance on their own and put it into operation immediately. The software is available in combination with the sensors, but is also sold separately. Users can determine for themselves exactly what they need for their systems. You can easily start working with 3D robot guidance in a flash, because instead of complicated programming, all you need to do is set a few simple parameters. With its new philosophy, ISRA will be pioneering new application areas for 3D machine vision. The days when users had to rely on experts to efficiently automate their systems is now a thing of the past. With “plug and automate”, users now have the freedom to use automation solutions of the future today. ☐ Courtesy: ISRA Vision > MORE@CLICK ADI03541 | www.AandD24.in
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EVENT | report
Creating information driven digital enterprises For a successful business transition, it is imperative for industries to adopt new information technologies, such as cloud computing, mobility, social technologies, Internet of Things, Big Data/analytics, and 3D visualisation. ARC Advisory Group’s 12th India Forum discussed this transition for the process and discrete industries at Bengaluru, recently. A post event report…
Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
Market forces, such as globalisation, resource constraints Advisory Group’s 12th India Forum for the process and discrete and environmental concerns, changing demographics, and IT industries, on the theme ‘Industry in transition: the information trends are influencing manufacturing companies and their driven enterprise in a connected world, was organised on July dynamic market ecosystems and value networks. India’s 10-11, 2014, at Bengaluru. economic growth has temporarily decelerated due to the global headwinds and domestic rumblings; but industry analysts Highlights predict that it’s just a matter of time before the growth engine The day 1 began with the welcome address by is back on track. However, for a successful transition it is imperative for industries to adopt new information technologies, Ganapathiraman G, Country Manager India, ARC Advisory such as cloud computing, mobility, social technologies, Internet Group, followed by keynote presentation by Ralph Rio, of Things, Big Data/analytics, and 3D visualisation. Information Research Director, Enterprise Software, ARC Advisory Group, driven digital enterprises leverage new technologies to achieve on “Industry in transition - the information driven enterprise agility and sustain a competitive edge. With the focus on in a connected world.” Rio focused on predictive maintenance maximising productivity and increasing RoI by channelising and how automation is bringing about a business transition. Arundhati Bhattacharya, General Manager, NTPC, in her relevant information and investing in technologies, ARC
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report | EVENT
presentation on “The Information Driven Enterprise – NTPC experience,” highlighted the processes automated at NTPC, various advancements in HMIs, connectivity in automation systems and the need for business analytics. Bhattacharya said, “Embracing IT & automation technologies is not a mere exercise but the need for business excellence today. Only such enterprise will have the competitive edge in complex and dynamic future business scenarios. The concept of information driven enterprise will change the business ecosystem.” Next, Sameer Prakash, Head - Automation, Siemens, detailed on “Future of manufacturing – Siemens perspective” and the digital enterprise platform as a basis for Industry 4.0. He said, “Integrating product and production lifecycle can reduce time-to-market by up to 50%.” He also shared an example of BMW-Brilliance manufacturing unit at Shenyang, China, which uses electrical and mechanical turnkey solutions as part of totally integrated automation. This was followed by a presentation on “Connected enterprise: amplifying value with integrated control and information” by K Srinath, GM, Rockwell Automation. He said, “Context building of data is very important. Legacy system, control system and many layers prevent Big Data from becoming accessible. Companies need to have networks for Big Data.” He also stressed on the connected enterprise and how it can be optimised for rapid value creation. On the theme of automation & enterprise trends,
A&D India | Aug-Sep 2014
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Ganapathiraman discussed integrated and interconnected enterprise. He spoke on the rise of cyber physical systems and the various industrial challenges to Internet of Things (IoT) – cyber security, technology standardisation, IP ownership, and socio-political issues. In the subsequent presentation on “Predictive analytics - maximising profitability in operations”, Sayantan Roy, Director - Software Sales, GEIPS, highlighted on industry’s first predictive diagnostic solution and the industry’s transition to brilliant machines. This was followed by a panel discussion and Q&A session. The second session started on the theme – advancement in control, network strategies, and MES, with the presentation on “Industry in transition: information driven manufacturing India specific challenges” by K Nandakumar, President, AIA. He shared the roadmap for modernisation of automation which included need for recognition to IPR, innovation & technology upgradation, technical collaboration, industryinstitute partnership, standardisation, addressing technology obsolescence, setting up additional R&D labs and joint ventures. Presentations by BT Narasimha, Sr Director – Software Sales, Schneider Electric, on “Getting the most out of an MES investment” and Dinesh Mungi, BDM – Packaging, B&R Automation, on “A new high in control solutions: scalable and ultra-fast automation” followed. Next, Sunil Mehta, Chairman, CLPA India, highlighted the topic “CC-Link IE and a trend for the future”, supported by Haruyuki Otani, CLPA – Technical Task Force Chairperson. Another presentation on “PLM software as key component of the digital enterprise platform” was presented by Gautam Dutta, Director – Marketing, Siemens PLM. He shared trends in PLM, manufacturing engineering and point cloud data management. The next theme of discussion was strategies to achieve asset performance management and MES. Under this topic, presentation on “Asset maintenance and management
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EVENT | report
Dignitaries on the dais during the inauguration of ARC Advisory Group’s 12 th India Forum
using FDT/DTM – an end user perspective”, was given by Mouleswara Reddy, Sr Manager Quality, India Engineering Centers, Flowserve, FDT Group, while Vivek Gupta, Head Instrument, DCM Shriram, highlighted on “Advanced Process Control (APC) in fertiliser plant including safety instrumentation”. The last presentation of day 1 was featured by Chandrasekhar, MD, Pioneer CT, ACE Micromatic Group, who discussed “Machinery manufacturing trends”. Another round of panel discussion and Q&A session followed his presentation. Day 2 began with a presentation on “Manufacturing challenges in aeronautical industry” by Dr B Ashok, Deputy Project Director, ADA, under the theme – Industry in transition: information driven manufacturing. He pointed out the various challenges that lie in the Indian aerospace manufacturing sector. This was succeeded by an interesting topic “Engineering the Internet of Things” discussed by Raja Shan, Head - Strategy, Engineering, & Industrial Services, TCS. He stressed on IoT to improve the solution value chain and analytics driven design. The next theme was on control strategies and energy optimisation. D P Majakar, AGM (EDN), BHEL & V Ramesh, SE, KPCL, presented the total automation solutions for super critical power plants, followed by a presentation on softwarebased optimisation in power plants by Peter Deeskow, Head – Product Development, STEAG. He spoke on how automated detection of deviations can support in decision making. Then, under the theme: strategies to achieve operational excellence, Rainer Lamping, VP - Construction Management Strategy, Product Strategy Group, AVEVA, discussed the importance of construction management in project execution. This was followed by presentations on “Operational excellence
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for process industry” by Jayant Kapoor, GM - Manufacturing IT, Ranbaxy and Manish Kumar Singh, Head - MES, Siemens; “Integrated information management for operational excellence - ports information management system” by Vipul Shah, Associate VP, Chairman’s Office, Adani; and “End user survey responses on engineering services by GSPs” by Neelam Singh, Senior Analyst, ARC Advisory Group. A panel discussion and Q&A session was held post these presentations. The last session of the forum was based on the theme information management. Under this, Rio shared insights on asset lifecycle information management, while Sanil Namboodiripad, Assistant VP - Operations, Reliance Power, discussed integrating plant control systems with business applications. Namboodiripad detailed on centralised monitoring and SAP journey of Reliance Power. The concluding presentation was given by Srinivasan Thiagarajan, Senior Consultant, TCS on ETO2WIN: information driven ‘engineer to order’ enterprises, followed by a panel discussion and Q&A.
Key takeaway The forum provided a platform to suppliers to disseminate and share new processes & technologies; and the end users gathered information about new technologies that could be deployed. With nearly 300 delegates, the two-day forum was reminiscent to the fact that to remain competitive & achieve operational excellence, organisations must sift through the information glut and adopt appropriate technologies. The presentations made it clear that adopting new processes and technologies is not an option - it is mandatory to achieve operational excellence and sustainability. ☐ > MORE@CLICK ADI03542 | www.AandD24.in
A&D India | Aug-Sep 2014
8/18/2014 10:36:15 PM
T E C H N O L O G Y | TA L K
Cable Trolley Solution The article deals with cable trolley system that is used to support, protect and manage flat and round cables for the transfer of electrical energy and data. Cable and hose systems are available in various different industrial applications as supply lines. They are only conceived for flat and round cables. To transport liquid and gaseous media, the round cables are replaced by hoses. These systems are employed in festoon application. To begin with, festoon application generally caters to material handling. Festoon cable is flat cable designed for power and control applications, particularly suitable for demanding environments, such as in mills and at port facilities. The flat construction allows for stacking multiple cables where space is at a premium. Additionally, festoon cables are best suited for meeting the requirements of applications facing engineering and design problems. These systems are ideal for overhead cranes, gantry cranes water treatment systems, car wash systems, bulk material conveyors, plating lines, and many other types of moving equipment.
Key features of cable trolleys Parts used are made of special galvanised steel and consist of four guiding rollers with special high-life ball bearings for smooth running. Cables are clamped with rubber plates of Neoprene, appropriately shaped that prevents sharp bends at the camping point. This ensures long life of cables. Flame retardant as per highest industry standards IEC; weather resistant for harsh environments; high data capacity and low electromagnetic interference; flat cables need less space than round cables and cost-savings through quality and constant innovation.
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Application range Cable trolley system caters to moving applications in key industries like process industry, food and beverages, textile, automation, material handling and mining. Additionally, these are used in machinery and equipment that are permanently exposed to the weather; conveying and hoisting equipment; construction Cable trolley solutions have been engineered and machinery; shipyard machinery. These are suitable for use in special tested to be oil, coolant and chemical resistant and withstand dry, damp and wet conditions and conditions such as industrial or therefore allow you to save money on downtime sea water. Cable trolley solutions and lost production have been engineered and tested to be oil, coolant and chemical resistant and withstand dry, damp and wet conditions and thus, allowing by the following factors. you to save money on downtime and lost Flat cable: Travel distance less than 20 m × 1.25 = cable length; travel distance 20production. 50 m × 1.20 = cable length and travel distance greater than 50 m × 1.50 = cable Key factors that determine the length selection of cable trolley system Round cable: Travel distance × 1.50 m = The factors include travel distance, cable length cable package-design (flat & round) and dimension. Support bracket-wall of roof How many trolleys do I need? mounting, I-beam with distance and Divide the cable length by the double beam dimensions are necessary to accommodate the trolley wheel diameter. cable sagging which will give you the Type of system: Provide a brief drawing number of trolleys including the towing of the placement of cable clamps. Choose trolley. Standard cable sagging is 0.75 m. type of system you would like to use (wire, Cable trolley length x number of trolleys + c-profile, I-beam, etc) with regards to towing trolleys length = parking space. cable weight, size, bending radius and The equation of number of rails and track couplers is travel distance + parking space environment. Cable length: Find out the cables length = total track length. ☐ you have to use in your system. Here fore Courtesy: Lapp Cables > MORE@CLICK ADI03543 | www.AandD24.in consider the travel length multiplicated
A&D India | Aug-Sep 2014
8/14/2014 7:31:29 PM
news | technology
OPC Unified Architecture for industry 4.0
Signal conditioners
B&R has advanced the integration of OPC UA in the automation studio development software. Automation studio supports OPC UA clients and servers directly on the controller, thus, allowing vertical communication to SCADA, MES and ERP systems as well as vendor-independent communication from PLC to PLC. With new PLCopencompliant OPC client function blocks, this communication can be easily implemented in the application These controllers can be software regardless of the hardware implemented as OPC UA servers being used. Through the support of and as OPC UA clients OPC UA subscriptions, larger amounts of data can be transferred faster. OPC UA is standardised in accordance with IEC 62541 and offers easy-to-use functions for vendor-independent data exchange. This makes it easy for software developers to engineer complex systems with high data communication demands. Implementing flexible and modular automation solutions more easily is the result. With POWERLINK, openSAFETY and OPC UA, the company offers its customers the perfect tools to meet the high demands of Industry 4.0.
Pepperl+Fuchs’ SC-system is a new development that combines the most powerful features of comparable products in a family of devices. For example, calibration is performed by fully automated laser trimming of fixed resistors. This means the best calibration results without production spread, and the risk of interference from trimming potentiometers due to their slider contact point is eliminated. Electrolytic capacitors The 6 mm system modules are have been omitted, and alternative mounted on a DIN rail components are used instead. The temperature-dependent reduction of the capacitance values observed with electrolytic capacitors, as well as signs of aging, is thus effectively counteracted. By replacing the electrolytic capacitors, the SC-system signal conditioners can be operated at an ambient temperature of up to 70 °C. The low-power design, which ensures low self-heating, contributes to the wide temperature range in which the products can be operated. The SC-system uses high-quality 3-way isolation between input, output, and supply which withstands a working voltage of up to 300 V and a test voltage up to 2.5 kV.
> MORE@CLICK ADI03544 | www.AandD24.in
> MORE@CLICK ADI03545 | www.AandD24.in
Screw clamp fuse terminal blocks
Heavy duty encoder
Connectwell’s screw clamp fuse terminal blocks are used in electrical and control systems which require protection. The CF series terminal blocks accept industry standard 5 X 20 mm and 5 X 25 mm glass cartridge fuses. These blocks are completely closed and do not need separate end plates. CF4SP series fuse terminal blocks have a thickness of 6 mm with a provision for using internal shorting links. In control and The CF series terminal blocks accept automation wiring circuits it can industry standard 5 X 20 mm and 5 X be used in an alternating 25 mm glass cartridge fuses configuration with some of the feed through terminal blocks CTS2.5UN, CTS2.5UE, CTS4UN and CF4SPFT. The CF4UL & CF4SPL series terminal blocks are used for offline indication in case of fuse blow out. These blocks can be used in AC & DC voltages. The width × length for CF4U is 8 × 57; CF4UL is 8 × 57; CF4SP is 6 × 58.5 and CF4SPL is 6 X 58. The voltage range of CF4UL is 6 – 60 V AC/DC 110 – 240 V AC/DC and CF4SPL is 6 – 60 V AC/DC 110 – 240 V AC/DC.
CST Sensors’s BEI heavy duty encoder is specially designed for heavy duty applications: steel & paper mills, lumber, cranes, etc. With solid shaft of 12 mm or 11 mm with RE0 115 mm flange (Euro flange B10) for tacho generator type mounting it has a resistance to shocks/vibrations and to extreme axial/radial loads. With a high protection level of IP67 it has a connection with terminal box (cable or connectors output also available). It is electronic compatible with industrial standards and electronic permits to drive different inputs (PLC + display, for example). With digital The encoder has a mechanical incremental output, optional analogue over-speed switch option output (tachoencoders, optotacho) or sine with protection against short output its resolution is up to 10000 ppr. It has a mechanical over-speed switch option circuits for electronics with protection against short circuits for electronics. Option “Max control’’: the encoder gives on real time its physical environment parameters: shocks and vibrations, too high or too low temperature, too low or too high supply, quality of the output signals.
> MORE@CLICK ADI03546 | www.AandD24.in
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> MORE@CLICK ADI03547 | www.AandD24.in
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technology | news
Intelligent earth leakage relay
Data Portal
ElMeasure’s microcontroller based Intelligent Earth Leakage Relay (IELR) with 4-digit 7-segments RED bright digital display, is unique as compared to conventional ELRs. Its features include inverse curve; continuous leakage current display (Programmable); continuous display of trip leakage current (Programmable); continuous scrolling display for set current and set time; field programmable through front panel keys with password protection; Its features include wide input range 60 mA to 12 A and the inverse curve; continues trip time programmable from 300 ms to leakage current display 30 seconds and manual test and reset (Programmable); continuous keys. Its specifications include second display of trip leakage update; auxiliary supply 80 to 300 VAC; current (Programmable); burden 4VA max; panel mountable 96 x continuous scrolling display 96 x 45; accuracy class 1.0 FS; relay for set current and set time contacts; CBCT standard size – 40, 65, and field programmable 100, 150, 200, 250, 300 mm tape wound through front panel keys with and weight (Approx): Unpacked – 250 gms password protection Shipping - 350 gms.
The latest version of the Eplan Data Portal will enable users to benefit from enormous time savings and increased project quality. The current 470,000 part data, including schematic macros, geometric dimensions and documents, can be imported to engineering automatically. This is made more simple thanks to innovative functions such as a newly integrated 3D viewer, which enables users Around 470,000 part data to view and assess components quickly and including schematic macros, easily. It is possible to call up several different geometric dimensions and views such as front, page or isometric views documents can be imported very easily with a click of the mouse. Free to engineering automatically rotation and zooming functions allow that using the Data Portal individual detailed views can be generated in a very flexible manner. The advantages for the user are obvious: e.g. when placing the part in the project, they receive reliable decision support as to whether the component is suitable for the proposed control cabinet. The surface of Eplan Data Portal has also been optimised. The view of the 66 manufacturers that are currently involved has been adapted to the design of Data Portal App.
> MORE@CLICK ADI03548 | www.AandD24.in
Relay interface modules Finder has introduced the 39 series MasterINTERFACE range of ultra-slim relay interface modules that provide a low-cost, space-saving solution for a host of industrial applications. This series incorporates an innovative, replaceable fuse for output circuit protection, plus busbars and terminals that simplify input and output wiring. Housed in a compact 6.2 mm wide package, this series offers integral coil protection circuitry, as well as a secure retention and ejection clip. Five dedicated module types are offered to meet the requirements The 39 series MasterINTERFACE of basic, enhanced, input, output and incorporates an innovative, replaceable timer interface functions. fuse for output circuit protection, plus The enhanced MasterPLUS module busbars and terminals that simplify adds the option of a quick connection input and output wiring replaceable output fuse and special leakage current suppression versions to mitigate detrimental effects caused by residual current in the input circuit. Both the MasterINPUT and MasterOUTPUT incorporate additional busbar jumper links and terminals necessary for the full connection of 2 or 3-wire input devices and output devices respectively. > MORE@CLICK ADI03550 | www.AandD24.in
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> MORE@CLICK ADI03549 | www.AandD24.in
Pressure transmitters & sensors made of titanium Keller AG für Druckmesstechnik has offered titanium versions of its products for use in heavily corrosive media. This metal has a host of advantages for applications under very special conditions. Titanium is used as a replacement for steel in the aerospace industry, mainly for reasons of weight. In the medical devices sector, the fact that titanium is chemically and biologically neutral is especially important. This property is due to a permanent layer of oxide on the surface of the material. Thanks to its presence, components made of titanium will not Titanium is more frequently chosen corrode even in salt water or chlorinated for process measurement technology water, unlike the high-grade steels that are applications involving waste water normally used in the sector. This is why that may be contaminated with titanium is more frequently chosen for unknown corrosive substances process measurement technology applications involving waste water that may be contaminated with unknown corrosive substances. A titanium housing makes it possible to carry out hydrostatic level measurements effectively in brackish water, or even in iron chloride. The development of an implantable sensor (Ø 9 mm) made of titanium has caused a sensation. > MORE@CLICK ADI03551 | www.AandD24.in
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8/18/2014 10:25:44 PM
news | technology
IT powered automation
Linear modules
To avoid breaks in technology and ensure the future capability of the automation solution, Phoenix Contact has offered components and systems that use mainstream technologies from IT area. In addition to the already proven automation protocols, international IT standards are integrated into the control system. The web server provides a free website for all 100-series controllers. These These web pages can be displayed using web pages can be displayed the WebVisit software and linked to the PLC using the WebVisit software program using data and linked to the PLC program using data. The web panels with integrated browsers display the pages and allow them to be visualised without any knowledge of Java. Using the FTP (File Transfer Protocol) server of the 100-series controllers, any type of file can be stored or uploaded to the flash file system of the PLC — for example, for exchanging parameters, log files, recipes, or for storing the current version of the PLC source code during servicing.
SCHUNK has recently presented the Delta 145C, a particularly compact module that enables powerful strokes up to 4,000 mm. Its inner dual-profiled rail guide ensures maximum rigidity and precision, thus, exhibiting superior performance in absorbing heavy loads. To increase the reliability and the service life of the module, a With a spindle drive, the series specially fixed plastic cover strip enables driving forces up to 6,000 N, protects the guidances, and drive speeds up to 2 ms-1 and a repeat elements from dirt. The Delta series is accuracy of +/- 0.03 mm finely graded and comprises a total of four sizes with profile widths between 110 mm and 240 mm and strokes up to 7,720 mm (Delta 240C). With a toothed belt drive, a maximum driving force of 2,200 N, a maximum speed of 5 ms-1 and a repeat accuracy of +/- 0.08 mm are achieved. With a spindle drive, the series enables driving forces up to 6,000 N, speeds up to 2 ms-1 and a repeat accuracy of +/- 0.03 mm. These can be flexibly integrated into systems by means of T-nuts or mounting strips.
> MORE@CLICK ADI03552 | www.AandD24.in
Handheld barcode readers
> MORE@CLICK ADI03553 | www.AandD24.in
Eddy-current measuring system
Cognex has introduced the DataMan 8050 and 8050X handheld barcode readers, which are designed with a rugged polycarbonate housing to handle harsh factory floor conditions and feature 1DMax+ with Hotbars barcode reading algorithms. The 210 mm x 115 mm x 85 mm readers feature a 752 x 480 global shutter sensor, integrated LEDs with near/far optics, and DataMan setup tool software, which enables image viewing, Java scripting, and data formatting options. Available with both corded and wireless communication modules, these series Available with both corded and support industry-standard communications wireless communication modules, including USB, USB Keyboard, RS-232 and these series supports industry- Bluetooth wireless communication to a base standard communications station. Built for tough work environments, including USB, USB Keyboard, these series have durable and industrial RS-232 and Bluetooth wireless product features as well as a range of communication to a base station industrial cables and accessories to complement the product. These barcode readers read 2-D DPM codes as well as 1-D and 2-D label-based codes quickly and easily. These are optimised for reading 1-D and 2-D label-based barcodes with the fastest performance.
Micro-Epsilon’s turboSPEED DZ140 is optimised for thin turbine blades made from aluminium or titanium. The system is thermally stable and very well protected from external interference. It is the fourth generation of eddy currentbased revolution counters for turbochargers. The sensor system is suitable for speed measurements of 200 to 400,000 The DZ 140 eddy-current measuring rpm. The sensor is just 3 mm in system is resistant to oil and dirt diameter, yet it provides the highest immunity to interference in harsh test conditions. The integrated temperature measurement feature records among other data the actual ambient temperature near to the sensor. It provides much higher immunity to interference than other eddy current-based revolution counters. The DZ140 eddy-current measuring system is resistant to oil and dirt. The maximum operating temperature of the miniature sensor is 285°C, which is a key advantage compared to optical speed measuring systems, as this helps to achieve high precision measurements on a continuous basis. The well engineered design also enables easy sensor replacement without further adjustments.
> MORE@CLICK ADI03554 | www.AandD24.in
> MORE@CLICK ADI03555 | www.AandD24.in
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h i g h l i g h t s | c o m pa n y i n d e x | I m p r i n t
Highlights - (Oct/Nov 2014) impRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net
»»Automotive & Machine Tools Keeping competitiveness in this fast-paced industry means reacting quickly to changes in the marketplace and on the plant floor. Many automation service providers have leveraged their combined capabilities to create integrated automation and information solutions that go beyond traditional MES to overcome corporate data organisation boundaries. By providing a unified view of processes and data, as well as providing data integrity, the new automation solutions deliver real-time connectivity, marrying MES and production systems to enable actionable response to a variety of automotive challenges. The next issue will highlight some of these trends.
»»Sensors & Encoders The rapid progress of sensor manufacturing technologies allows the production of systems and components with a low cost-to-performance ratio. The recent advances and future development trends in the field of sensor technology focus on novel sensor structures, manufacturing technologies and signal processing methods in individual and multisensor systems. The predominantly observed future development trends are: the miniaturisation of sensors and components, the widespread use of multi-sensor systems and the increasing relevance of radio wireless and autonomous sensors. Check out the next issue for more details.
»»Robotics & Handling Once guardians of large- and heavy-part handling, robots are now involved in moving the smallest and most delicate of parts with dexterity. Vision technology advances have led to robots being able to pick and place randomly located parts. From threedimensional bin picking to food-grade applications, robotics are moving into new manufacturing frontiers. Also, the use of material-handling robots has increasingly become a solution to raise productivity and manufacturing versatility, while enhancing worker safety as they historically have. The next issue will feature articles discussing these trends.
Features Writer Megha Roy megha.roy@publish-industry.net Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net
company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Ajay Kumar Garg Engineering College . . . . . . . 41 Analog Devices . . . . . . . . . . . . . . . . . . . . . . 36 ARC Advisory Group . . . . . . . . . . . . . . . . . . 88 B&R Industrial Automation . . . . . Cover, 8,9, 93 Baumuller . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Bharat Bijlee . . . . . . . . . . . . . . . . . . . . 12, 41 Bosch Rexroth . . . . . . . . . . . . . . . . . . . 29, 48 Chanto Air Hydrantics Co . . . . . . . . . . . . . . . 13 Connectwell Industries . . . . . . . . . . . . . . 11, 93 Cognex . . . . . . . . . . . . . . . . . . . . . . . . 83, 95 Contrinex Automation . . . . . . . . . . . . . . . . . 15 CST Sensors . . . . . . . . . . . . . . . . . . . . 19, 93 Delta India Electronics . . . . . . . . . . . . . . . . . . 3 Dynalog India . . . . . . . . . . . . . . . . . . . . . . . 49 Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electronic Relays (India) . . . . . . . . . . . . . . . . 39 Eplan . . . . . . . . . . . . . . . . . . . . . . . . . 45, 94 EIMeasure . . . . . . . . . . . . . . . . . . . . . . . . . 94 Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 4 Finder India . . . . . . . . . . . . . . . . . . . . . . 54, 94 Fieldbus Foundation . . . . . . . . . . . . . . . . . . . 12
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Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Frost & Sullivan . . . . . . . . . . . . . . . . . . . . 14 Galil Motion Control . . . . . . . .Back Inside Cover GUDEL India . . . . . . . . . . . . . . . . . . . . . . . . 30 HART Communication Foundation . . . . . . . . . 12 Hilscher India . . . . . . . . . . . . . . . . . . . . 27, 76 HMS Industrial Networks . . . . . . . . . . . . . . . 51 Hummel Connector Systems . . . . . . Back Cover ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 57 IFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 IED Communications Ltd . . . . . . . . . . . . . . . . 12 IFM Electronic India . . . . . . . . . . . . . . . . . . . 61 Igus India . . . . . . . . . . . . . . . . . . . . . . . 2, 72 ISRA Vision . . . . . . . . . . . . . . . . . . . . . . . . . 86 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Keller AG . . . . . . . . . . . . . . . . . . . . . . . 35, 94 Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . . 68 Kubler Automation . . . . . . . . . . . . . . . . . . . 55 KUKA Robotics India . . . . . . . . . . . . . . . . . . 30 MathWorks . . . . . . . . . . . . . . . . . . . . . . . . . 14 Messe Frankfurt . . . . . . . . . . . . . . . . . . 64, 79 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . 7, 95
Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 75 MMI India . . . . . . . . . . . . . . . . . . . . . . . . . 53 National Instruments . . . . . . . . . . . . . 6, 14, 42 Omron Automation . . . . . . . . . . . . . . . . . . . . 1 PTC India . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Phoenix Contact . . . . . . . . . . . . . . . . . . 43, 95 Prosoft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pepperl+Fuchs (PA) . . . . . . . . . . . . . . . . . . . 93 Red Lion . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Renu Electronics . . . . . . . . . . . . . . . . . . . . . 47 Rockwell Automation . . . . . . . . . . . . . . . . . . . 5 Schunk Intec India . . . . . Front Inside Cover, 95 Sesame Motor Corp . . . . . . . . . . . . . . . . . . 81 Siemens . . . . . . . . . . . . . . . . . . . . . . . 16,17 Siemens PLM . . . . . . . . . . . . . . . . . . . . 10, 22 Turck India Automation . . . . . . . . . . . . . . . . . 14 TUV SUD Chemie Service GmbH . . . . . . . . . . 26 VDMA Robotics + Automation Association . . . 24 VDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wind River . . . . . . . . . . . . . . . . . . . . . . . . . 80
Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Ph: + 91 - 20 - 6451 5752 Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Annual Subscription Price: Rs 600 includes shipping and VAT. AandD.india@publish-industry.net Ph: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.aandd24.in
A&D India | Aug-Sep 2014
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GALIL MOTION CONTROL ALL THE RIGHT MOVES FOR ULTIMATE PRECISION +DQGOH XOWUD KLJK UHVROXWLRQ V\VWHPV &ORVH WKH ORRS DW D ORZ UDWH RI N+] 3URFHVV FRPPDQGV LQ DV OLWWOH DV V 0LQLPL]H VHWWOLQJ WLPH
Our cost effective standard or custom motion controllers can handle virtually any application. Select any number of axes and I/O. Choose internal servo or stepper drives for one small package, or connect to external drives. Our products are easy-toprogram, can be up and running in minutes, and are backed by unparalleled technical support.
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