A&D Dec-Jan 2015 by publish-industry India

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A U T O M AT I O N & D R I V E S

DEC’14-JAN’15 I VOLUME 07

Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong

AUTOMATION & DRIVES

VOL 07 | DEC’14-JAN’15

BUILDING WIRELESS INFRASTRUCTURE

Tips to industrial wireless network planning

FOCUS Food & Beverage P. 34, 38, 42 A&D - Interview

ROUND-TABLE Revamping the power industry P. 28

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General Manager (PE-C&I) & CTF (Muzaffarpur & Darlipali Projects) NTPC (p.26)

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Arundhati Bhattacharya

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Tracking the developments! Wireless in homes was probably a rare concept ten years back. However, today, most of us count on it for not only computers, tablets, and phones, but also for music & television. Similarly, industrial wireless, at one time, was only for “must have” applications such as overhead cranes or automatic guided vehicles, rotating equipment, etc. Today, it’s moving rapidly from those few, critical “point” solutions to a “must-have” ingredient on production floor. Workers can now take the control room with them as they address production needs wherever they are. Though wireless infrastructures provide very good reliability and flexibility, factories and other industrial facilities have long been a challenge for wireless deployments. The Cover Story in this issue provides the tips for a successful execution of wireless infrastructure projects. Power plant control systems, over the years, have evolved from DCS-centered platforms with proprietary software, to totally integrated plant automation systems with almost unlimited connectivity. In the future, control systems will no longer control the process — they will supervise it! These developments bring in their own set of challenges and requirements when it comes to modernising a power plant, especially for a country like India where the power demand-supply gap is huge. Check out the Round-table to know more about it. The Industry Focus this time is Food & Beverage, where the articles talk on the latest trends in automation solutions and components that help address the issues related to changing consumer preferences and increasing government regulations. Hope you will find the contents useful and interesting!

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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

Interfaces: Ethernet / EtherCAT RS422 / analogue

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

editorial_Dec14-Jan15.indd 3

Diameter

Segment

Centre

Gap

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 | Dec’14-Jan’15

Edge / Position

Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd

www.micro-epsilon.in MICRO-EPSILON | 94496 Ortenburg / Germany Phone +49 85 42/168-0 | info@micro-epsilon.com Phone contact: +91 20 2674 1009 3 Email: pragnesh.mori@micro-epsilon.de

12/17/2014 6:09:04 PM

CONTENTS

Market

Management

Focus

Food & Beverage 10 NEWS 16 “FOCUS IS ON ENERGY SAVING TECHNOLOGIES”

Interview with Ajay Bhargava, Managing Director, Rittal India

26 “BUSINESS ANALYTICS TO PLAY LARGER

34 PACKAGING BOTTLES THROUGH

ROLE IN BUSINESS OPERATIONS”

3D SENSORS

Interview with Arundhati Bhattacharya, General Manager (PE-C&I) & CTF (Muzaffarpur & Darlipali Projects), NTPC

The article briefs on efector pmd3d vision sensor that detects objects in three dimensions 38 WILL THE FOOD INDUSTRY CRACK UNDER

18 “WE ARE FOCUSSING ON SLIO TECHNOLOGY”

Interview with Joseph Cherian, Joint MD, Vipa Automation India EVENT REPORT 72 PLATFORM FOR QUALITY AUTOMATION

ROUND-TABLE

PRESSURE?

The feature explains how F&B manufacturers can remain competitive by balancing costs & productivity

28 REVAMPING THE POWER INDUSTRY

A discussion on the latest developments in industrial automation and IT solutions for the Indian power sector

42 THE FOUR M’s OF FOOD MANUFACTURING

An article on the four M’s of food manufacturing which elaborates on sustainability and line integration in the manufacturing process

SOLUTIONS

A pre-event report on SPS Automation India 2015 74 INTRODUCING FUTURISTIC TECHNOLOGIES

A post event report on the 11th NIDays 2014

MORE TOUCH. MORE PC. MORE POWER. www.br-automation.com/multitouch

Phone: +91-20-41478999

Contents_Dec-Jan15.indd 6

Email: sales.in@br-automation.com

12/17/2014 6:15:59 PM

CONTENTS

Advt

Technology

Cover Story 20 Tips to industrial wireless network planning

FIELDBUS & NETWORKING

Safety lifecycle management

A feature providing 13 handy tips to ensure planning of a successful industrial wireless network & design

INDUSTRIAL COMPUTERS & PERIPHERIES

Facilitating process optimisation The article deals with computer tomography which ensures measuring accuracy and comparability of the optical measurement

MOTORS & DRIVES

Adopting high efficiency motors

The article discusses the importance of energy conservation and the benefits derived with the use of energy efficient motors

IMAGE PROCESSING & MEASURING

Tracing the right part

The article discusses the top considerations for implementing Direct Part Mark traceability process into a fully automatic manufacturing line

An application story on how AIT has incorporated safety PLCs, motion control, safety and standard I/O on a single PROFINET network for efficient automation

SENSORS & ENCODERS

Changing face of Indian sensor market

The article deals with latest market developments & technologies emerging in the Indian sensor market

TECH TALK

Solutions for the machine tool industry

An insight into primary cable requirements of the Indian machine tool industry

Cover Image courtesy: SHUTTERSTOCK & FESTO INDIA

New Products 77 Noiseless

brush motors; Thermocouple terminal blocks; Power & signal connectors; Test & evaluation kit for real-time Ethernet 78 Remote management solution; Energy saving LED luminaries; Magneto-inductive displacement sensors; Fieldbus station for control cabinets 79 Wireless sensor development kit; Detection scanners for field monitoring applications; Configurable control systems; Compact mechatronic rotary module for flexible rotations

Columns 07 08 80 80

Editorial Contents Highlights - Next issue Company index Advt

Contents_Dec-Jan15.indd 7

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market | news

ABB manufactures 1,200 kV circuit breaker

CD-adapco signs agreement with JSOL

ABB has recently designed, manufactured, installed and commissioned a 1,200-kV circuit breaker. Once the switchgear is fully operational, it will have a switching capacity of 10,400 MW—a switch capable of turning on or off the electricity generated by 10 large power plants. The circuit breaker is deployed at the 1,200 kV national test station constructed by Power Grid Corporation of India Limited (PGCIL), Madhya Pradesh. “PGCIL is fully engaged in developing a robust and integrated national grid along with reliable partners in technology like ABB. This development takes us a step further in the development of our ultra high-voltage transmission network,” said The solution comprises R N Nayak, Chairman & MD, PGCIL. The solution a gas-insulated comprises a gas-insulated disconnector, current disconnector, transformers and monitoring & diagnostic current transformers equipment. It requires only half the space that and monitoring & would be needed for one with conventional diagnostic equipment air-insulated designs. The configuration also protects critical components from environmental exposure and makes it more resilient against earthquakes.

CD-adapco™ recently signed a development agreement with JSOL to jointly develop co-simulation methods in the domain to coupled thermal & electromagnetic simulations. The partnership was forged last year, when establishing a data transfer process between the two companies’ simulation codes, passing electromagnetic loss distributions and component temperature distributions. The The performance of components within performance of components the majority of electromagnetic devices within the majority of is temperature dependent electromagnetic devices are temperature dependent, therefore, finding the final 5% of an optimum design requires the co-simulation of such processes. Doing so will unleash the final 5% to product designers. A first release is expected in 2015 and the example problems are now being trialed. “We hope that together we can provide smooth and reliable multi-physics/multi-disciplinary simulations with STAR-CCM+ and JMAG for that will benefit our joint customers,” said Takashi Yamada, Manager—Electromagnetic Engineering Group, JSOL.

> MORE@CLICK ADI03595 | www.AandD24.in

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SCHUNK robot competition held in Germany

Making India global supply centre of valves

The SCHUNK robot competition was recently held at Germany, where 14 students of the Hölderlin Gymnasium Lauffen competed at the European Robotics Week. There were two mixed teams who had to perform a series of several tasks with a robot they designed. Several cylinders had to be collected, and, in order to win this competition, had to be converted into a penalty kick. The competition was split into two parts—subtasks had to be solved first and then the complete sequence without converting the robot. Both teams Both teams designed different robot designed different robot models models with impressive creativity, with impressive creativity, technical technical skill, and team spirit skill, team spirit, and were optimised in several test series. The Green Team was declared the winner. “It was our aim that young people should be inspired by the possibilities of robotics, and to show them the options of mechatronic solutions. Both teams convinced with great commitment, curiosity, and smart ideas,” said Martin Aichert, Trainer—Automation Technology & Mechatronics, SCHUNK.

The CII Valves National Conference 2014 was recently held in Mumbai, with the theme—Going Global. I S Malhotra, Chairman - Valves & Actuators Division, CII & Pentair Valves and Controls opined that making India a global supply centre of valves is a part of the “Make in India” programme. “We need to upgrade our infrastructure so that India can produce The CII Valves National Conference 2014 high-end engineered valves. was based on the theme ‘Going Global’ China is no threat since these valves are for the high end. The Indian valve industry was worth $2 billion, while the global market was worth $60 billion, which only showed the growth potential,” he added. According to Anil Gupta, Executive Director (QA&I), National Thermal Power Corporation (NTPC), the company would be generating `1.28 lakh megawatt power and would thus, need different valves. “Valves should have zero defects, which would delight customers and help this sector in going global. As India is building super critical power plants, the valves should withstand high temperature and pressure, and exhibit high quality and total reliability.”

> MORE@CLICK ADI03597 | www.AandD24.in

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market | news

Software for mine planning introduced

Danfoss recognises best practices in cold chain

Bentley Systems has recently launched BeMineCycle software applications, which facilitate optioneering to help mining industry participants address most pressing challenges, including the need for a continuous mine planning cycle. The software products are based on industry-proven, pacesetting Bentley software foundations, with MineCycle Designer extending the company’s High-quality 3D renderings enable OpenRoadscapabilities, MineCycle Survey compelling proposals and improved extending Bentley Map capabilities, and stakeholder communication MineCycle Material Handling extending Bentley OpenPlant and OpenRoads capabilities. MineCycle Material Handling enables engineering, procurement and construction (EPC) firms and consultants to accelerate the preliminary design of bulk material handling (BMH) facilities. Through optioneering, it helps EPCs optimise cost, footprint, and other key factors by empowering them to quickly consider multiple scenarios. “The optioneering ability to quickly assess operational planning and engineering alternatives was one of the ‘musts’ that our syndicate development sponsors identified,” said Robert Mankowski, VP - Simulation Product Management, Bentley.

Danfoss India recently presented the Indian Cold Chain Excellence (ICE) Award, 2014 in Ahmedabad, recognising cold chain players in the dairy & food processing sector who follow best practices of energy efficiency in their facilities. “Recognition of profitable yet energy efficient facilities like Banas Dairy is required to encourage stakeholders in this sector to shift to better technologies that enable optimum use of energy. With Gujarat taking the lead in dairy output in the country, better benefits can be reaped by milk cooperatives and processing centres through technology upgradation,” said Rajesh Premchandran, VP— Rajesh Premchandran, VP, Refrigeration & A/C Division, Danfoss Refrigeration and AC Division, Industries India. Banas Dairy from Danfoss handing over the Ahmedabad received the best food Best Food Processing Facility processing facility award for using the Award to Banas Diary most updated technology in bulk milk coolers and condensing units, such as multi-refrigerant scroll compressors that help in achieving high energy efficiency levels for milk refrigeration, processing and storage.

> MORE@CLICK ADI03599 | www.AandD24.in

> MORE@CLICK ADI03600 | www.AandD24.in

Dow Corning opens application development centre

HARTING bags “Factory of the Year” award

Dow Corning has recently set up a new application development centre in India to serve the growing demand for silicon materials & services. “The application development centre provides a platform for application development and technical support & expertise. It is staffed by scientists and engineers who work closely with sales & marketing professionals to more effectively collaborate with customers and meet their needs. This allows the company to offer better access to customised siliconbased solutions in key Indian industries like automotive, beauty and personal care, construction, household care, packaging and The centre enables state- textile,” said Serge Creutz, Director— Science of-the art local support & Technology, India & Europe, Dow Corning. for the company’s global The centre enables state-of-the-art local innovation support for the company’s global innovation and sustainability initiatives. “The new centre, along with our India office and distribution centre, enables us to take better advantage of the growth opportunities in the Indian silicon market,” said Peter Cartwright, Regional President — India, Central & Eastern Europe, Middle East & Africa, Dow Corning.

HARTING Electronics has been felicitated with the “Factory of the Year” award. “Factory of the Year / Global Excellence in Operations (GEO)” is the most well-established benchmark competition for the manufacturing industry in Germany since 1992. Torsten Ratzmann, Senior VP—Production & Logistics, HARTING Technology Group said, “Our continual efforts to achieve streamlined and effective production processes have been acknowledged with receipt of the According to Torsten overall winner award.” The jury lauded the Ratzmann, Senior VP— continuous development over the years in Production & Logistics, its verdict along with strong focus on HARTING Technology employees. Its reasons also included Group, the company’s HARTING having a clear orientation on efforts to achieve strengths and differentiation in global streamlined and effective competition. The jurors praised the good production processes have production system focused on continuous been acknowledged with improvement and development of in-house the receipt of the award systems, e.g. for electroplating to ensure technical differentiation.

> MORE@CLICK ADI03601 | www.AandD24.in

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market | news

E-commerce portal for cabling by Lapp

Online tool for tracking location from Emerson

Lapp India has recently introduced ‘e-Shop’, its new e-commerce portal for the cabling industry. The portal offers the widest range of cabling solutions to customers in India. With this venture, the company takes the big step forward to catapult their online presence across India. It will ensure speedy delivery of cables/ accessories to customers and will enable customers to quickly locate relevant products along with detailed information. The user-friendly interface will enable customers to navigate through the portal and help them pick & choose products in a simple and efficient way. The company expects primary demand for the e-Shop from customers across maintenance, repair, and overhaul (MROs) industry, research institutes (for prototype creation), engineering companies and institutes, laboratories and SMEs. “Lapp India has always emphasised on delivering high-end customer buying experience and through the e-Shop, we will scale up our services to a wide range of customers and a larger part of the country,” said Marc Jarrault, MD, Lapp India.

Emerson’s power transmission solutions has recently introduced the industry’s first online tool for tracking location, life history and latest revision drawings & installation instructions for all critical drivetrain couplings owned by customers, whether installed or in spares inventory. Developed by Emerson’s Kop-Flex business unit, the web-based tool Asset Management Program (AMP) for couplings, accurately identifies couplings, graphically displays the location in a specific drive, AMP identifies couplings & graphically identifies parts/couplings at the displays the location in a specific drive site that are interchangeable, makes assembly drawings a click away and gives a detailed service history and action to be taken during service intervals. It will be introduced in Emerson’s booth 1231 in the Turbomachinery Show, to be held on September 22-25, 2015 at Texas. “Plant engineers plan shutdown maintenance with tight timeframes, yet they struggle to identify couplings by make, model, serial number, stock code, manufacturer’s part number, etc,” said Parimal Deshpande, Sr Industry Specialist, Kop-Flex.

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NORD Drivesystems receives F&S award

OMRON to strengthen its business in Tamil Nadu

NORD Drivesystems has been recently awarded with Customer Value Omron Automation India has recently announced its business in Tamil Leadership Award in the Indian gearboxes & geared motors market in 2014 Nadu at its Affinity Seminar held in by Frost & Sullivan. The Coimbatore. These seminars have already award followed a rigorous been conducted earlier in Hyderabad, Indore methodology by Frost & and Ahmedabad. Attended by more than 200 Sullivan in 8 to 10 participants, comprising of OEMs, channel parameters research partners, system integrators and end users, process including end the symposium was an interactive platform users interviews & to make the participants acquainted with the feedback. The awards company’s key offerings such as SYSMAC were presented to PL platform, vision inspection solution, robotics Muthusekkar, MD, NORD solutions and machine safety solutions. Sameer Gandhi, MD, OMRON The awards were presented to India; Satyen Das, GM— “This year, we are taking our efforts to the Automation India, speaks PL Muthusekkar, MD, Satyen Das, Finance, NORD India and next level by further exploiting the on the initiatives taken by GM—Finance and Dhanraj Kalbhor, Dhanraj Kalbhor, VP— automation needs across its huge the company to exploit the VP—Operations, NORD India Operations, NORD India. “We manufacturing industry base, especially, in automation needs across are the reliable partners in the textile, automotive & engineering sector its huge manufacturing motion who support our customers globally. We would like to thank Frost & through channel expansion in categories of industry base Sullivan and the jury for awarding us Customer Value Leadership company vision, safety and sysmac. This will also help of the Year. We would also like to thank our valuable customers for this us to reach out to more small & medium award that acknowledges our best practices and excellent team,” said OEMs and customers in Kerala,” said Sameer Gandhi, MD, OMRON Muthusekkar. Automation India. > MORE@CLICK ADI03605 | www.AandD24.in

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news | market

HANNOVER MESSE 2015 to showcase India’s manufacturing might Prime Minister Narendra Modi to attend HANNOVER MESSE, Germany in April 2015 to strengthen Indo-German bilateral relations HANNOVER MESSE 2015 will provide a boost to India’s manufacturing competence while adding a new leaf to IndoGerman bilateral relations. India will be the official Partner Country for this year’s HANNOVER MESSE edition to be held from April 13-17, 2015. “India is an emerging economic giant which is going to open up enormous sales potential for our German and international exhibitors at HANNOVER MESSE,” commented Dr Jochen Köckler, member of the Deutsche Messe Managing Board. There were three main reasons for India’s selection: fastgrowing economy, the many years of good relations between German-Indian enterprises and the positive experience of having India as the Partner Country at HANNOVER MESSE 2006. Together with German Chancellor Angela Merkel, Prime Minister Narendra Modi has confirmed to officially open HANNOVER MESSE 2015 on April 12, 2015. Under the slogan of “Make in India”, Modi will be promoting the modernisation of India’s factories and infrastructure and greater foreign investment in local production. Highlighting on India as the Partner Country, Marc Siemering, Senior VP, Deutsche Messe AG, said, “Partner Country India is coming at exactly the right moment. India will be showcasing itself to the world as a modern, upwardly mobile economic power, while it simultaneously takes advantage of the opportunities offered by HANNOVER MESSE to invest in modern technology to strengthen its domestic economy.” “Boasting of an average annual growth rate of 10% over the last 10 years and with current growth running at around 5%, India is one of the world’s fastest-growing economies. The country is brimming with opportunities and manufacturing industry is leading this fresh wave of growth. Through the HANNOVER MESSE show, we aim to catalyse this momentum and highlight the colossal Indian talent pool,” said Mehul Lanvers-Shah, Managing Director, Hannover Milano Fairs India.

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Partnership for better representation EEPC, under the aegis of the Ministry of Commerce recently signed up with Deustche Messe as the official partner agency to facilitate India’s participation as partner country for HANNOVER MESSE 2015. Through this partnership, Ministry of Commerce will showcase approx 350 Indian companies under an area of over 3500 sq metres. Along with EEPC, India Brand Equity Foundation (IBEF) and CII will also organise high-level participation from India. Deustche Messe’s Indian subsidiary – Hannover Milano Fairs India (HMFI) will be playing a crucial part in organising participation from all agencies.

Figures say it all Last year, HANNOVER MESSE attracted 180,000 visitors in 5 days; out of this 57% of visitors were from European Union and 20% from South, East and Central Asia. A total number of 5,000 exhibitors from more than 100 countries showcased their products. The 2015 edition of the fair will comprise ten flagship fairs – Industrial Automation, Motion, Drive & Automation (MDA), Energy, Wind, MobiliTec, Digital Factory, ComVac, Industrial Supply, Surface Technology and Research & Technology. ☐

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market | interview

“Focus is on energy saving technologies” Ajay Bhargava, Managing Director, Rittal India, briefs on the current scenario of power distribution and climate control in India and the latest trends emerging in this sector, during an interview with Megha Roy How do you look at the current scenario of power distribution and climate control in India? What are the major challenges faced in this sector? Power distribution is critical and is required across industries & verticals. The standards on power distribution are getting higher every day. Safety and reliability are the key attributes that will shape this business in the future. There are global standards like 61349, increasingly specified by customers. The biggest challenge for the industry is to be aware of the safety issues and implement the right design to ensure environment’s safety. Industrial climate control is another critical subject in few industries like automotive, steel, textile, O&G, etc. Now, the focus has been on energy saving technologies as cooling is a vital requirement in most of the industries. Our company has already launched high-end products like Blue E, LCP for energy savings. Please brief us on the RiTherm app. Our company has multiple configurators that are created to help customers size cooling units. RiTherm is one such software that is used to calculate heat load based on a specific customer requirement. Keeping in mind the technology driven market in India, what are the innovations expected from your company? Our focus is to create multiple cooling solutions. We have launched water based cooling solutions for a very high heat load called industrial LCP. We have also developed new concepts in IT data centre space, where we have preconfigured data centres. This can be implemented in a timeline of 3 to 4 months. Our key focus has been energy efficiency, safety & fast implementation. We are also working to create solutions from engineering to automation & moving towards Industry 4.0. Our recent acquisition of Keisling completes the value chain from Eplan to Rittal to Kiesling. Are there any plans for further manufacturing expansion in the Indian market? We are continuously working to increase our manufacturing

Ajay Bhargava_Market Interview.indd 16

capacities in India. We have invested in upgrading our machines in the current factory that will increase capacities by 30 to 40%. We will evaluate the need for a second factory in 2016 as markets are expected to show substantial growth in the next 3 to 5 years. Given that the global economies are on the mend and a new government at the centre brings renewed hope, what are your views on the changing Indian economy? We are optimistic on the economic growth in the next 5 years. Investment climate is changing faster than what we expected. Fortunately, the central government is absolute majority and they can take some tough decision on labour, land & tax reforms that will boost industry confidence. What are the latest trends witnessed in your sector? We are seeing changes across segments due to globalisation & many of our customers have global customers. Therefore, customers are increasingly demanding a higher quality, standardisation, products meeting global benchmarks, reduced lead times and high energy efficient products. What are your global market expectations in 2014-15 term? In process industries like O&G, food, pulp & paper and steel, we see a moderate growth. However, many MNCs are using India as a manufacturing base for global markets and we see excellent business in the export segment. In the energy sector, which includes conventional power and renewable sector, we see a good growth in the coal-based power plants. Wind energy will grow slowly but solar energy will be a big boost to Rittal. The telecom and infrastructure sector is growing at a double digit due to the 3G & 4G roll-out by many leading telco players. For infrastructure, a big growth has been observed in the metro sector. However, in the automotive & ancillaries, we will see a slow growth in 2015. This is likely to speed up from 2016 onwards. Also, we see a good growth in the IT sector, primarily driven out of cloud computing and e-commerce space that will need a high level of IT infrastructure. ☐ > MORE@CLICK ADI03608 | www.AandD24.in

A&D India | Dec’14-Jan’15

12/17/2014 6:12:29 PM

HANNOVER MESSE. Are you ready for the 4th Industrial Revolution? 13 – 17 April 2015 Hannover ▪ Germany hannovermesse.com

t t abou e u o d Fin th ory of l t c a f al the – and s. e r u t u d f st tren e t a l the

Partner Country

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market | interview

“We are focussing on SLIO technology” Joseph Cherian, Joint Managing Director, Vipa Automation India, in this interview with Megha Roy, discusses the benefits of implementing the VIPA motion control concept and the four modules under VIPA Green Solution, that helps reduce costs and optimise the production process VIPA and Yaskawa together have recently presented the SLIO CPU iMC7 for motor control functions. Can you elaborate on this? iMC7 solution is the first common project for VIPA & Yaskawa. The motion control functionality inside the SLIO CPU with the latest SPEED7 technology offers a completely new market. It expands the already existing SLIO product range with EtherCAT network integration and offers in combination with VIPA SPEED7 studio modern motion control functions. After the activation of the motion control functions with the VIPA setcard-motion, the project engineering and programming can start immediately. The solution offers a new and highly efficient drive configuration. Moreover, the VIPA motion control concept focuses on the automation tasks. System functions can also be configured without special system knowledge with the motion control library according to PLCopen standards and coupled with the Step7 programming. The advantages are considerably simplified processes and minimised development effort. Special drive, fieldbus and communication programming are not required any longer for the motion control applications. The best of the VIPA PLC and Yaskawa drive world such as Sigma-5, Sigma-7, A 1000, V 1000 and virtual positioning and speed axis are now combined. On EtherCAT, one can easily set up a direct connection to the Yaskawa servo drives or frequency converters in SPEED7 studio. High performance clock synchronisation and multiaxis applications are possible with EtherCAT.

The processes will be organised and this allows energy efficient work — efficient, intelligent and tailor made. It also optimises production, increases transparency, becomes economical and sustainable, optimises processes within a closed control circle and connects the machines and plants of the production to the management system. In this context, the VIPA Green Solution offers four modules. The first module is energy management (according to DIN EN ISO 50001), which includes energy management, energy monitoring and energy measurement. The second module is load management, which includes energy controlling, intelligent process control, energy adaptation according to the process and intelligent conservation of resources. The next module is plant information system, which includes overall equipment effectiveness / OEE, core error analysis, preventive maintenance, quality management and factory data recording. The last module is ERP/SAP – top floor & shop floor, integration in SAP, structuring a transparent communication between ﬁeld, process, installation and enterprise level and complete traceability from raw materials up to end product. What are the major sectors generating demand? The major sectors currently generating demand are automobile, auto ancillary, food & beverage, water & waste water and power generation.

How are the latest developments helping in creating new value for customers? How does your company plan to work towards “Energy Currently, we are focusing on the SLIO technology based management in practice”? on the latest SPEED7 technology. In combination with the Our company started with a new solution called “VIPA Green Yaskawa product portfolio, we are on the right way to come Solution” in 2012. We offer an energy management system, which to the market with new solutions, offered by one single hand. functions simply and reliably, with the added value of advice, Our target is to move from a hardware supplier to a solution products and solutions as well as implementation through our provider. With our partners around the world in more than 60 company from a single source. This energy management system countries, we are well equipped for this challenge. ☐ enables easy certification in accordance with DIN EN ISO 50001 > MORE@CLICK ADI03609 | www.AandD24.in or DIN EN 16247. This will rapidly reduce the energy costs.

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BUILDING WIRELESS INFRASTRUCTURE Tips to industrial wireless network planning With multiple Wi-Fi technologies in the market for industrial applications it becomes difficult for engineers to choose the bestfit. As an engineer looks at the application requirements to make informed decisions regarding which technology to use while moving from a wired to a wireless infrastructure, the handy tips presented in this article help ensure the planning of a successful industrial wireless network and design. 20

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Mike Werning Field Application Engineer Moxa Americas

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Wi-Fi is now present everywhere and people have become This causes latency in the network. If you plan to connect many comfortable using it for just about any application. For example, devices to your industrial wireless network, then you should many systems designers are choosing to move their industrial also plan to add multiple access points to allow different clients applications from wired Ethernet to wireless utilising Wi-Fi. to use different access points, and thereby reduce the number The advantages of moving to a wireless design are numerous. of collisions on the wireless network. Wireless allows for client devices to be located in difficult to Tip 3: Know how your application will send and receive data reach areas, and it saves on installation and wiring costs in — Many industrial protocols send small packets of data that are remote locations. The advantage is not to re-wire the plant only a couple hundred bytes long. Other applications, such as infrastructure when relocating machines on the plant floor. for video or data storage utilise large blocks of data that require Thus, it is easy to expand as additional devices are required. transmitting thousands of bytes. Knowing the characteristics There are many different Wi-Fi technologies that can be used of how your application will use the network allows you to in industrial applications. Whether it is an existing application make an informed decision about which Wi-Fi technology is or a new design, an engineer must look at the application best suited for the intended application. For example, 802.11n requirements to make informed decisions regarding which is better suited for applications that need to transfer large technology to use. When deciding to move from a wired to a amounts of data since it contains features that help to optimise wireless infrastructure, here are the following tips to ensure large transfers. One such feature supported by 802.11n is called Block Acknowledge. This feature lowers the amount of that the design is successful. overhead in the wireless channel by allowing the receiving device to send an acknowledgement after many transfers by Ensuring successful design the sender. The result is better bandwidth utilisation. By Tip 1: Know your application’s throughput requirements — comparison, 802.11a/b/g sends an acknowledgement after To know the data rate that an application’s client devices will every transfer. send and receive is critical for planning the network. This Tip 4: Know which protocols the application plans to use — information will be used to determine things like which Wi-Fi Industrial protocols and other networked applications use TCP technology to use, and how many access points will be required for control applications or when reliability is critical and to provide the desired throughput. In a Wi-Fi system, the message loss is not acceptable. This is because TCP allows the actual throughput that is available to the user’s application is receiver to request that missing or corrupted packets be resent. generally about 50 to 60% of the overall bandwidth of the TCP is known as a reliable protocol. Contrast this with UDP, Wi-Fi technology selected. This is due to control and which is a connectionless protocol. This means the sender will management overhead in Wi-Fi systems. If the application transmit one packet after another without worrying whether needs more than what is available, then the application will not or not the packets were transmitted successfully. On wired work. networks, typically there is little to no packet loss and the low Tip 2: Know how many clients will be accessing the Wi-Fi overhead of UDP can be taken advantage of. However, many network — This tip goes hand-in-hand with the application other factors need to be considered on wireless networks, such throughput requirement discussed in Tip 1. Wi-Fi works in a as client roaming or RF interference, which can corrupt packets manner similar to how Ethernet hubs work. That is, Wi-Fi uses in transit. While 802.11 has the ability to retry transmissions a single collision zone for all the devices connected to the Wi- that it does not receive an acknowledgement for, depending on Fi network. This means that only one device can transmit at a the length of time the interference lasts, packets can still get time, and all the other devices must wait until the network is lost. What this means is that an application’s sensitivity or idle to transmit. When multiple devices try to transmit at the tolerance to packet loss must be considered. To mitigate this same time, there is a higher chance that collisions could occur. potential loss, highly available transmission features, such as

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Additional access points increase the overall available throughput

Data is sent on both client links, providing redundancy and noise immunity

Moxa’s dual redundant packet solutions, can be employed to avoid this problem. When migrating to a wireless transmission medium for existing applications, application designers may need to tweak the mechanisms used for transmitting data, or make other adjustments. Tip 5: Determine the capabilities of the client devices that will be deployed on your network — Will the client devices all use the same technology or will there be a mix? Decisions regarding which devices will be supported are critical in maintaining application throughput. For example, if both 802.11b and 802.11g devices need to be supported, there will be less overall throughput on the wireless channel. This is due to the fact that the access point will have to slow down to 802.11b speeds when communicating with those clients. The time it takes to perform transfers at the lower rate steals time from the higher performing clients and limits their overall throughput on the network. If mixed mode operation is required, make sure you have enough throughput to support the application. If you can avoid supporting legacy devices, by all means do so, and limit the access point to only support a particular wireless technology to improve performance. For example, limiting the access point to 802.11g only or 802.11n will improve performance by not allowing legacy devices to connect to the access point. Tip 6: Plan for throughput — Knowing how much throughput your client application needs is critical in planning how many access points you need to install. Just because you have selected 802.11n and can support up to 300 Mbps of available bandwidth does not mean that every signal from every access point will transmit at 300 Mbps. The farther a client radio is from the access point the weaker the signal will be, and as the signal gets weaker, it gets closer and closer to the noise floor. The difference between the signal and the noise floor is the signal to noise ratio. A high signal to noise ratio means that a higher performing modulation and coding scheme can be used by the radios. As the signal to noise ratio degrades, the radios must utilise a lower performing modulation and coding scheme to

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deal with the interference on the channel. This is called dynamic rate switching. This means that the farther the client is from the access point the lower throughput it can achieve. If your application throughput needs are high, then you must design your wireless network with more access points in closer proximity to the client radio’s location, since doing so will ensure that the radio will be able to sustain higher data rates. Tip 7: Know the application roaming needs — With industrial wireless networks, it is common for clients to move about in a facility. Clients are often used for location tracking or for obtaining the GPS coordinates of an object’s next location. In other cases, the clients are used for machine control on moving conveyors, rail cars, or cranes. The system designer should identify the latency the end application can tolerate while objects move between access points. When a client roams from one access point to another, the time it takes to connect to the new access point introduces a transmission delay. With commonly used Wi-Fi clients such as computers, the delay could be several seconds. If the application requires fast roaming, then plan on using Turbo Roaming in the design. This means that the client must be a Moxa client radio. Turbo Roaming can provide as fast as 100 ms roaming between access points, and if faster roaming is required, then consider a controller based approach such as the Moxa WAC. The wireless controller approach allows for 50 ms roaming for clients. Tip 8: Know the characteristics of the environment — Industrial applications are notorious for using machines that can cause RF interference. In addition, industrial applications are often housed in buildings made of metal, or are full of reflective materials. Utilising 802.11a or 802.11n in the 5 GHz band can help to avoid the interference issues of the overloaded 2.4 GHz band. However, as the frequency increases, the range and penetrating power of the signal decreases. This means that you will need more access points or higher gain antennas to obtain the same coverage as in the 2.4 GHz band. It is a good idea to use two antennas per radio in these environments. Two antennas allow the radio to take advantage of the diversity

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c o v e r s to r y | t e c h n o l o g y

Throughput (Mbps) decreases as the client gets farther from the access point

Turbo Roaming provides faster handoff between access points

antenna system, which can help manage reflected Tip 9: Know how to handle directly connected vs external antennas — It is common in enterprise or office environments for the access point to utilise built in antennas or directly connected antennas. These are usually low gain solutions in the 2 to 4 dB range. In industrial environments, it is not uncommon to have the radio mounted inside a control cabinet connected to antennas mounted on the outside or on a pole. In these situations, the engineer must pay close attention to the gain of the antennas and account for all the losses due to the cable and connectors used. In short cable runs, using LMR-200 cable provides for acceptable low signal attenuation. For longer cable runs, make sure to use LMR-400 or above to minimise the losses. For example, a 3 metre LMR-200 cable will have a combined cable/connector loss of 1.9 dB at 2.4 GHz and 2.8 dB at 5 GHz. The same solution using LMR-400 cable has less than half the attenuation. For optimum performance, make sure to minimise and match the lengths of the cables to each remote antenna connected to the radio. Tip 10: Design your channel allocation plan — When using more than one access point or when there are other access points in the area, it is important to identify the channels that will be utilised on each adjacent access point. When doing this, it is important to avoid using the same channel as an adjacent access point. In the 2.4 GHz range only three channels do not overlap. These are channels 1, 6, and 11. If at all possible, make sure to stagger the access points in these channels. This will minimize a kind of interference known as co-channel interference. When using the 5 GHz range, each channel is non-overlapping if you are using a 20 MHz channel width. This is known as HT20 mode. If the access point is using 802.11n with 40 MHz channel bonding (known as HT40), then you need to stagger access points every two channels to avoid overlap. Tip 11: Pre-plan your access point placement using a predictive site survey — For applications that must utilise

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multiple access points to provide coverage, it is most helpful to use a software tool to provide a preliminary plan for access point locations. Doing so can result in a big time savings later on when visiting the site to perform an actual site survey. These tools typically take in a floor plan of the facility. Using data from the planned access points and clients in use, as well as building materials at the site, the predictive site survey can provide a placement plan for the site as well as the number of access points required to provide the throughput the end application needs. Tip 12: Perform an on-site survey to identify access point locations — Although predictive site surveys can be useful, they do not take in account the obstacles, machinery, equipment, and other radiating devices inside the building, which is why it is essential to do an on-site survey. Once you have a plan for where you want to deploy the access points, visit the site and perform measurements using the actual radios and antennas that will be used in the deployment. Using the preplan as a guide, measure signal levels using the actual devices you plan to use in the deployment to verify coverage. Try to maintain a line of site between the access point and client radios wherever possible. A variety of site survey tools are available on the market for measuring signal levels to create a heat map of the actual coverage in the area and for identifying problem areas. In the absence of advanced site survey tools, plan a 15 to 20 per cent overlap between adjacent AP cells at the minimum data rate required by the application. Tip 13: Check your work and verify throughput— After the radios are deployed verify the throughput in the network at various locations. Use a software utility such as jperf to measure throughput and verify that adequate throughput exists at edge cases in the Wi-Fi cell boundaries. These tips ensure that the wireless deployment is successful. ☐ > MORE@CLICK ADI03610 | www.AandD24.in

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management | interview

“Business Analytics to play larger role in business operations” Arundhati Bhattacharya, General Manager (PE-C&I) & CTF (Muzaffarpur & Darlipali Projects), NTPC – India’s largest power company, in this interview with Sumedha Mahorey, highlights her experience with automation service providers (ASPs), and the various critical aspects of the use of latest automation tools for power generation. Brief us on the challenges faced by NTPC while executing the automation/modernisation projects. How did you manage to overcome these challenges with the help of NTPC’s own experts as well as automation service providers (ASPs)? C&I in terms of overall project cost is only 3-4%, whereas its impact in the overall operations is quite substantial. This makes the challenges multi-fold – ensuring quality, speedy implementation and easy maintainability while keeping pace with technology. As an example, one such philosophy adopted

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for improved site maintenance was single DCS platform for main plant BOP & all offsite areas. But obtaining data of offsite equipment from the OEM and doing in-house engineering for these areas is by no means an easy task, especially with the minimal resources. Similarly, in the project construction phase, C&I has a daunting task of maintaining erection quality while adhering to stringent timelines, as typically it is the last in the execution sequence. This makes accurate engineering and testing a pre-requisite.

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i n t e r v IE w | m a n a g e m e n t

“Advanced controls or APC as it is termed in automation parlance, has a huge potential in terms of operation cost savings; as it directly intervenes with the closed loop controls but it requires equally huge efforts on the part of the APC vendor to realise its benefits” Arundhati Bhattacharya

Again, modernisation projects (i.e. R&M jobs) have challenges of execution in the brief shutdown period. But thanks to the in-house engineering and meticulous planning of our own experts as well the support provided by automation service providers, C&I R&M jobs have been executed in the given short time span; some as less than 35 days making it a benchmark in project execution. Even in the power project phase, there has been no delay on account of C&I.

we have advanced controls for steam temperature, but in other areas, we have a long way to go. Also, training in this niche area needs augmentation. Please elaborate on the need for business analytics in the power generation business. Can you share any measures implemented or benefits derived by NTPC with the use of business analytics? Considering the challenges of the current scenario of power generation business, especially the new regulatory regime, business analytics is likely to play a larger role in the business operations of power generation companies. Already, Enterprise resource planning (ERP) systems are in place in NTPC where data (including real-time data) is leveraged to optimise several business processes like operations, maintenance, engineering, finance, ultimately increasing the profitability. Of course, scope for further improvements is always there.

How has been your experience with ASPs so far? What are your expectations in terms of making an effective win-win partnership with them? Our experience with automation service providers have been by & large good. Probably, NTPC is one such organisation which got the unique opportunity of working with multiple DCS vendors (more than 8-9). This has helped us to consolidate our operational requirements and implement it in different systems in an optimised way. On the other hand, for automation vendors also, working in NTPC projects is What is your definition of information-driven enterprise? a good learning experience. In this process, some of the How do you predict this enterprise to be in the coming functionalities we normally provide in NTPC specifications decade? eventually become part of their standard system, leading to I do not have a formal definition but I think any enterprise product enhancements & knowledge enrichment of their which converts data into actionable information for driving execution team. However, we expect improvement in areas its business processes & also bases its business decisions on such as site support which includes process expertise as well it, falls in the category of Information-driven enterprise. as system side expertise, clearer responsibilities for their site The main point is how effectively an organisation plans & personnel, & more project ownership. As far as partnerships implements such systems taking into account the changing are concerned, being a public sector enterprise, tendering is market dynamics. With the connectivity & IT enablement on L1 basis; thus formal long-term strategic partnerships with prevalent today, such enterprises will definitely have a leading automation vendors are not done. edge in the coming decade. How can the potential of advanced controls be fully utilised? How is NTPC’s experience? Advanced controls or APC as it is termed in automation parlance, has a huge potential in terms of operation cost savings; as it directly intervenes with the closed loop controls but it requires equally huge efforts on the part of the APC vendor to realise its benefits. There are three factors affecting the success of such systems, i.e. skilled manpower at the automation vendor’s end, guidance & cooperation of plant equipment supplier and support of site management. In NTPC,

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How do you perceive the present level of risk management and safety engineering in the Indian power plants? I can elaborate only about the safety instrumented systems (SIS) which we are engineering for power plant equipment protection. Currently, we are specifying SIL-2 or better level for boiler protection systems. Safety engineering is definitely a very important area in Indian power plants & likely to gain prominence in the future. ☐ > MORE@CLICK ADI03611 | 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

ReVAMping the power industry Highlighting the latest developments in industrial automation and IT solutions for the Indian power sector, this feature discusses the views of industry players to help the industry modernise and enable efficient operations in the coming years... As the global demand for power continues to outstrip supply, expanding the power generation capacity becomes quintessential. This calls for an efficient power generation system to be established and sustained. However, the challenges that confront the Indian power industry, such as, widening demand-supply gap in power generation, low per capita power consumption and poor risk management necessitate greater utilisation of automation and information technologies for its efficient operation & management. As such, it becomes imperative that breakthrough automation and information technologies are leveraged to the maximum towards this objective.

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Megha Roy Features Writer megha.roy@publish-industry.net

Addressing the major challenges in the Indian power industry and highlighting the latest developments in this arena are industry giants such as G Ganapathiraman, Country Manager, ARC Advisory Group India; Parag Marathe, Engineering Manager, Power Generation Products, GE Power & Water; Sunil Kumar Vuppala, Research Scientist, Infosys and Pradeep Nair, Business Development Manager â&#x20AC;&#x201C; Energy, National Instruments.

Indian power sector: Now & then Over the past decade, power plant control systems have

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evolved from DCS-centered platforms (distributed control system) with proprietary software, to open systems using industry standard hardware and software, and then to totally integrated plant automation systems with almost unlimited connectivity and the ability to interrogate field instruments from many different manufacturers. Sharing his thoughts on the changes experienced in the power industry, Ganapathiraman opined that unified architecture is the next big thing. “It is an important step, especially when it comes to the supercritical power plants. In a thermal power plant, DCS with fully integrated turbine and boiler control system provides a common engineering & operator environment. Under such a platform, along with flexibility in operations, accurate process information can be leveraged and delivered at the right time to the right person within an individual plant, and possibly across various geographically dispersed units, further enabling operational excellence and higher reliability.” On the other hand, Nair focuses on the next phase of change that is quickly catching up, the emergence of software centric hardware platforms, with better computation, control & communication power. “These 3Cs together make the platform turn into a state-of-the-art cyber physical system (CPS). Currently, though the communication protocols between various IEDs are standardised, the IED(intelligent electronic devices) or other computing devices in the power plant is still a black box. A software centric automation platform like National Instrument CompactRIO system is changing the way these IEDs are build, making it more open and flexible. Using such technologies, the same platform with appropriate I/O can be modified into various kinds of power devices like PMUs, DCU, bay controllers, condition monitoring systems, etc.” Considering the technology driven market in India, it has become imperative to have a technological presence in every sector. As such, when it comes to the power industry, it has been observed that Internet of Things and smart grid concepts will make the industry experience various developments.

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According to Vuppala, such systems will be proactive in predicting the issues much earlier before the problem occurs. “Early warning system for wide area system stability, real time monitoring for situational awareness are few examples in that direction. With this, operators are playing the role of supervisors rather than controller of the system. We can control the system from anywhere but poses the challenges of security, which needs to be taken care of. Besides, concept of virtual power plants can provide more flexibility and efficiency and it can do load aware power generation with short notice. Micros-grid with small distributed power generation plants and consumers becoming prosumers (producers & consumers) is another trend observed these days,” he said.

Addressing the key challenges According to Ganapathiraman, the demand supply gap in the Indian power generation necessitates capacity augmentation to be done at a quicker pace compared to developed economies. “From the present capacity of around 243 GW, India plans to add 76 GW by 2017 and additional 93 GW by 2022,” he said. However, when compared to developed countries, it has been observed that the cost per unit of power is more in India. As such, it creates enough scope to improve on low cost of operation & maintenance. “For safety and risk management, the major black-out in 2012 indicates lack of coordination in operating the power grid. Various organisations such as TSDSI (Telecommunications Standards Development Society, India) and ISGF (India Smart Grid Forum) are working towards preparing the standards for India as well as participating in international standard bodies. Compared to developed countries, we need smart products at lower cost to support massive rollouts,” asserted Vuppala. In fact, it is not only the low cost. Much needs to be addressed on maintaining the structure and productivity of the Indian power sector too. Therefore, renovation and modernisation of power plants is critical for efficient running

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r o u n d - ta b l e | m a n a g e m e n t

“Projects like clean coal technology (CCT) are being implemented to improve the efficiency and environmental standards of conventional power plants” G Ganapathiraman, Country Manager ARC Advisory Group India

“Automation solution providers & users can have a mutually beneficial long term partnership” Parag Marathe, Engineering Manager Power Generation Products, GE Power & Water

of older power plants and ensuring high availability. In this context, Ganpathiraman further added, “Projects like clean coal technology (CCT) are being implemented to improve the efficiency and environmental standards of conventional power plants.”

How to modernise power plants?

trips. Further, virtual technology and simulation of control systems can be used in operator training programs to keep the operator aware of dynamic plant scenarios,” he added. When it comes to infrastructure, Nair opined that the availability of communication networks like FO or GSM will allow the latest IED to be installed in remote locations and be networked to servers, making data accessible at a central location. “Training plays a major role in the modernisation program. There has to be a good hand-holding between academia & industry to train engineers on the latest technologies. We need to have a pool of trained engineers who can analyse the large amount of data that these networked IEDs generate in order to make the whole system work more effectively. National Instruments works with various academic institutes to set up state-of-the-art centre of excellence where power engineers can be trained,” he added.

It goes without saying that India is witnessing a modernisation spree. Same applies to the power sector. As such, the power plants can be modernised through automated devices and control systems. “It needs to deploy new M2M devices for real time monitoring of vibration, speed, turbine protection and synchronisation. When these power plants are installed with automated devices and control systems, the plant operators should be trained to respond quickly for the system raised alerts to increase safety and reliability of the plant. Necessary security implementations need to be taken care in Facilitating efficient operations the new infrastructure of the plant too. Cyber security is The importance of automation in the power industries has another training element as the modernisation allows access to increased dramatically in recent years with the view to the control the plant remotely,” opined Vuppala. It is also seen that there has been a continuous need to current energy situation and environmental issues. According invest in training and updating skills in India. Emphasising on to Ganapathiraman, power companies are now progressively a strong database for an efficient power plant structure, leaning towards an “information driven” business model. Ganapathiraman believes that the database needs to include all Using concepts like Big Data goes a long way in achieving this. critical and non-critical/major/minor assets in terms of their “As far as Industry 4.0 is concerned; Big Data and cloud procurement & operational phase. “While the main equipment computing are its major facilitators. The progress towards a like boiler/turbine have 25-30 years of lifecycle; control systems digital enterprise is encouraging. With plant wide network and HMI have short lifecycle of 3-8 years and need continuous using intelligent automation and open communication upgrades in terms of OS and hardware obsolescence. So, it is protocols, data integration is becoming increasingly easy and essential that the O&M staffs at project sites are trained enterprises are becoming more agile.” Speaking on Big Data, Nair said, “If we talk about Big Data, adequately prior to systems failures that may lead to major

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“Necessary security implementations need to be taken care in the new infrastructure of the plant” Sunil Kumar Vupalla, Research Scientist, Infosys

“Pilot projects, for trying out the latest technologies, are the best way to gain the confidence of the user”

Pradeep Nair, Business Development Manager – Energy, National Instruments

the largest or the biggest data is not generated by digital or social media but by equipment’s like turbines and energy meters. If the data generated by all turbines in the power plants that we have in the country is clubbed with the data generated by PMUs on the transmission grid along with the ones generated by AMR systems on the distribution grid then these analog data generated are much bigger than the ones generated by digital media for an equal timespan.” In this regard, GE has come up with Predix – the software platform for the Industrial Internet that enables predictive insights from Big Data, business analytics and state-of-the-art user experience. “To put it into perspective, if we are able to offer just 1% of fuel savings for all gas power plants, it would mean saving $ 66 billion over a period of 15 years. The potential is huge,” said Marathe.

Integrating suppliers and users Automation solution providers can have specific devices to power plant sectors for synchronisation, vibration monitoring, speed control, load control and turbine protection. Underlining this thought, Vuppala opined that there is a role for system integrators in customising automation solution to the need of the users. “Vendor selection has moved beyond the conventional terms of product/service offerings, as customers want a partner who can address more than their technology requirements. Moreover, a differentiated value proposition by the vendor built on a consultative approach helps in bridging the end user-client partnership expectations,” added Ganapathiraman. Marathe further highlighted that automation solution

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providers & users can have a mutually beneficial long term partnership, based on how these solutions are enabling better controls, better utilisation of assets and improving efficiency by connecting deep domain knowledge to automation technology advancements. “Pilot projects, for trying out the latest technologies, are the best way to gain the confidence of the user. By doing this, we can ensure a continuous engagement between users and automation suppliers,” said Nair.

Can intelligent self-controlling power generation become a reality? Speaking on self-controlling power, Marathe believes that power plants having single pushbutton start-up operations and advancement of control & instrumentation systems already exists. “However, this has still not reached the level of optimum controls and that’s where our company with advanced technology solutions can help power producers.” On the other hand, Ganpathiraman said, “Self-controlling power generation is unlikely to become a reality, because in a thermal power plant there are more than 20,000 major components and millions of other components to be connected on real time.” Moreover, in the fluctuating scenario of power supply, generators can adjust the active, reactive power to compensate power fluctuation. Highlighting this thought, Vuppala concluded that M2M devices and actuators coupled with analytics can make the intelligent self-controlling possible for the power generators. ☐ > MORE@CLICK ADI03612 | www.AandD24.in

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Food & Beverage | Focus

Packaging bottles through 3D sensors

To enhance a full crate inspection system in the beverage industry, scrutinising and checking irregularities in the bottles is essential. The article briefs on efector pmd3d vision sensor that detects objects in three dimensions at a glance, thus, ensuring maximum quality and reliability.

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Focus | Food & Beverage

In the beverage industry, a lot of glass is handled on a typical bottling line. Every hour up to 60,000 bottles are filled on each line. Numerous different sensors ensure that processes run smoothly. At the end of the production, the “full crate control” checks whether the crates are filled with the correct number of bottles. If a bottle is missing, the crate is rejected and the missing bottle added manually before the crate leaves the plant.

Fault sources Fortunately, it rarely happens that a bottle is missing in a crate. If this happens, the reason for this is often the bottle packer. With its pneumatic grippers, it takes the bottles from the sorting system and puts them in the empty crates. When doing so, it can happen that a bottle is not correctly gripped. Therefore, a full crate inspection unit is installed on the following conveyor belt. With an optical 3D sensor, it looks at the crates from the top to check them for missing bottles before they are palletised and delivered.

Conventional control for missing bottles Worldwide conventional bottling processes use diffuse reflection sensors arranged in a matrix to look at the caps of the bottles from the top. If a bottle is missing, no light is reflected back to the sensor. The sensor provides an error signal to the controller.

Control using a 3D sensor This installation uses the full crate inspection system from the OEM Recop. The heart of the system is efector pmd3d from ifm electronic. This sensor is a 3D camera with integrated evaluation. Its resolution is 64 x 48 pixels. For each of the 3,072 pixels, the sensor supplies a distance value which is

A&D India | Dec’ 14-Jan’ 15

Food & Beverage -Focus- ifm.indd 35

precise to the nearest millimetre, up to 25 times per second. It looks at the crate from the top. The distance between the bottle cap and the sensor is evaluated at defined positions in the camera image. If it is outside the set range, the sensor provides an error signal and the crate is rejected. One sensor alone can reliably detect several missing bottles.

Advantages of the 3D control Compared to the conventional crate monitoring using diffuse reflection sensors, efector pmd3d can find additional faults in the crate. Due to the distance measurement, which is precise to the nearest millimetre, it detects small differences in height. If, for example, broken pieces of glass are between the bottom of the crate and the bottle, the bottle would be slightly higher. This would be detected by the 3D sensor rejecting the crate. Photoelectric diffuse reflection sensors, however, would not detect this fault. In addition, the vision sensor can be easily set to different shapes of crates and bottles via software parameter setting. The reference image can be selected later by using a simple switch. This eliminates the need for a mechanical modification of the reading matrix as would be necessary for the diffuse reflection sensor method. This saves time and money when the plant is retrofitted. The surface characteristics of the bottle caps, e.g. silvery or matt dark print, which again and again lead to faults with the diffuse reflection sensor method, is not a problem for the 3D sensor. Since the 3D image is evaluated in the sensor, an external controller is not needed. The sensor’s switching output can trigger via a switching signal that crates with missing bottles are rejected.

Rejects at a glance There is also a Ethernet process interface of the sensor to

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Food & Beverage | Focus

Missing bottles are shown in red and statistically evaluated

visualise the test result on a touch panel display. The machine operator can read the distance values for every bottle in the crate. A statistics function enables to detect the faults over a defined period. Even the information which bottle positions often lead to faults can be evaluated via statistics. Therefore, the machine operator can find and rectify machine parts, which do not function properly. This analysis is useful especially when machines are set up.

Price advantage

time. The image of the object on the chip matrix and the respective distance values correspond to a 3D image. These values enable the detailed assessment of the object’s or scene’s characteristics up to a range of 6.5 m with an unambiguous range up to 48 m. The evaluation unit is integrated into the device. The results can be transferred to the controller via two switching or analogue outputs and an Ethernet process interface. The parameters of the sensor are set via pushbuttons on the device or a PC software. The sensor has an Ethernet interface for parameter setting and communication.

Apart from the technical advantages, efector pmd3d provides a clear price advantage of replacing a whole matrix of Conclusion diffuse reflection sensors. Depending on the size of the crate, Using the vision sensor, the bottler could enhance their 12 to 24 bottles have to be monitored. The costs for cable and controller electronics have to be added. It also provides 3,072 full crate inspection system with additional diagnostic features. measurement points and costs much less. The evaluation An adaptation to different geometrical shapes of the crates is done easily via the software, eliminating the need for a electronics are already integrated into the sensor. mechanical modification. Therefore, the plant can be retrofitted much more easily and quickly. It has a better Technology advantage performance and costs less than the conventional solution The efector pmd 3D is the first industrial 3D sensor that with a diffuse reflection sensor matrix. The sensor can also be can detect objects in three dimensions at a glance. The time- integrated easily for quality control in other industrial areas of-flight measurement based on the PMD technology enables and was another important step to improve their high quality the assessment of different applications, for example the standard. ☐ detection of volume, distance or level. The sensor chip has 64 Courtesy: ifm electronic GmbH x 48 pixels. Each pixel of this chip matrix evaluates its distance > MORE@CLICK ADI03613 | www.AandD24.in to the object. This results in 3,072 distance values at the same

Food & Beverage -Focus- ifm.indd 36

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Food & Beverage | Focus

Will the food industry crack under pressure? In recent years, manufacturers around the world have been under growing pressure to increase production with reduced costs. This article explains how food and beverage manufacturers can remain productive by balancing between increasing raw material prices, energy prices and pressure from retailers.

Food & Beverage -Focus- European Automation.indd 38

Jonathan Wilkins Marketing Manager European Automation jonathan.wilkins@euautomation.com

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Focus | Food & Beverage

According to the 2013 food statistics pocketbook, food prices in the UK have risen in real terms by 12% since 2007. This price increase is emulated internationally and is partly associated with the increasing costs of raw materials and energy. It also reflects the pressure giant retailers have been exercising on food and beverage manufacturers to provide cheaper end products.

Between a rock and a hard place This situation leaves manufacturers stuck between a rock and a hard place since they need to comply with retailer demands and respond to particularly precarious customer preferences, while finding a way to reduce production expenses and not pass cost increases on to customers. In a recent industry survey, 83% of the food and beverage manufacturers that responded expressed concerns of pricing pressure from retailers were threatening the quality of ownlabel products. Around 74% further estimated that this pressure was threatening to cut into new product development budgets. As in any other industry, lack of research and development limits innovation, which in turn, reduces investment, growth and profit. While the food and beverage industry is one of the industries that will not suffer, its potential would be significantly limited should investment in innovation decreases.

How do you reduce costs? Moving manufacturing operations to a cheaper territory stopped being a viable solution long ago. Cheap labour isn’t strategic in the long run and most industries have already turned their backs on this option.

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Another way of protecting manufacturers’ interests would be to impose legal restrictions that ensure key obligations for retailers. One example would be guaranteeing that retailers give reasonable notice to change supply arrangements, that they deal fairly and lawfully and don’t constrain manufacturers to obtain goods, services or property from a preferred third party. When these codes exist, they are often limited by the free market and competition law, which means that reducing manufacturing costs needs to come from somewhere else.

Think ‘lean’ The fastest and most efficient way to reduce costs is by designing and managing a manufacturing process that results in the lowest possible unit cost. This means taking a good look at the operations and identifying how they can be improved. Today, production lines operate at less than 60%, which means there is considerable room for improvement. Identifying planned losses (cleaning, preventative maintenance or decreasing product demand), operational losses (changeovers, stoppages or shortages) and quality losses (scrap products or defective materials) is the first step in making manufacturing lean. The next step is utilising existing real-time data collection from the process equipment to improve Overall Equipment Effectiveness (OEE). Intelligent automation solutions help minimise process variability and maximise asset use and productive capacity.

Become flexible A flexible manufacturing line allows companies to match

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Food & Beverage | Focus

A flexible manufacturing line allows companies to match their products to ever-changing consumer behaviour, which is essential in the food and beverage industry

their products to ever-changing consumer behaviour, which is Automation, most parts, including variable speeds drives essential in the food and beverage industry. (VSDs), motors, programmable logic controls (PLCs) and Batch automation allows the manufacturing of certain human machine interfaces (HMIs), are easier to find even if products in determinate batches, rather than in a continuous these are obsolete. Besides, a specialist like us can deliver them production process. Batch operations in the food and beverage in as little as nine hours, which minimises down time and industry include mixing, blending, mashing and fermenting, reduces costs. while continuous operations refer to baking, forming and If everything else fails, purchasing completely new pasteurisation. equipment or refurbishing the production line should be A flexible production line guarantees consistent product considered. quality for all batches, allows a more dynamic product offer and ensures efficient use of the shop floor. Busting the myth

Manage breakdowns Breakdowns are inevitable, but the way they are managed, it can make or break a business. Lean manufacturing principles state that when a breakdown occurs, the first step is to try all the options that don’t incur additional costs. Whether it’s a simple case of “turn-it-of-and-on-again”, checking the system for blockages or performing an emergency maintenance, internal resources first should be used. If the breakdown is due to faulty equipment, it’s likely that manufacturers will be able to resolve the situation by getting the part repaired or just purchasing a spare industrial automation component. For an expert business like European

Food & Beverage -Focus- European Automation.indd 40

One of the myths surrounding the food and beverage industry is that it’s an out-of-date and old fashioned sector, which doesn’t offer exciting professional prospects. The challenges and external pressures the food and beverage industry is faced with make the rhythm of innovation particularly swift. At European Automation we have definitely sensed a shift towards intelligent automation, reflected in the purchases our clients make. Our food and beverage clients have started purchasing newer generations of PLCs, HMIs, digital sensors and transmitters. This means that despite being under pressure, the food and beverage sectors is still a leader in innovation and has great potential for growth. ☐ > MORE@CLICK ADI03614 | www.AandD24.in

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Food & Beverage | Focus

The four M’s of food manufacturing Improving operational efficiency in manufacturing is a vital element in the process of food & beverage production.To do this, it is important to consider the entire production-cycle spectrum, right from raw material receipt to finished goods. This article briefs on the four M’s essential in food manufacturing, while highlighting sustainability and line integration in the manufacturing process to acheive operational efficiency.

With high complexity and low margins, it often pays to take a simple approach to food & beverage production, to drill down to a few essentials and ensure that one is performing at optimum levels. While improving operational efficiencies, one should consider the entire production-cycle spectrum, from raw-material receipt to finished goods. At each point during production, there are four key areas that one will be required to evaluate while using the assets in the most productive way. These four categories are all intertwined, so increased efficiency in one area can impact the other three, just as waste in one category can cascade down the rest of the manufacturing process.

Food & Beverage -Focus- rockwell.indd 42

Cheryl Lange Global Marketing Programs Manager— Consumer Packaged Goods & OEM Industries Rockwell Automation indiamarketing@ra.rockwell.com

The four M’s Machinery: Innovations in machine-building means that these changes don’t have to hold up productivity, with machines planning ahead for the next batch before finishing the task in hand via visible and automated processes. By implementing end-to-end quality assurance, one can both keep quality high and drive costs down by controlling wastage and process inefficiency. Standardisation helps to maintain consistency of product wherever manufacturing is carried out. Materials: In common with many food and beverage manufacturers today, one will probably be producing more

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Focus | Food & Beverage

unnecessary activities. It could be that operators still carry out tasks manually when there may be a more efficient way of doing them. Can these be automated? How might one make better use of your existing team’s skills, and what one needs to do now to legislate for the skills shortages currently facing the industry? There will always be unexpected issues that cut into the day. Even more reason to focus on the day-to-day essentials on a regular basis, one’s core assets and how they interrelate, to ensure that one is performing efficiently, competitively, and in line with industry and technological developments.

Sustainable food & beverage manufacturing

products in more varieties in a greater range of packaging options. For this reason, it’s vital that the machines can move efficiently from batch to batch, while maintaining recipe quality and consistency for each product and minimising waste. Methods: As technology advances, manufacturing methods and capabilities evolve. Is the equipment that one is currently using the most suitable for business needs? How could one make modifications to existing processes to reduce costs or wastage without affecting productivity? Manpower: With proper manpower, it is important to be focused on the task at hand while eliminating time spent on

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As per a survey conducted by Global Food Security, by 2050, the global population is estimated to reach 9 billion. “Along with the need to feed this growing population is awareness of the impact the necessary increases in production have on the environment. An increase in energy usage required to drive production, increased waste for landfills, and depleting natural resources will all result from higher, more concentrated population levels”, says David Lefebvre, Industry Sales Manager CPG - EMEA, Rockwell Automation In this scenario, manufacturers have the responsibility of balancing the need to meet increasing demand with operating safely and sustainably at the lowest possible cost. Most manufacturers are starting to track energy consumption in some capacity, whether at a site level or down to specific production lines. By monitoring consumption, these companies can make operational changes to reduce energy consumption & costs. Access to historical data also permits management personnel to address intermittent or persistent power-quality issues, such as voltage sags or harmonics. By doing so, they can save thousands of dollars in damaged equipment or poorquality product, and avoid penalties associated with powerfactor problems on the energy grid. This type of data monitoring and analysis is critical to make improvements. Though one cannot improve what cannot be measured, but OEMs also can help their customers look ahead to what’s next. Visible and actionable water, air, gas, electricity and steam data allows managers and operators to constantly see and resolve issues. It’s especially important to secure on-going gains because improved management of energy consumption won’t necessarily deliver substantial improvements immediately. Energy management is a marathon, rather than a sprint, with savings measured in hour-to-hour and day-to-day increments: When and why did a machine exceed typical energy draw? Why did an equipment changeover cause startup surges? Why did a component change extend the production cycle into a peak-draw period?

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Food & Beverage | Focus

Many food and beverage manufacturers today are producing more products in more varieties in a greater range of packaging options. For this reason, it‘s vital that machines can move efficiently from batch to batch while maintaining recipe quality and consistency for each product, and minimising waste

Visibility is the only practical way to keep track of progress. While behaviours relying on human observation and intervention – involving managers and team members that perform the activities of plan, do, check, and adjust; the key to accelerated energy-efficiency improvements lies within the streams of data running to, through and from equipment.

Line integration – time on your side How many times has one heard saying that there are simply aren’t enough hours in the day or time waits for no one. We all know what it feels like being up against the clock, but what if one could get time back on one’s side? We haven’t found a way of getting more hours into a day or having time stand still when we need it to, and despite many successful years of developing retro-encabulator technology, the Rockwell automation R&D department has not perfected a time machine. So, how can manufacturers get some time back? It is well understood in CPG that flexibility and agility are attributes of superior integration. Those at the forefront of line integration implementation for the CPG industry are getting new products to market in as little as half the time they were able to before integrating their lines and can be benefitting from a huge decrease in downtime attributed to cycle changes and unscheduled downtime due to failures. This also allows them to be more flexible and responsive to consumer demands for variant flavours, special editions, new packaging and all manner of product specifications. The sheer variety of functions required by packaging machines means that they have been supplied by a vast range of machine builders to perform their various functions; filling, case making, wrapping, labelling, palletising in various flavours of performance vs cost. While the increased adoption of machines onto the ISA-88 and packaging machine language PackML practices has improved the ease of integration, it has not solved the ever present level of disparity even when standards are applied. The game changer is in the use of public

Food & Beverage -Focus- rockwell.indd 44

interfaces that can completely normalise these disparities for a specific line integration solution. Now, rather than those machines needing customised integration work and extensive coding for all integration into new lines, the standardised format allow supervisory systems to monitor and control all of the machines regardless of the OEM or specific programmer, in a connected, configurable, and repeatable format. This opens up visibility of the throughput of the individual machines as well as a centralised view of how the overall line is performing. That saves the OEM or system integrator plant engineering, and management time. It also helps the end user to be more agile and responsive to consu mer needs, again, by being efficient with time. While good integration can be achieved without this type of machine interfacing, reducing the time, cost and variability of line startups and vertical integration is not fully realised without it. Having good line control and performance management capabilities working early in the line startup process has the biggest impact on the return time of capital investment. This, in turn, enables more continuous improvement and capital project investments to happen sooner. Manufacturing that relies on traditional integration where line control and performance monitoring are completely separate efforts live in the world of lost time. Without having these two capabilities tightly integrated, it is hard to know the root cause of problems in real time. A sophisticated report that is delivered well after the fact is too late. Again, timely information at the fingers of the operators running the line provides the best results. The longer these problems linger, the more the potential costs of spoiled or scrap product resulting from the failures. Many of the associated costs can be avoided with a system that can communicate to the operator where the failure is, as well as communicate directly to other machines in the process to react as needed, whether that is to slow, stop or to continue as normal in order to balance the line. ☐ > MORE@CLICK ADI03615 | www.AandD24.in

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Industrial Computers & Peripheries | technology

Facilitating process optimisation The article deals with computer tomograph (CT), a digital model analysed in 2D section and cut 3D view, to ensure measuring accuracy and comparability of the optical measurement Three-dimensional digital models of components can be created with the help of a computer tomograph (CT). The various materials of the component are represented in the digital model by different gray tones. This allows the different materials to be switched in or out of display, as desired. In addition, the digital model may be sectioned in any plane and subsequently analysed both in 2D section as well as in a cut 3D view. This can serve as a replacement for laborious manual grinding. By means of an analysis of foreign material within the component, the distribution of pores and voids may be visualised. This enables targeted process optimisation of injection moulding and high pressure die-casting processes. The digital model can be used to determine the surface of the component. The surface contour of the component allows its dimensions to be established. Digital cutting of the surface

Technology Industrial Computers & Peripheries HARTING.indd 46

Dr Stephan Middelkamp Head, Corporate Technology Services Harting Technology Group, stephan.middelkamp@harting.com

contour yields contours similar to those from optical measurement of sections. An advantage of using CT for dimensioning is that the measurement programs for determining the dimensions can simply be reused. This is especially useful with highly reentrant tools. A further possible assessment method is the direct comparison of the actual surface contour with the data of the CAD model. Here, deviations are displayed with colour codes, simplifying the recognition of sunk areas and component distortion.

Principles of operation Computer tomography is an X-ray-based procedure in which the test object is scanned from different angles. The test object is, therefore, positioned on a turntable between X-ray source and detector. The X-radiation from the X-ray source is

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Industrial Computers & Peripheries | technology

Cone

beam

X-ray source

Test object

X-ray detector

Figure 1: Principle of operation of computer tomography (Source: Werth Messtechnik)

partially absorbed by the test object and thus attenuated. The degree of attenuation depends on the irradiated material and the path length. The attenuated radiation is registered by the X-ray detector. This provides the radiograph of the test object from one angle. Then, the test object is rotated slightly and another radiograph is taken. This continues until the test object has completed one turn, where the number of radiographs may be set to reflect the desired accuracy.

All about the 3-dimensional digital model After the CT scan, a digital model of the test object is calculated from the individual radiographs. In the digital model, the dependency on the path length is eliminated and the different materials of the test object are represented by different gray tones. The accuracy of the model is a factor of the number of pixels in the detector and also the degree of magnification of the component. Since the component is placed between the X-ray source and the detector (Figure 1), its magnification increases with its closeness to the X-ray source. This magnification determines the size of a pixel of the digital model. Interpolation between the pixels allows accuracy of the model to be increased still further. With 3-dimensional models, the term voxel is used instead of pixel. The model contains a gray tone for each voxel, which depends on its material. For a test object consisting of only one material, there is, therefore, one gray value everywhere in the test object and another gray value, where there is air. This transition between air and test object allows the surface of the test object to be determined. The analysis of components takes

Technology Industrial Computers & Peripheries HARTING.indd 48

place on the digital model of the test object. Here, different materials can be displayed or hidden, and digital sections can be performed in any plane. The model can be displayed either in a 3D or 2D section. As a part of the final checks before release, the contact overlap is checked to ensure the reliability of the connection. This is conventionally performed by making sections. A section must be made to check the overlap of the power contacts. In addition, the deflection of the RJ 45 connector in the various levels of its spring must be checked. Thus, computer tomography allows a considerable simplification of this procedure. The connector is connected up and scanned, and a digital model of it is produced. Cavities and material defects exhibit different X-ray absorption characteristics than the solid material. This allows cavities and defects to be found by the use of CT analysis of components. These can be then displayed in the digital model or colour coded to reflect their size. A cavity analysis can be performed for both plastic and metal components. The company has used this possibility for optimising process parameters with regard to the size, number and distribution of cavities.

Determining the dimensions of components The surface contour may be extracted from the digital model of the test object. This can be used to determine the dimensions of the component. Sections can be placed through the contour, so that dimensioning of a section is possible, analogously to conventional dimensioning. Geometrical elements can be defined in the sectional view, allowing the

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Industrial Computers & Peripheries | technology

False colour comparison of a Han housing

dimensions corresponding to the drawing to be determined. The definition of the dimensions proceeds manually by the writing of a measurement program. However, several advantages result in comparison with conventional dimensioning. Here, sections must be made laboriously and there is the danger of distortion caused by grinding the test object. With CT dimensioning, any number of digital sections can be produced without additional effort. This allows, for example, the shape of a chamber in the vertical direction to be examined by sections at different heights. So, it is only necessary to define the measurement program in a plane. Subsequently, the location of the sectional plane can be shifted in a loop. In addition, the measurement program need only be created once, and can be reused simply by replacing the contour. This is especially useful for the dimensioning of components with several cavities.

Calibration accuracy The calibration accuracy of the computer tomograph is determined with a pin array and a cube containing spherical caps. To ensure measuring accuracy and comparability of the optical measurement with CT dimensioning, in addition to the calibration of CT with the standard calibration jigs, investigations on HARTING components have been conducted. For instance, a chamber in a male connector was measured optically and with the CT. The optical dimensioning was performed with a plan view, and was carried out several times by several users in order to minimise the influence of the user. For CT dimensioning, the component was scanned several times and was then performed in a defined sectional plane. While comparing the measurement results, different measurement strategies must be taken into account. With the optical measurement in plan view, a minimal dimension of the chamber breadth is read, since it is always the corresponding outermost contour which appears as the edge. With the CT,

Technology Industrial Computers & Peripheries HARTING.indd 50

the measurement is determined exactly in a sectional plane. This can be freely defined, which similarly allows the minimal dimension of the chamber width to be determined. Then the optical and the CT measurement results are in good agreement.

Optimised measurement procedure Since measurement programs, once written, can easily be reused, the possibility of an optimised measurement procedure arises. When the CAD model of a new component is produced, it is used to produce the corresponding tool. But this model can also serve in parallel as the basis for producing the measurement program, using the surface contour defined in the model. When the first samples fall out of the tool, these will be scanned in and the artificial surface contour based on the CAD model will be replaced with the actual surface contour of the sample. Using the previously produced measurement program, the dimensions can then be obtained automatically.

False colour comparison In addition to the determination of individual measurements, deviations between two contours can also be represented through false color comparison. Here, the deviations between the contours are indicated with colours. On the one hand, this allows a comparison between a real contour and a CAD contour. This enables a good overall impression of a component, which goes beyond the comparison of dimensions. For instance, this allows easy recognition of the distortion of a component or the sinking of individual contours. Besides, two real contours can be compared with one another. In this way, the condition of a tool can be monitored or individual cavities can be compared with one another. â&#x2DC;? > MORE@CLICK ADI03616 | 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

Adopting high efficiency motors Motors are the workhorses of manufacturing industry offering large potential for energy cost reductions. This article deals with the significance of energy conservation by adoption of energy efficient motors across industries and benefits derived by the users and the environment. Renewable energy and energy efficiency are said to be the “twin pillars” of sustainable energy policy. Both resources must be developed in order to stabilise and reduce carbon dioxide emissions. Sustainable energy apart from other renewable energy focuses on the ability of an energy source to continue to provide energy is distinct from low-carbon energy, which is sustainable only in the sense that it does not add to the CO2 in the atmosphere. Moving towards energy sustainability requires changes not

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K N Hemanth Kumar Chief Manager Energy Efficient Motors & Transformers International Copper Association India

only in the way energy is supplied, but in the way it is used, and reducing the amount of energy required to deliver various goods or services is essential. Efficiency slows down energy demand growth so that rising clean energy supplies can make deep cuts in fossil fuel use. Opportunities for improvement on the demand side of the energy equation are as rich and diverse as those on the supply side, and often offer significant economic benefits. The solution is to find sustainable energy sources and more efficient means of converting and utilising

A&D India | Dec’14-Jan’15

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A&D_210x273_Automotive November.pdf

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13/11/14

6:54 PM

M OTO R S & D R I V E S | T E C H N O L O G Y

energy. There is significant energy conservation potential by adoption of energy efficient motors in the industries. Motors and motor driven systems are huge consumers of electricity, they are estimated to account for 43%-46% of all global electricity consumption as well as 69% of all electricity used by industry.

Electrical motor efficiency Inefficient electric motors waste electrical energy. Since most electricity is generated from fossil-fueled power plants, motors and motor-driven systems are indirect contributors to greenhouse gases produced by these plants. Hence, there are compelling economic and environmental reasons to increase the use of energy efficient motors. This is a problem for several reasons like inefficient electric motors waste electrical energy, thereby increasing electrical demand and associated electricity costs required to power motors. When electricity is generated by oil- or coal-fed power plants, the burning of fossil fuels produces carbon footprints from the usage of natural resources and emissions of greenhouse gases. Electrical energy losses from inefficient motors, therefore, waste precious natural resources, cause increased emissions of greenhouse gases, and increase operating costs (i.e. increases utility bills).

Increasing electrical energy efficiencies of motors There are compelling economic and environmental needs to evaluate the benefits of energy efficient and premium efficiency electric motors versus their standard counterparts. A well-designed motor can convert over 90% of its input energy into useful power for decades. When the efficiency of a motor is raised by even a few percentage points, the savings, in kilowatt hours (and therefore in cost), are enormous. For example, it has been estimated that if all countries adopted best Minimum Energy Performance Standards (MEPS) for industrial electric motors, by 2030 approximately 322 terawatthours of annual electricity demand would be saved. The electrical energy efficiency of a typical industrial induction motor can be improved by reducing the electrical losses in the stator windings (e.g. by increasing the crosssectional area of the conductor, improving the winding

Tech Motors & Drives- ICAI.indd 54

technique, and using materials with higher electrical conductivities). Reducing the electrical losses in the rotor coil or casting (e.g. by using materials with higher electrical conductivities), decreasing magnetic losses by using better quality magnetic steel, improving the aerodynamics of motors to reduce mechanical wind age losses and minimising manufacturing tolerances. In addition to energy savings, other benefits of high efficiency motors over standard motors include cooler operating temperatures due to lower heat generation, which results in lower maintenance and a longer life; improved tolerance to voltage variations and harmonics; extended manufacturersâ&#x20AC;&#x2122; warranties and rebates & tax incentives in some regions from utilities and municipalities.

Tools to evaluate motor efficiencies and lifetime costs As part of its initiative to enhance the efficiency of motors, Motor Energy Saving Calculator, a free tool can help calculate approximate annual savings in choosing IE2 & IE3 versus a lower efficiency model. Older operating motors with low efficiencies can also be evaluated for replacement. These motors cannot be rewound to exceed their original electrical efficiency design standards.

Induction motors Motors have evolved into a variety of types according to user requirements, design, and production costs. This section will address copper in energy-efficient alternating current (AC) induction motors because these motors are widely used in industrial drives. The main parts of an AC induction motor are the fixed housing body (stator), a rotating assembly (rotor) and electromagnets consisting of coils of copper or aluminium wire around a core of magnetic steel. Copper and aluminium can both be used in the stator coils, although copper coils are the standard as they are more flexible and they enhance motor electrical efficiencies due to their higher electrical conductivity. Aluminium die-cast rotors are the standard material but copper die-casting of rotors is an improved new technology that is increasingly used to enhance motor energy efficiency.

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M OTO R S & D R I V E S | T E C H N O L O G Y

The use of copper in place of aluminium for conductor bars and end rings of induction motor rotors results in improvements in motor energy efficiency due to a significant reduction in IR losses

Sustainable technology: Copper die-cast rotors

(2-pole and 4-pole), 132 kW (6-pole) and up to 110 kW (8-pole). Based on CEMEP, efficiency levels eff2 (improved The electrical efficiency of motors can be improved by efficiency) and eff1 (high efficiency) had been defined. Apart replacing the standard aluminium electrical conductor in the from the efficiency class, this standard also specifies other rotor with copper, which has a much higher electrical performance parameters like breakaway torque, breakaway conductivity. Until recently, die-cast motor rotors were current, minimum speed, maximum full load current, etc, for produced only from aluminium while researchers worked on each of the ratings. In other words, this outlines performance solving technological issues with copper pressure die-casting. specifications for energy efficient motors. Today, copper pressure die-casting is a proven technology and The Bureau of Energy Efficiency also launched its voluntary thousands of die-cast copper motor rotors are produced labelling plan in 2007 based on standard IS 12615:2004. The annually for motor applications where energy savings are labelling plan had limited success since it awarded voluntary prime design objectives. endorsement labels of eff2 and eff1 to the eligible applicants. The use of copper in place of aluminium for conductor The major motor manufacturers had recognised efficiency as bars and end rings of induction motor rotors results in a differentiator from the other motor manufacturers and improvements in motor energy efficiency due to a significant introduced motors with higher efficiency values than the eff1 reduction in IR losses. Motor modelling by a number of levels. Hence, the endorsement label failed to encourage such manufacturers has demonstrated that motors with copper manufacturers to adopt the labels. Upon the introduction of rotors yield overall rotor loss reductions from 15 to 20% the new IEC standard 60034-30 for the efficiency classification compared to aluminium. of induction motors and subsequent regulations based on the The advantages of motors with copper motor rotors on an same adopted by different countries, the Indian manufacturers, equivalent basis with aluminium include increased electrical Bureau of Indian Standards (BIS), Bureau of Energy Efficiency conductivity of the copper rotor material, plus the need for a (BEE) and other stakeholders realised the threat of trade smaller volume of steel enabling motors to be shorter in barriers for exports from India and potential influx of length; motors have 1â&#x20AC;?5% higher energy efficiency ratings, so inefficient motors into the Indian market. The global consuming less energy and motors have lower overall harmonisation of efficiency classes, testing methods and manufacturing costs. access to global markets triggered the Indian motor industry to harmonise its standards with the latest IEC standards. During the annual sectional committee meeting of BIS for Scenario of energy rotating machines, the BIS and BEE urged the motor industry efficient motors in India to harmonise its standards with IEC with the immediate focus Bureau of Indian Standards had first introduced an on revising the existing Indian Standard, IS 12615:2004 to exclusive standard for energy efficiency motors in 1989 (IS make it in line with IEC 60034-30. On the basis of IEC 6003412615), which covered 4-pole motors up to 37 kW. Later, the 30 and the performance parameters specified in the existing same standard was revised in 2004 with a proactive approach version of IS 12615: 2004, the draft of the revised standard IS from the motor manufacturers. This revision covered the 12615:2011 has been finalised and is published in August scope for all standard continuous duty motors up to 160kW 2011.

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G R

EERIN GIN EN

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AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD

EG E

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Affiliated to Uttar Pradesh Technical University, Lucknow

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B.Tech. Computer Science & Engineering Electronics & Communication Engineering Electrical & Electronics Engineering Electronics & Instrumentation Engineering Information Technology Mechanical Engineering Civil Engineering

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n 98% MCA and 97% B.Tech students graduated with 1st Division/Distinction during 2013-14 n Over 500 students placed in reputed companies during the session 2013-14 n Recipient of CMAI award for Best Industry Interface from the Hon'ble Minister of Science & Technology, U.P. n The only Institution in U.P. to have received approval from DST, Govt. of India, for establishment of Centre of Relevance and Excellence (CORE) in the field of Industrial Automation & Robotics n The only Institution in India to establish Industrial Robotic Training Centre, jointly with KUKA Robotics of Germany to provide Internationally recognized certification for Basic, Advance and Expert Level Training programs n The only Institution in U.P. to establish NI - LabVIEW Academy in collaboration with National Instruments n The only Institution in U.P. to establish Centre of Competence in Automation Technologies in collaboration with Bosch Rexroth n The only institution in North India to establish PLM Centre of Excellence in collaboration with Siemens n 1000 Networked computers and Wi-Fi for 24x7 internet with 100 Mbps fiber optic connectivity n Modern Hostels having accommodation for 1500 boys and girls n Sprawling campus spanning over 40 acres with Excellent Infrastructure

M OTO R S & D R I V E S | T E C H N O L O G Y

The advantages of motors with copper motor rotors on an equivalent basis with aluminium include increased electrical conductivity of the copper rotor material

• • • • •

The main features of the revised standard are: The ranges covered are from 0.37 kW to 375 kW for 2, 4 and 6 poles Intermediate ratings are considered based on the Indian markets. The efficiency classes are in line with IEC 60034-30 termed as IE2 and IE3 The testing method specified is as per IEC 60034-2-1. Checking and building capacity is the major task in implementation. The other performance parameters like starting torque and starting current are considered and specified for all three levels (IE2 and IE3)

Way forward The standard making body, BIS and the regulatory body BEE have been working towards bringing the supply chain, end users and other stakeholders together to harmonise Indian standards with IEC taking into account the Indian market needs and conditions. The effort of harmonisation of motor standards globally and the regulations introduced in different countries have been a trigger to move in a positive direction. On publishing the new motor standard, BIS and BEE are planning to draw a realistic but firm timeline to introduce minimum Efficiency Performance Standards of IE3. The following barriers that need to be addressed for smooth implementation of these policies are: • Capacity building of small and medium scale motor manufacturers to manufacture high and premium efficiency motors • Adequate test facility establishment as per prescribed testing standards. • Awareness creation among end users regarding life cycle cost • Establishment of incentive mechanisms for adopting high and premium efficiency motors and penalties in case of deviations

Tech Motors & Drives- ICAI.indd 58

•

Premium efficiency design have an effect on other performance parameters like stating current, starting torque, slip etc, and the barriers from the markets to accept these parameters is important Integrate motor driven systems into the process so that the original equipment manufacturers also appreciate benefits of premium efficiencies. In India, the comparative star labeling of pump sets is the best example in this direction.

Conclusion Motors are the workhorses of manufacturing industry offering large potential for energy cost reductions. Traditionally, capital equipment purchases are based on lowest first cost principles and motor selection is no exception. This needs to change to life-cycle costing based purchase. Purchase specifications for motors need to include efficiency in addition to basic parameters like KW and RPM. Apart from energy savings, EE Motors have a superior built and provide intangible benefits and a longer life. The penetration of high efficiency motors and premium efficiency motors is low in India. Efforts are being made to address existing barriers. These efforts include regulatory measures, standards making and harmonising Indian standards with global trends. In spite of the regulatory measures and the supply side involvement, it is required to address the end users so as to create a pull for high efficiency motors. BIS and BEE have been working with all the stakeholders to implement this standard (IS 12615:2011) by addressing the barriers and planning a way forward to move towards premium efficiencies in the next 2 to 3 years and compete in the global market. This combined effort of all the stakeholders will ensure that the goal is achieved. Although there are several barriers, the adoption of energy efficient motors can give immense benefits to the user as well as the country and environment. ☐ > MORE@CLICK ADI03617 | www.AandD24.in

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Image processing & measuring | technology

Tracing the right mark The article highlights the top considerations for implementing a Direct Part Mark (DPM) traceability process onto a fully automatic manufacturing line with fixed-mount code readers Part tracking or traceability is vital for those that make, store or move items through supply chain because the data is used in production output calculations, inventory control, revenue forecasting and other business operations. Traceability also improves quality by ensuring that the appropriate processes are performed in the correct sequence on the right parts. To track a part through its full lifecycle, manufacturers mark it with a permanent two-dimensional (2-D) code known as a Direct Part Mark (DPM). These codes are used due to their small size, error correction and amount of data that can be stored as compared to traditional 1-D barcodes. They also help with anti-counterfeiting measures as they are more difficult to replicate. Automated image-based ID readers are the only technology capable of decoding such marks as laser scanners are only able to read 1-D linear barcodes. Automatic identification technology eliminates any need to manually enter data during

Cognex_ Image processing & measuring technology .indd 60

Didier Lacroix Vice President â&#x20AC;&#x201D; International Sales & Marketing Cognex Corporation didier.lacroix@cognex.com

production, avoiding human error and increasing efficiency. On fully automatic manufacturing lines, parts are handled and moved by conveyor, indexer or robot and the ID reader is mounted in a fixed position where the mark can repeatably be placed in front of the reader. Similarly, a presentation reader operates in a continuous reading cycle, automatically performing the decoding task once the operator places the part in front of the reader. This guide highlights the top considerations for implementing a DPM traceability process onto a fully automatic manufacturing line with fixed-mount code readers.

Code selection Industry standards groups define codes for a given application like ISO 29158 (formerly known as AIM DPM). The Automotive Industry Action Group (AIAG) has guidelines

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Image processing & measuring | technology

If the bumps on the surface of a cast part are similar in size and/or shape to the dot peen marks of the code, readability suffers because the code blends in with the bumps in the surrounding image

as do the Air Transport Association (ATA), the US Department of Defense (DoD), GS1, SEMI and others. When specified, it generally makes sense to follow the industry guidelines because it improves efficiencies throughout product manufacturing and the supply chain. However, if no guidelines are available within the industry, one can use an existing guideline to create their own, noting that Data Matrix ECC200 is strongly recommended and is clearly becoming the choice for most industries involving metal, glass, ceramic or plastic materials. It is very flexible as it offers 24 square formats and six rectangular formats to encode anywhere between six and 3,116 digits in a single code. It also supports Reed Solomon error correction that allows a code to be successfully decoded even though as much as 60% of the code may be damaged. Since this code is in the public domain, marking and reading equipment suppliers have invested significant R&D resources to improve the performance of supporting equipment.

Marking processes & placement

surface to melt, vapourise or change in some way in order to produce a mark. The resulting quality of the mark depends upon the interaction of the laser with the material it is marking. It is most often used in the semiconductor, electronics and medical device industries. Electro-chemical etching (ECE): It is a process whereby a mark is produced from the oxidation of metal from the surface being marked through a stencil impression. ECE is a timeconsuming process and has a high cost for on-going consumables. It is used for low volume marking of round surfaces or for stress-sensitive parts of jet engines, automobiles and medical devices. Inkjet printers: It precisely propels ink drops to the part surface creating a permanent pattern of modules. It may require preparation of the part surface, as it is the chemical interaction of the ink to the surface of the part that determines the level of mark permanence and contrast. It provides fast marking of moving parts and offers very good contrast. The location of the code on a part can directly impact the readability of the code. It should be clearly visible throughout the manufacturing process and, wherever possible, it should provide a “clear zone” free of part features and edges, noise/ texture or other interference. Parts that present some of the most difficult reading situations include cylindrical or shiny parts that can create code distortion and specular reflection.

The 2-D DPM codes are marked on the part using several methods depending upon material composition, part application and environmental conditions. Important factors influencing the marking process decision include part life expectancy, material composition, environmental wear & tear and production volume. Dot Peening: It is achieved by striking a carbide or diamond Data encoding & readability tipped stylus against the surface of the material being marked. Data encoding refers to the amount of information that is Reading solutions must utilise lighting techniques to create contrast between the indentations forming the modules of the “stored” within the generated data matrix code. Deciding on symbol and the surface of the part. It is widely used in the what information to encode is typically driven by the company automotive & aerospace industries due to demanding lifecycle specifications and/or the requirements of the traceability project. In selecting what data to encode, one should also requirements. Laser marking: It applies heat to the part that causes the consider the amount of available space on the part as code size

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Image processing & measuring | technology

Laser marking applies heat to the part that causes the surface to melt, vaporise or change in some way in order to produce a mark

can affect readability. Readability defines how easy or difficult it is for a reader to successfully read a code. If a code is not readable, the part is not processed and/or the production line stops. Manufacturers live with varying read rates but should strive to achieve six sigma read rates which equates to only 3.4 defects per one million reads. One factor that contributes significantly to overall readability is the quality of the mark. The process of inspecting the quality of a mark is known as verification. The verification process is defined within the industryâ&#x20AC;&#x2122;s guidelines and generally takes place offline. Besides mark quality, one must consider other factors that can affect overall read rates. Successful location of the code within the field of view is the first step in successful reading. The next step is for the reader to determine which modules are light and which modules are dark. A code pattern with modules that are consistent in shape and size, but distinctively different from other features on the surface of the part provide the most reliable decoding. However, because of the very nature of DPM applications, this can be challenging due to variations in the surface texture, part presentation during the process, variability of the marking machines and changes that the parts undergo throughout their lifecycle.

Selecting a solution There are three categories to review during the evaluation process to ensure the highest read rates possible: decoding software, image formation and ease of use. Decoding software: Code reading algorithms form the basis

Cognex_ Image processing & measuring technology .indd 64

for any image-based ID reader. There are many variables that impact the readability of the code like distortion due to part material composition and variations in part presentation or variability caused by the manufacturing process. Powerful algorithms can read codes marked on any surface with any form of degradation. One can test a solution with as many sample parts and variations that one can imagine. But even the most advanced algorithms can perform better and faster with the help of resolution, lighting and optics. Image formation: A reading solution should tolerate changes in contrast, focus and degradation to the code without a need to change the underlying parameter settings. One should test the setup by adjusting the aperture or exposure to simulate change in contrast, focus to simulate change in depth of field and position of the light to simulate background problems. When determining the resolution requirements, the most important thing to consider is the number of pixels per module (PPM) one will need within your field of view. Higher resolution readers can maintain a high PPM for a larger field of view, allowing for more positional uncertainty. For very high speed applications, a standard resolution reader will generally provide faster performance. Some high resolution imagers, however, allow the application to use only part of the imager, which can create even faster response times. Lighting is especially important for DPM applications involving metals or other difficult-to-read materials. The proper lighting technique for dot peen applications, for example, can make or break a process. These marks are difficult to read unless lighting adjustments can be made. An intelligent tuning technology

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technology | Image processing & measuring

with controllable lighting is a key for this application. A reader that allows the user to change the lens offers greater adaptability for the reader to be deployed for different working distances based on the machine design requirements. Very often, the machine is designed long before a reader is considered, so having flexible optics in the reader makes retrofitting easier. Ease to use: When readers are deployed, different parameters are set up to optimise the application. A step-by-step process should be intuitive for any floor personnel. In addition, the reader must be able to communicate the results to another device, easily integrating into existing plant networks through whatever communications method is required: Ethernet, RS232, etc. For establishing a communications link between a reader and a PC at the enterprise level, one has to make sure that the reader supports a broad range of standard network protocols, including: EtherNet/IP, PROFINET, MC Protocol and Modbus/TCP. This connection also gives you a centralised way of managing the readers. Thus, the ID reader selected will allow managing and controlling activity over the network from

6A 5& D I n d i a | D e c â&#x20AC;&#x2122; 1 4 - J a n â&#x20AC;&#x2122; 1 5

Cognex_ Image processing & measuring technology .indd 65

remote locations in the plant and beyond. Having an easy to use setup tool minimises the time it takes to integrate the reader and reduces the overall maintenance effort of the system.

Conclusion DPM reading can be a very challenging application requiring technology and expertise solving difficult image analysis problems. Typically, companies experienced in industrial machine vision have the right expertise and technology for providing the highest DPM read rates. The chosen vendor should also be able to provide the support necessary to thoroughly qualify the application, guide one through to installation success and have the financial stability to maintain their role as your DPM reading solutions provider for the long term. â&#x2DC;? Courtesy: Cognex > MORE@CLICK ADI03618 | www.AandD24.in

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I m a g e c o urT es y: Boeing

Fieldbus & Networking | technology

Safety Lifecycle Management An application story on how Advanced Integration Technology (AIT)—an aerospace automation provider has incorporated safety PLCs, motion control, safety and standard I/O on a single PROFINET network for more efficient & compliant automation. Integrating control and safety requires a holistic safety mindset built around Safety Lifecycle Management, as specified by major safety standards such as IEC 61508, IEC 62061 and ISO 13849. This is a systematic, phased approach to safety with steps that are well documented and verified, from initial hazard and risk analysis to safety system implementation all the way through to system decommissioning.

Integrating safety The steps of integrating safety include: and engineering, including risk assessments & identification, and definition of safety functions needed for a safe manufacturing process; Installation and commissioning, including testing of safety functions and training personnel in for safety; Operation and servicing, including access to documentation and spare parts for keeping machines functioning safely, periodically testing of operations and fast diagnosis of faults; Maintenance, including the inspection and regular

• Design • •

•

Fieldbus & Networking - Profibus_rep.indd 66

replacement of safety-relevant components; and upgrading, including the implementation of functional safety advancements as a machine’s safety design and engineering allows. Following these steps, Advanced Integration Technology (AIT), a 20-year-old supplier of turnkey industrial automation systems for the leading aerospace suppliers, made major strides in machine safety. As a prime contractor on the Boeing 787 Dreamliner, AIT had responsibility for the final assembly and body join functions, charged with delivering a fully automated positioning and joining system. A comprehensive safety scheme with Safety PLCs is a central element in the system, which communicate using PROFINET. To help plant operators and safety engineers comply with the requirements of IEC 62061 and ISO 13849-1 standards, a TÜV certified online Safety Evaluation Tool (SET) was also available.

• Modernisation

Alignment & positioning For the application, two complete assembly systems and one positioning system were provided. The three main sections

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Fieldbus & Networking | technology

The basic scheme of the motion control system comprises: a motion controller, a Windows-based HMI, the Safety PLC, plus fail-safe and standard I/O modules, all running on a PROFINET network

of the fuselage are joined using 14 positioners mounted to transport structures that move either independently or interlocked and indexed to the factory floor for stability. Realtime positioning measurement data are logged with an integrated indoor GPS. AIT designed the alignment and positioning systems that roll under the aircraft dollies, radically reducing auxiliary equipment needs, materials handling requirements, and additional positioning steps. Onsite at Boeing, the 14 positioning system components were moved into their respective locations near the cradle dollies. Once the system is rigidly joined, a measurement system onboard locates the airplane sections. This information is fed to the system’s software application. From those data points, the system calculates how much each section (nose, tail, left and right wings) needed to move to ensure an exact fit to the adjoining section. This precise alignment ensures a smooth, rapid build of each fuselage. Siemens was tapped to provide equipment for AIT. “We looked for a supplier with an off-theshelf selection of automation and motion control solutions, who could offer us global support,” says Ed Chalupa, President, AIT. “Our goal was to utilise all current software, integrated safety, and control technology advancements. Both Boeing and AIT were keenly sensitive to lifecycle security issues in this critical area of the project.”

selections, the final body-join assembly tool runs as a single entity. Running together in this configuration, the safety devices work coherently, providing proper response levels to all Emergency-stop situations. Each unit motion controller receives commands to perform uniform group movements with the tool as a whole via network communications from the HMI. The integrated safety concept on this overall system is based on three core principles: increasingly layered safety architectures, greater degrees of integration between the control and safety systems, plus more use of networking, especially PROFINET. In operation, these safety principles manifest themselves in the form of physical barriers and mechanical means such as walls, gates, door interlocks, and more. They all isolate personnel from danger. Meanwhile, the control systems including safety PLCs monitor operating conditions within established parameters. The final protections are safety shutdown systems such as automatic shutdown via PROFIsafe-enabled safety PLC and manual shutdown via E-stops.

Conclusion

With integrated safety and control, the project has a single system for standard and safe automation. Having one PROFINET network and one engineering system for both standard and safety technology, further reduces cost. As a collateral benefit, the software solutions allow easier replication Employing PROFINET of series machines. Likewise, faster troubleshooting and AIT designed the overall layout of the control architecture, extensive diagnostics onboard reduces downtimes, with faster programmed the Motion Control system with the PLC, restart after issue resolution. Functionally, safety integration in distributed the I/O, and integrated safety and provided support the control system allows uniform user interfaces and data on the Boeing internal structure and lifecycle support libraries, plus a reduction in the variety of control cabinets. requirements. The basic scheme of the motion control system With advanced PLC and PROFINET networking technologies comprises: a motion controller, a Windows-based HMI, the combined, the system safety for AIT and its customer is a Safety PLC, plus fail-safe and standard I/O modules (linked via production asset that protects the workers from harm and also PROFIsafe), all running on a PROFINET network. This basic ensures maximum availability and uptime. Reductions in initial architecture was then multiplied by the number of control capital expense and field operating expense are also realised. ☐ nodes for each specific operational system in the overall Courtesy: PROFIBUS PROFINET production line being designed by AIT. > MORE@CLICK ADI03619 | www.AandD24.in With the addition of a few PROFINET cables and mode

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Sensors & encoders | technology

Changing face of Indian sensor market Sensors are very important components that are installed in products for different applications across varied industries. This article features the latest market developments & technologies emerging in the Indian sensor market, based on rising demands from various sectors. In terms of innovation, sensing technology is moving towards smarter, more compact and more secured solutions. All players are keenly looking into bringing in smart and miniaturisation technology so as to enhance product performance towards minimising human error and improving overall product reliability. The contemporary sensors are a smart ensemble of electronics, integrated intelligence, microcomputers and software. Advanced sensing technologies are being provided and employed for edge, positioning, profile measurement & sensing applications at higher speeds & accuracies which were not possible till date. Another interesting trend is the advent of industry-specifi c sensors. In terms of demand, the fastest growing segments are image sensors, accelerometers and position sensors (according to India Sensors Market Forecast & Opportunities2018). Also, optical sensors, laser sensor systems, vision

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Manoj Kodakatery Business Development Manager OMRON Electronic Components India

technology and MEMS (Micro Electro Mechanical Systems) sensors are showing significant growth adding to the overall growth of the sensor market in India.

Growth areas: Applications and geographies Automotive and consumer electronics industries are contributing substantially to the demand for sensors in India. In addition to these, the boost in the industrial sector led by a surge in the number of process industries is turning out to be a key driver. Internationally, many players are diverting their core focus from mature markets such as North America and Europe to emerging economies such as China, Thailand, Indonesia and India. These emerging economies hold a significant growth potential for sensor applications. According to a report issued

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technology | Sensors & encoders

Fence sensors uses special wires which can sense very small vibrations in the fence and can be calibrated according to the customer requirement

on ‘Sensor market opportunities in BRIC countries 2016 – Brazil, Russia, India, China’, low manufacturing cost, cheap labour, presence of OEMs are some of the factors proving effective in driving the growth of sensors market in BRIC countries. Starting with automotive and industrial applications, the sensors have made their way in other areas too in these countries such as consumer electronics and medical equipment. Continuous technological innovation and increasing application areas for new-age sensors are pushing their demand in the market. Despite the sluggish growth of the manufacturing sector, the market is likely to remain positive during the 201516 period and is expected to grow at the CAGR of 14% till 2018.

endeavour include: HVC (Human vision component) sensor: This sensor component allows devices to understand people. Just mounting the HVC on the device makes image sensing a reality. This leads to the best matching of machines to people on every device. HVC can be used in varied aspects of building automation such as access control, operations of vending machines, home appliances and automotive. It can also be used for market analysis in retail stores to understand customer preferences even when the shops are closed. Magnetic, radio wave & shock sensors: These are sensors which are very sensitive, accurate & can be calibrated as per the spec requirement. These are used for protection against tampering of equipment like smart meters, gaming machines and vending machines. Trends in India Fence sensors: This sensor uses special wires which can sense very small vibrations in the fence and can be calibrated Being a fast growing economy, security is one of the key according to the customer requirement. Mainly used for areas to which India is looking into. Aiming to address this protecting unauthorised entry to restricted areas. issue, Omron is striving to provide high-quality products and With many companies introducing the ‘smart’ factor into services, based on forte in sensing and control technology, so sensors, they are here to stay although the adoption has been as to contribute towards the social needs pertaining to safety. slow due to inherent needs of such platforms. By now, one can Omron’s electronic components’ business mantra for this ‘sense’ that there is much more in-store than one can imagine decade is “Shaping our sense of security with sensing in the applications of sensors. The ever increasing and technology”. Along with safety, the company also aims to make omnipresent need to automate every product so that it can its presence felt in other emerging areas of Indian market such sense, feel and act will never cease to end and so will keep on as energy, building automation, medical and automotive. In continuously encouraging innovation in the sensors segment. fact, MEMS technology has enabled Omron to develop This continuous technological innovation and increasing advanced micro component sensors ideal for a wide variety of application areas will continue to be key drivers pushing applications in consumer, commercial and industrial domains. demand of sensors in the market. ☐ > MORE@CLICK ADI03620 | www.AandD24.in Some of the key sensing solutions which are driving this

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EVENT | report

Platform for quality automation solutions SPS Automation India, scheduled on February 5-7, 2015, at Ahmedabad, will provide a platform for innovations in automation, through a vast range of products, systems and services. A pre-event report... Organised by Messe Frankfurt Trade Fairs India, latest technologies in factory & process automation. More than SPS Automation India 2015 will be held on February 5-7, 2015 100 exhibitors from India and abroad are expected to showcase at the Mahatma Mandir Convention & Exhibition Centre, their latest technologies in industrial automation, in the show, Gandhinagar, Ahmedabad. Indian Profibus Profinet underlining its stance as a sophisticated global business Association will support SPS Automation India 2015 to platform. With India emerging as a global manufacturing and showcase innovation in manufacturing, system integration supply hub in several verticals, Indian manufacturers are and highlight the benefits of Profibus and Profinet fieldbus recognising the need to invest in intelligent automation and systems, while collaborating the best automation technology control systems to maintain their competitive edge. Currently, available for the Indian manufacturing industry. estimated at ` 12,000 crore (USD 2 billion), India’s automation industry is growing at an annual average of 12% which translates to massive untapped potential and huge opportunities Showcasing modern automation solutions for the sector. Focused on modern automation solutions for the Indian Commenting on India’s high-growth path over the next market, SPS Automation India, like the mother event SPS IPC decade, Raj Manek, Managing Director, Messe Frankfurt Trade Drives, Nuremberg, Germany, will represent a leading platform Fairs India, said, “India has established itself as an economic for advancements in automation and their cost optimising and powerhouse and has the potential to become the world’s 5th

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report | EVENT

“The exhibition is important as India is a big growing economy with different industries that need precise sensors for their machines & devices to optimise production processes in the future” Johann Salzberger, Managing Director Marketing and Sales, Micro-Epsilon

largest consumer market by 2025. With the projected industrial expansion stemmed by stimulation in demand for products & services, automation companies are expected to see a surge of opportunities across all verticals.” He further stated, “With the fair being centred in Gujarat, this will be the perfect opportunity for sector players to establish and strengthen their presence in the Indian market.”

Concurrent shows Exhibition companies P E Schall GmbH & Co KG and Mesago Messe Frankfurt GmbH are joining forces by collaborating on a trade show project in India to draw attention to dynamically expand the Indian market. The companies want to combine SPS IPC Drives, Motek, and Control – the leading industry trade shows. While SPS IPC Drives is Europe’s premiere event for electrical automation, Motek (International trade show for production and assembly automation) and Control (International trade show for quality assurance) set the global benchmark in their segment. At the fair, industry professionals will be able to gain a firsthand experience on smart, safe and sustainable automation solutions that will help improve business profitability and optimise manufacturing processes to make operations cleaner, safer, secure and more efficient.

Seminars and demos A technical conference has also been planned along with the three fairs to provide sector professionals an understanding of new processes and technology trends making a headway in the manufacturing sector. Day 1 of the SPS Automation India seminar will witness a session on Industry 4.0, briefing on what has been achieved in Europe and the way forward for India. This will highlight Internet of Things and interoperability by Ravi Aggarwal, Director, Pepperl+Fuchs. Besides, there will be presentations on operational & functional safety, advances in sensor technology, control systems, drives and motors – innovations for Indian market for better energy efficiency. Presentations on manufacturing competitiveness and role

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“The show will introduce the latest technologies and products for automation, to create the necessary network & community in this domain in India” Ravi Agarwal, Director, Pepperl+Fuchs (Factory Automation)

“SPS Automation India 2015 will offer the visitors a new & perfect platform to source the right solutions for their automation tasks” Atul Dave, Managing Director, SICK India

of automation technology by SN Ambardekar, former VP— Manufacturing, Commercial Vehicles Business Unit, Tata Motors; significance of first-step automation for small & medium scale industries & top technical challenges by Vipin Bhogal, Consultant, Steinbeis India and significance of standards in industrial automation by Dr S Rominus Valsalam, Associate Director & Head— Automation Systems Technology Centre (ASTeC) will be discussed on day 2.

Major exhibitors at the fair Some of the major exhibitors participating in the exhibition include Pepperl+Fuchs, SICK India, Baumer Technologies India, Delta Electronics India, Endress+Hauser India, Geissel India, Harting India, ifm electronic India, Micro-Epsilon, Omron India, Themis Automation (Murr Electronik), Nikon India and Vipa Automation India, among others. With the “Make in India” campaign in the backdrop, the three-day fair will provide visitors the unique opportunity to witness the latest innovations in industrial automation to suit their emerging market & technology requirements. ☐ > MORE@CLICK ADI03622 | www.AandD24.in

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EVENT | report

Introducing futuristic technologies The 11th annual NIDays2014 was recently held in Bengaluru by National Instruments to showcase new age technologies for software-defined systems in test, measurement & control. A report… National Instruments, a world-wide leader in the test and measurement industry, recently hosted the 11th annual NIDays 2014 in Bengaluru. The event, attended by more than 800 engineers, academicians and researchers, witnessed participation from NI customers and alliance partners across a range of industries including healthcare, semiconductor, aerospace, automotive, life sciences, robotics and telecommunication. More than 1000 innovators got the opportunity to learn about the latest technologies to accelerate productivity for software-defined systems in test, measurement and control. The keynote during the event was delivered by Alex Davern, Chief Operating Officer, National Instruments. Addressing the conference, Davern said, “NIDays is the biggest platform to witness how our Indian customers are solving some interesting challenges with NI tools. Our successes have come from a philosophy of relentless investment in innovation. We

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Srimoyee Lahiri Sub-editor & Correspondent srimoyee.lahiri@publish-industry.net

have a team of 170 R&D specialists in Bengaluru and over 2000 people over the world. With the latest technology advancements, we feel like the technologies in the offing can really help redefine how industry works to continue addressing the world’s biggest challenges.”

Significance of NI Days in the Indian market The conference included technical sessions and dedicated stalls to demonstrate various solutions in sectors like aerospace, life sciences, robotics and telecommunication. “It’s a prime opportunity for our company to launch latest products in the Indian market. We have around 2000 customers including influential professors, engineers and scientists. Since our core application LabView is used in a wide spectrum of industries & academia in India including IIT, TATA & Indian military, our focus is to bring low cost technology in the Indian market”,

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report | EVENT

“With the tremendous amount of aging machinery in power plants, steel mills and factories in India, the industrial Internet of Things is a critical element that will ensure the uptime and optimisation of these systems” said Davern. “The Indian market is very open to experimenting the latest hi-tech automation related technologies with better functionality. We believe engineering students need to be given better opportunities for experiential learning and innovative thinking. To make this happen, we are actively working with many universities in India, by developing centres of excellence where students get to work with our technology to prototype their concepts”, he added. Addressing the conference, Victor Mieres, Vice President, Emerging Markets, Asia / Rest of World, said, “NI’s Indian operations have more than 300 personnel, with around 120 members catering to its R&D activities. NIDays for us is to showcase the newest products, in the Indian market. More specifically, we like to showcase what our customers are doing with our products, i.e. the impact of the technologies in their lives & business. We drive inspiration from our customers and it is a great opportunity to highlight some of the successes of our partners.” He also highlighted how in the area of test, the company has come up with higher frequency RF communication device test product that empowers users to do test in RF devices in a much faster & sophisticated way. “We have also announced the new version of LABVIEW 2014, the flagship software of NI with hundreds of new benefits. Apart from this, we also have a product in the offing dedicated to the market of rotating machinery”.

Display platter The seminar launched the NI InsightCM Enterprise, a new software solution that helps companies gain insight into the health of their capital equipment for machine maintenance and operations. NI InsightCM Enterprise is an end-to-end software solution that addresses big analog data challenges and builds on the industrial Internet of Things. As the Internet of Things (IoT) evolves to become more mainstream, the company is committed to bridge the gap between vision and implementation. The Internet has undergone various levels in its relatively short life span from consumer IoT to industrial IoT. This evolution will benefit individuals and businesses by removing physical barriers. Internet-powered technology innovation within the industrial operations space adds new dimensions to the technology space.

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Alex Davern, Chief Operating Officer, National Instruments

“We drive inspiration from our customers and NIDays is a great opportunity to highlight some of the successes of our partners” Victor Mieres, Vice President, Emerging Markets, Asia / Rest of World, National Instrument

Davern said, “With the tremendous amount of aging machinery in power plants, steel mills and factories in India, the industrial Internet of Things is a critical element that will ensure the uptime and optimisation of these systems. We believe that NI InsightCM™ Enterprise will enable organisations to monitor critical machinery, analyse vast amounts of data and make meaningful business decisions.”

Key benefits The key benefits of NI InsightCM Enterprise are: Cost-effectiveness: It lowers the instrumentation cost for monitoring both critical and other plant equipment at a fleetwide scale; offers open software architecture to access data and gain interoperability with third-party enterprise software packages, such as CMMSs, database historians and prognostics tools. Easily scalable: It scales from one to hundreds of nodes per NI InsightCM Enterprise server and replicates one solution at multiple facilities Flexible: It incorporates CompactRIO to adapt to changing sensory needs while maintaining the user’s investment in the platform. The company is also working on 5G technology which will make the industrial IoT much more accessible and feasible. The event concluded with an award ceremony where the Application of the Year was awarded to the team from National Aerospace Laboratories for their application titled Drishti Transmissometer. ☐ > MORE@CLICK ADI03622 | www.AandD24.in

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T E C H N O L O G Y | TA L K

solutions for machine tool industry The article highlights the primary cable requirements in the Indian machine tool industry which enhance substantial high-end machine tools manufacturing India stands 16th in production and 11th in the consumption of machine tools in the world as per the 2014 Gardner Business Media survey. The country is set to become a key player in the global machine tools industry and is likely to see substantial high-end machine tools manufacturing. Industry experts say that the phenomenon is linked to the spurt in manufacturing, for which the machine tools sector serves as the mother industry. Since, the manufacturing capacity is stagnating and the growth rate for the machine tools industry is falling in developed economies, shifting machine tools capacity to low-cost high skill geographies like India, has become imperative.

able to sustain vibrations. The connecting glands must be unaffected by the oil as well. The cables must be ingress protected. IP is a European rating standard for measuring the degree of protection offered by mechanical and electrical equipments against solid and liquid particles. It is mandatory for cables used in the machine tool industry to be IP67 and IP68 certified i.e. the cables should be dust resistant and must be protected against temporary/ continuous immersion in liquids. HFFR (halogen free fire resistant) cables are mandatory accounting for the safety of the staff and surrounding equipments.

Benefits

Key trends

Depending on the application, Lapp suggests the types of cable from its wide range of power and control The key trends pertaining to India’s Machine cables. Care is taken Tools Industry are: Perfect cable solutions for tight spaces: Since the to ensure the • T op 20 players in the sector account for over 70% equipments have space constraints, the cross-sectional data cables of its domestic production. size of the cable has to be as small as possible without are adequately • T he market is dominated by imports which affecting the nature and the performance of the protected from the account for 67% of the total industry demand. equipment. electromagnetic • T he machine tool industry is expected to grow at Cables for safe and secure transmission: Control interference a healthy growth rate (CAGR) of 20% until panels and machine automation systems require produced by the 2020. transmission of signals from one point of the system to The industry growth drivers include key user power and control another. This is possible through data communication cables industries like automobile, defence, aerospace and cables, which can transfer large amounts of data in a power are set to fuel the growth. The domestic fast and secure manner. Care is taken to ensure the demand is expected to grow at 15% and domestic data cables are adequately protected from the production between 20-25% and the industry is moving towards electromagnetic interference produced by the power and control increasingly sophisticated CNC machines driven by demand. cables. Reharnessed cables to keep hazards at bay: The hazards of a loosely connected wire can be avoided by using reharnessed Characteristics of cables in the cables whenever possible. These cables are accompanied by their machine tools industry respective cable glands. This arrangement ensures that the cables Machine tool industry is inherently complex and cable are securely connected and one does not have to look for other requirements of this industry vary from machine to machine cable gland suppliers. depending on the type of equipment. However, some of the Finding cables made easy: Since the underside of the control common characteristics include all machines require constant panels and machine automation systems looks like a colourful oiling and regular maintenance in order to ensure no harm assortment of noodles, it becomes extremely confusing for the comes to the machines on repeated usage. The cables, however, technician to locate faults. To respond to this problem, the should be oil resistant. Oil has a tendency to get absorbed into company provides cable marking products. ☐ the cable resulting in swelling & softening and eventually Courtesy: Lapp Cables > MORE@CLICK ADI03623 | www.AandD24.in degrades the tensile property of the cable. Cables must also be

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news | technology

Noisless brush motors

Thermocouple terminal blocks

Crouzet Motors’ DCmind brush motors are quiet, even under full load, and offer efficiencies, long service life, and a wide range of gearboxes and accessories. With virtually noiseless operation, these motors are particularly well suited to applications in medical, biopharmaceutical, laboratory, industrial machinery and high performance office equipment and systems. These can also be used in a variety of other high DCmind Brush Motors performance applications such as pumps and valves, railway and railcars, as well as military and aeronautics. These motors have a noise level of only 35 dB, about the sound of a whispered conversation and 20 dB less than the current motor standard range. The new product range includes 15, 25 and 55 watt motors with a 42 mm diameter, and 55 and 104 watt motors with a 63 mm diameter. These motors support 12, 24 and 48 volt power supplies and are available with seve ral accessories and adaptations, including rear brake, optical or hall effect encoders (1 or 2 channels), connectors and wires, voltage, speed and power, etc.

Connectwell Industries has released the thermocouple terminal blocks that are used with thermocouple wires in measurement applications. As per DIN 43713 & DIN 43714 the current carrying element of the terminal block is made of the same material as the thermocouple wire. These special current carrying elements ensure that there is no loss of potential at the connecting points. There are different types of thermocouple wires that can be connected using standard thermocouple terminal blocks. It includes Etanorm SYT pump series ‘K’ type – chromel (Ni/Cr), alumel (Ni/Al); ‘J’ type – iron (Fe), constantan (Cu/Ni); ‘T’ type – copper (Cu), constantan (Cu/Ni) and ‘E’ type – chromel (Ni/Cr). The terminal pitch is 43 mm; connection possibility: stranded wire 0.2 – 2.5 sq mm, solid wire 0.2 – 4 sq mm; approvals: IECEE, CE; rated voltage of 1000 V and rated current: 10 A. These terminal blocks are an ideal choice for heaters and boiler applications with thermocouples.

Custom Sensors & Technologies | Bangalore Email: india@cstsensors.com | Tel: +91-080-4113-2204/05

Connectwell Industries | Mumbai Email: connect@connectwell.com | Tel: +91-251-3980-600/3980-800

> MORE@CLICK ADI03624 | www.AandD24.in

> MORE@CLICK ADI03625 | www.AandD24.in

Power & signal connectors

Test & evaluation kit for real-time Ethernet

Fischer Connectors has recently launched MiniMax™ series – a high density miniature solution with a unique combination of power & signal contacts which enables more functionality into smaller devices and lowers the total cost of ownership. This connector is ideally suited for hand-held or body-worn applications, for instrumentation and for test equipment where userFischer MiniMax™ Series friendliness and easy handling are a must. The pin socket version of the series is available as standalone connector, mounted on a flex or cabled by the users, or as a complete pre-cabled solution. While the 24-pin configuration is available with 4 power and 20 signal contacts, the 19-pin configuration of these series features 4 power and 15 signal contacts as standard, with a unique feature to increase the number of power contacts depending on the cable used. Within the signal contacts, there are 2 advanced contacts for USB power connections as an available option.

Hilscher GmbH has introduced a test and evaluation kit for the six most common Real-Time-Ethernet systems. The kit is suitable for development, test labs, education & end users. It contains a cifX master PC card, three NXIO slave test-devices and a netANALYZER as Ethernet analysis device with Gigabit-Ethernet PC-interface. Furthermore, the kit contains Ethernet cables, power supply and Real-Time-Ethernet master and slave firmwares for EtherCAT, EtherNet/IP, Modbus TCP, POWERLINK (slave only), PROFINET and sercos. The comprehensive documentation helps the user in a step-by-step guide through the configuration of the network using SYCON.net and explains the measurement of important network parameters using the netANALYZER which has no influence on the network, analysis methods supported with graphic output, captures all process data with name resolution & always passive with zero delay.

Fischer Connectors India | Delhi Email: raman.kalra@fischerconnectors.in | Tel: +91-0124-4255-642/ 45

Hilscher India | Pune Email: www.hilscher.in | Tel: +91-8888-750-777

> MORE@CLICK ADI03626 | www.AandD24.in

> MORE@CLICK ADI03627 | www.AandD24.in

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technology | news

Remote management solution The Netbiter Remote Management solution from HMS Industrial Networks allows automation devices using EtherNet/IP to be monitored and controlled via the web. By connecting a Netbiter EasyConnect 300-series gateway, users of EtherNet/IP-based equipment can do maintenance from any location. With Netbiter, users can configure EtherNet/IP devices remotely using their regular configuration software (RSLogix for example); log trends and monitor performance over time. The user connects an EtherNet/IP-based automation device to a Netbiter gateway via the LAN port. The gateway sends data via Ethernet or the cellular network to the cloud-based data Netbiter Remote Management centre called Netbiter Argos. Users can access Netbiter Argos at www.netbiter.net using a regular web browser. They can also set up a secure tunnel to the remote machine or equipment which enables commissioning and debugging just as if they were on site. Other included features of the new Netbiter release includes the ability to group and filter alarms and free access to map functionality showing the exact location of each Netbiter gateway. HMS Industrial Networks India | Pune Email: in-sales@hms.se | Tel: +91-20-2563/ 0211

> MORE@CLICK ADI03628 | www.AandD24.in

Magneto-inductive displacement sensors

Energy saving LED luminaries Samudra Electronic System has launched Smart series energy saving LED luminaries — the high mast lights that are designed for outdoor and indoor applications. Its multiple applications include illumination of sea ports / air ports; municipal roads; outdoor sports arenas; gas stations; general area; tunnels; shop floor of auto industry / workshop; warehouse; LED Luminaries petrol pumps at canopy portion and many other locations which are at heights and not easy for routine maintenance. Its technical specifications include a lifespan of 40,000 - 50,000 hrs; colour rendering index (CRI)>80Ra and isolated power supply with spike protection. Its input voltage range is 85-265 V AC with 50-60 Hz. It can operate in a wide voltage range and has active power factor correction of >0.98 with an efficiency of power supply of 84%. It is available in colour temperatures of 4000 K (warm white), 5700-6500 K (cool white) and its metal core PCB is used for efficient heat management. LEDs are mounted on metal core PCB under anti-static environment by SMT automatic pick-and-place CNC machine. Samudra Electronic System | Pune Email: info@samudraled.com | Phone: 91-20-2712-2486/85

> MORE@CLICK ADI03629 | www.AandD24.in

Fieldbus station for control cabinets

Micro-Epsilon has offered the mainSENSOR MDS-40-MK and LP series of sensors — a new generation of cost-effective and flexible magnetoinductive sensors. Four MDS-40-MK series predefined sensor variants are available with different connector, power supply and output options. These parameters, including the protection class, can be individually configured to suit the customer’s specification for series production of 200 pieces or more. Regardless of the order quantity, the mainSENSOR MDS-40-MK printed circuit board of the MDS-40-LP sensors can be adapted to suit the individual application and to other customer requirements. With both series, the measuring ranges can be defined by selecting the corresponding magnet type for the respective target and measuring arrangement. The sensor is based on an innovative measuring principle, which has been developed to combine the advantages of both inductive and magnetic sensors. As different strength magnets are applied, measuring ranges of up to 55 mm can be achieved.

MurrElektronik's Cube20S is a compact, efficient fieldbus station for control cabinets. The new modules also feature modular designs - a characteristic for these products. Cube20S connects slim input and output modules with a width of only 12.5 mm for base modules with integrated bus nodes. Digital and analog modules with two, four or Cube20S eight channels are available, as well as function modules like counters or potential distributors. Combining the standard output modules with safety MIRO Safe+ make it possible to safely switch off non-safe outputs up to category 3 PLd. Modules for active safety applications up to SIL3 and PLe are also planned. The fieldbus stations can be precisely configured according to the engineers’ need for their installations. It is available for the fieldbus systems Profibus, DeviceNet, CANopen, Profinet, Ethernet IP, Ethercat, and Modbus. This wide variety of models and the short response times (up to 20 μs) make Cube20S suitable for a large number of applications.

MICRO-EPSILON | Pune Email: pragnesh.mori@micro-epsilon.de | Tel: +91-20-2674-1009

MurrElektronik India | Bangalore Email: Chetan.t.a@murrelektronik.in | Tel: +91-9900-57-344

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> MORE@CLICK ADI03630 | www.AandD24.in

> MORE@CLICK ADI03631 | www.AandD24.in

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news | technology

Wireless sensor development kit Analog Devices has introduced a suite of comprehensive development kits enabling manufacturers of industrial equipment to easily add remote sensing and monitoring capabilities to their Internet of Things and Big Data products via a scalable wireless network. The wireless sensor development kits significantly reduce the time and effort required to move designs from proof-of-concept to production release. The out-of-the-box kits allow engineers to establish a working wireless sensor system in 15 minutes to report and Comprehensive development kits analyse remotely various types of sensor data, such as temperature, humidity and motion/ vibration. Along with two multi-sensor-node boards, the demo kits include a base station connector, an emulator platform, and a full-featured software package that includes a robust communications protocol stack and rich graphical user interface. The bill-of-materials for the multi-sensor boards is comprised of an integrated RF transceiver and ARM Cortex M3 microcontroller (ADuCRF101) as well as multiple sensor elements that include the industry’s lowest power triple-axis accelerometer (ADXL362).

Detection scanners for field monitoring applications Pepperl+Fuchs’ powerful Pulse Ranging Technology (PRT), the R2000 detection scanner is the ideal solution for demanding field monitoring applications and assistance systems. Empty bay detection and gap recognition are as easily accomplished as the detection of overhanging and interfering products in high-speed AS/RS applications. Assistance systems for collision avoidance in both automatic guided vehicles or manually controlled forklifts and tuggers are another class of applications where the PRT-enabled R2000 detection offers outstanding features and performance. The speed and performance of the scanner is due to the revolutionary PRT measurement principle, a true R2000 detection scanner time-of-flight technology based on ultra-short, high-intensity light pulses. The scanner offers exceptional ambient light immunity and unparalleled precision, even at long distances. Together with all products in the R2000 family it uses a unique rotating measurement head instead of an complex rotating mirror design. This approach provides several important functional enhancements including a wobble-free scan plane and a 360o field of view.

Analog Devices India | Bangalore Email:cic.asia@analog.com | Tel: +91-80-43002000

Pepperl+Fuchs India | Gurgaon Email: fa-info@in.pepperl-fuchs.com | Tel: +91-124-3894000

> MORE@CLICK ADI03632 | www.AandD24.in

> MORE@CLICK ADI03633 | www.AandD24.in

Configurable control systems

Compact mechatronic rotary module for flexible rotations

Pilz has recently introduced PNOZmulti configurator — configurable control systems that bridge the gap between classic safety relays and programmable control systems. The configurator guides the programmer step-by-step. First of all, the user selects the hardware he needs for his machine via “drag & drop”. This consists of a base unit and, if necessary, expansion modules with safe inputs and outputs, the number of which is displayed in table form. The integrated feasibility check stops the user selecting expansion modules incorrectly: only the PNOZmulti configurator modules supported by the inserted base unit are made available for selection. The PNOZmulti configurator provides assistance if the permitted number of expansion modules is exceeded or if modules are positioned incorrectly. Online help is always available during configuration. The configurator downloads the entire safety program on to a chip card. The chip card does not necessarily have to be inserted in a base unit. The program can also be copied via an external read/write device.

SCHUNK’s ERS rotary modules are developed for rotary movements in the medium load range. The compact mechatronic rotary module is available in unit size 170 with a height of 66 mm, achieving a nominal moment of 5 Nm, and a maximum moment of up to 17 Nm. It is used for implementing flexible and compact system concepts. The core piece is a torque motor with a hollow shaft. It is light-weight and compact, and is absolutely wear-free, making it ERS rotary modules very reliable. It can endlessly turn up to 250 rpm to any intermediate position at a repeat accuracy of 0.01°. In contrast to rotary modules with a conventional servo motor, the ERS has no additional interfering contours and no elasticity. In order to feed compressed air or signals without hoses or cables through the module, the compact module is available in a version with pneumatic-electric feed-through, by using a slip ring or air channel of up to eight electric signals (24 V DC / 2 A), and a fluid with a pressure of up to 8 bar.

Pilz India | Pune Email: s.handoo@pilz | Tel: +91-20-2421-3994/95

SCHUNK Intec India | Bangalore Email: rakhi.singh@in.schunk.com | Tel: +91-80-4058-999

> MORE@CLICK ADI03634 | www.AandD24.in

> MORE@CLICK ADI03635 | 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 - (Feb-Mar 2015) 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

»»Pharma & Packaging As per recent reports, the Indian pharmaceutical market is projected to grow at a CAGR of 12-14% to become a $ 24 billion market by 2015. With this in the background, the next edition will feature the latest automation case studies and technologies catering to the emerging requirements of this industry. The next issue will also highlight the latest technologies in packaging automation, while discussing latest innovations and R&D in this domain.

»»Drives & Components With a consistent programming structure and common operator interface, drives ease programming and configuration, and reduce set-up time, training, and operation. Today’s drives offer a broad range of control modes, features, options, and packaging, as well as global voltages and many power ratings. The next issue will feature latest drives & components with details on the current developments in this area.

»»Software & Engg Tools Software & engineering tools automate project management activities; manage all work products produced throughout the process, and assist engineers in their analysis, design, coding and testing work. The next issue will see how these tools can provide for better productivity and efficiency.

Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk

company Index

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Hannover Messe 2015

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Ajay Kumar Garg Engineering College . . . . . . 57 Analog Devices . . . . . . . . . . . . . . . . . . . . . 79 ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B&R Industrial Automation . . . . . . . . Cover,8,9 Bentley Systems . . . . . . . . . . . . . . . . . . . . 12 Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . 25 Connectwell Industries . . . . . . . . . . . . . 11, 77 Contrinex Automation . . . . . . . . . . . . . . . . . 31 Cognex . . . . . . . . . . . . . . . . . . . . . . . . . . 60 CST Sensors . . . . . . . . . . . . . . . . . . . . 19, 77 CD-adapco . . . . . . . . . . . . . . . . . . . . . . . . 10 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Delta India Electronics . . . . . . . . . . . . . . . . . 3 Danfoss . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dow Corning . . . . . . . . . . . . . . . . . . . . . . . 12 Eplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 European Automation . . . . . . . . . . . . . . . . . 38 Emerson . . . . . . . . . . . . . . . . . . . . . . . . . 14 Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 2

Features Writer Megha Roy megha.roy@publish-industry.net

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Fischer Connectors . . . . . . . . . . . . . . . . . . 77 Galil Motion Control . . . . . . . . Back Inside Cover Hannover Milano Fairs India . . . . . . . . . . . . . 17 Hannover Messe . . . . . . . . . . . . . . . . . . . . 15 Harting Technology Group . . . . . . . . . . . 12, 46 Hilscher India . . . . . . . . . . . . . . . . . . . 37, 77 HMS Industrial Networks . . . . . . . . . . . . 49, 78 Hummel Connector Systems . . . . . . Back Cover ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 55 IFM Electronic India . . . . . . . . . . . . . . . 34, 61 ICAI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Igus India . . . . . . . . . . . . . . . . . . . . . . . . . . 4 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Janatics . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Kubler Automation . . . . . . . . . . . . . . . . . . . 59 Lapp India . . . . . . . . . . . . . . . . . . . . . 14, 76 Messe Frankfurt . . . . . . . . . . . . . . . . . . . . 63 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . 7, 78 Moxa Americas . . . . . . . . . . . . . . . . . . . . . 20

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 65 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . 53 MurrElektronik India . . . . . . . . . . . . . . . 33, 78 National Instruments . . . . . . . . . . . . . . . . 6, 74 NORD Drivesystems . . . . . . . . . . . . . . . . . . 14 NTPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Omron Automation . . . . . . . . . . . . . . 1, 14, 70 Profibus Profinet . . . . . . . . . . . . . . . . . . . . 66 Pepperl + Fuchs . . . . . . . . . . . . . . . . . . . . 79 Pilz India . . . . . . . . . . . . . . . . . . . . . . . 51, 79 Rittal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Renu Electronics . . . . . . . . . . . . . . . . . . . . 45 Rockwell Automation . . . . . . . . . . . . . . . 5, 42 Samudra Electronic System . . . . . . . . . . . . . 78 Schunk Intec India . . . Front Inside Cover, 10, 79 SPS Automation . . . . . . . . . . . . . . . . . . . . 72 VEGA India Level and Pressure Measurement ��13 Vipa Automation India ��18

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A&D India | Dec’14-Jan’15

12/17/2014 6:19:40 PM

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.

1.800.377.6329

galil.com

Hummel Back Cover RNI number.pdf

12/16/2014

6:03:22 PM

RNI No.: MAHENG/2010/34602

CMY