VOL 09 | Dec’16-Jan’17 | ` 100 www.industr.com
A U TO M AT I O N & D R I V E S
Automation & Drives
INDUSTRIAL INTERNET OF THINGS
Efficient Manufacturing
A&D - Interview Ashish M Gaikwad Managing Director Honeywell Automation India (p.22)
FOCUS Semiconductors & electronics P. 32 VIEWPOINT Enhancing human ergonomics
with robots
P. 24
In association with Advt
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
Maturity & user perspective in India
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E D I TO R I A L
Announcing www.industr.com Manufacturing businesses all over the world are feeling the effect of disruptive technologies and the power of the digital economy. The digital technologies are bringing major changes in the nature of demand, causing shifts in customer relationships, and affecting the distribution of profits across many value chains. For example, Industry 4.0 (along with Industrial Internet of Things) is offering improved linkages between the digital and physical worlds, which, in turn, is transforming many sectors and causing headaches for many companies with traditional business models. At the same time, new competitors and participants in sector value chains, as well as increasingly influential digital giants such as Google, Amazon and Apple, are disrupting traditional competitive structures. This is presenting manufacturing incumbents with a number of opportunities and challenges, asking for agile strategic responses from them. Those who will embrace the potential of disruptive technologies & strategically respond to make the transformation will be able to enter the next industrial revolution with confidence. At this juncture, we are excited to announce the launch of our brand new website with a fresh look – www.industr.com! Our goal with this new website is to provide our readers a better platform to know about the manufacturing industry, in general and industrial automation, in particular, in a more appropriate way – be it developments in the market or trends in technology or strategies in management. We will be constantly updating our contents with latest market news, interesting articles, thought-provoking interviews, new product & technology updates, and a lot more. We hope you will find the new website fresh, modern & user-friendly. Please do visit and write to us with your feedback!
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EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari President Honeywell India
Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India
Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant
Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants
Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A&D India | Dec’16-Jan’17
Phone +91 20 267 410 09 5 www.micro-epsilon.in/capa
CONTENTS
Market
08
NEWS
12
“SENSOR TECHNOLOGY JOINS IoT”
Management
22
Focus
“IIoT CAN BE A KEY ENABLER FOR THE 32
‘MAKE IN INDIA’ MISSION”
Interview with Ashish M Gaikwad, Managing Director, Honeywell Automation India
Interview with Deepak Aran, Country Manager, Contrinex Automation
Event Report 56
Viewpoint 24
ENHANCING HUMAN ERGONOMICS WITH
ADDRESSING FACETS OF A CONNECTED
ROBOTS
WORLD
The viewpoint section analyses ideas from industry leaders to hit the point of dilemma of the ever-increasing sides of humans with machines
A post-event report on the NI Days 2016, held at Bengaluru
Semiconductors & Electronics MINIATURISING IoT DESIGNS
The article highlights the challenges that come with designing connected devices into increasingly smaller products, specifically antenna integration and how systems-in-package modules can help
Cover Story 14
INDUSTRIAL INTERNET OF THINGS
IIoT has begun transforming the industrial sector, and technology users can dramatically improve both asset performance and operating performance with IIoT technologies. But what is the reality on the ground and is the industry exploring this opportunity? The feature suggests recommendations for companies that have not yet started active use of the IIoT, and useful insights for those that have.
One small step for a man -
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CONTENTS
Advt
Technology
Industrial Computers & Peripheries 38
Gears & Motors 50
POSSIBILITIES
The article talks about the many-core industrial server that is able to run the world’s largest automation applications 46
52
THE SWEET SIDE OF SIMULATION
61
Process control in the cloud; Industrial PC; Brake motors; Trio for the Industry 4.0 lifelines;
62
Modular linear axes system; Sensor for adhesive & sealing applications; Diaphragm operated poppet valve-2/2; Waterproof solar cables;
63
Thickness measurement sensor; Visualisation software; Linear modules; Modular power distribution systems
An application story on the usage of the multiphysics simulation that is used to enhance the perfection of the chocolate production
Image Processing & Measuring 42
New Products
Manufacturing IT
OPTIMISING MOTION CONTROL SYSTEM
The feature briefs on the questions to be asked so as to ensure that a new motion control system can continue to evolve along with the application’s changing requirements and continue to provide a run on investment
LASER CUTTING HEAD
The FiberCut laser cutting head by Laser Mechanism cuts metal like butter, accurate and fast. The proper gap between laser head and workpiece is controlled by maxon DC motors and planetary gearheads.
AUTOMATION TECHNOLOGY WITH ENDLESS
Cover image courtesy: Shutterstock
ACCELERATING PRODUCTION OF TURBINE BLADESS
An application story on the usage of laser scanning acquisition system that is used for QA and reverse engineering, which has helped fine forge to increase productivity and accuracy levels
Columns 05 06 64 64
Editorial Contents Highlights-Next issue Company index
Advt
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MARKET | NEWS
Award for plain bearing apps goes into the 8th round A joint initiative of igus, the Institute for Composite Materials, the technology to go new ways.” The application phase for the competition for Industrieanzeiger and the Technical exciting polymer plain bearing University of Cologne, the solutions will be made official at the prestigious manus award will be Motek in Stuttgart. held for the eighth time to show the The opportunity to apply for the tremendous potential of plastic prestigious international manus bearings technology. The award award will now be open for function will honour plastic plain companies and individual developers. bearing applications that are Whether serial applications for the characterised by technical prowess industry or individual parts – anyone and economic efficiency as well as can apply with a polymer plain the creativity of the developer. bearing application. Whether in water, on land or in The winners will be awarded at the air, there is hardly an area or the 2017 Hannover Messe, and the field where the polymer plain prize money is up to 5,000 euros. bearings do not display their Gerhard Baus, the authorised agent for plain bearings, igus, said, "The term The last 2015 manus award had numerous characteristic advantages. 'manus' symbolises the drive in the bearing technology to go new ways” witnessed 467 contestants from 34 They save weight in the solar countries. They showed the whole aircraft, protect against corrosion in the wave power plant, ensure a smooth exciting range of application potentials of plastic plain bearings, from the drive on the road and are more economical and durable when compared to prototype to the serial application. This included a variety ranging from the metallic solutions. spherical bearings in a steeringless bicycle from Italy and linear bearings in a Elaborating further on this, Gerhard Baus, the authorised agent for plain French machine for cake decoration to the plain bearings in an Indian car bearings, igus, said, "The term 'manus' symbolises the drive in the bearing washing machine.
New solutions presented at WindEnergy expo
Emerson launches IIoT solutions in India
B&R made a demonstration recently at the WindEnergy expo in Hamburg. The demonstration showcased how the wind turbine wear can be minimised through optimal yaw control. This is made possible by utilising intelligent control concepts based on the ACOPOS P3 servo drive. The drive is designed to operate flawlessly under harsh offshore conditions, such as continuous 1 g vibrations. Additionally, the coated circuit boards are impervious B&R's new solutions for azimuth control to humid, salty air. Using the minimise wear by optimising the yaw system modular software blocks of mapp technology, wind turbine manufacturers can implement active yaw systems with minimal time and effort. Speaking on this, Peter Kronberger, Global Technology Manager, B&R, said, “Joined by intelligent links, mapp components make software development easier and faster. By placing a wide variety of standard functions at your fingertips with only a few configurations to make, mapp eliminates many potential sources of error.” APROL PDA is an open and scalable system for process data acquisition. All the data generated by a wind turbine is collected seamlessly in a central location.
Emerson recently launched its operational certainty programme in India to help industrial companies achieve top performance in safety, reliability, production and energy management. It is a technology and engineering-based programme designed to help industrial companies achieve top performance and recover over USD 1 trillion in operational losses globally. With this launch, Emerson is also expanding its highly acclaimed Plantweb digital ecosystem, a scalable portfolio of standards-based hardware, software, intelligent devices As per Peter Zornio, Emerson has and services for securely implementing revolutionised the automation the Industrial IoT with measurable landscape with Plantweb business performance improvement. Commenting on this ecosystem, Peter Zornio, Chief Strategic Officer, Emerson Automation Solutions, said, “Emerson has revolutionised the automation landscape with Plantweb, the first fieldbased digital plant architecture.” Elaborating further on this, Amit Paithankar, MD & Vice President, Emerson Automation Solutions – India, said, “The digital transformation is in full swing in India, which makes it the right time for us to be future-ready. Emerson’s operational certainty solution provides a clear roadmap and enables us to help customers deliver measurable results.”
8
A&D India | Dec’16-Jan’17
NEWS | MARKET
New partnership offers robotic warehouse solution
ABB energises transformer at 1.2 million volts
GreyOrange recently entered into an exclusive partnership with Godrej & Boyce. As a part of this collaboration, Godrej Storage Solutions will exclusively market and distribute one of GreyOrange’s proprietary warehouse automation solutions – the Pick-Put-To-Light (PPTL) system in India. With this strategic partnership, GreyOrange aims to tap into the growing demand for entry-level warehouse automation solutions and take its robust systems to more customers in the country. Speaking on this, Yaduvendra Singh, Global Head & Vice President – Sales, Marketing & Solutions Group, GreyOrange, said, “Fueled by the growth in sectors, such as manufacturing, automotive, retail and FMCG in India, the supply chain and logistics industry is expected to see an unprecedented demand for automation. We always look for strategic partnerships to take the best of our advanced technologies to customers across verticals and solve real business problems. Godrej Storage Solutions is the leading player in the warehousing space with vast reach and network, and is an ideal partner to help us expand our customer base in India.”
ABB has recently developed, manufactured and energised a 1,200-kilovolt (kV) ultrahigh voltage power transformer to support India’s plans to build a 1,200 kV transmission system, supplementing the existing 400 kV and 800 kV transmission grid as demand for electricity increases. This 1.2 million volt transformer represents the highest alternating current voltage level in the world and is installed at the national test station at Bina, Madhya Pradesh in Central India, as part of a collaborative initiative by the country’s central transmission utility, Power Grid The transformer is installed at the national Corporation of India Limited test station at Bina, Madhya Pradesh (POWERGRID). The transformer was manufactured and tested at ABB’s facility in Vadodara. According to Pitamber Shivnani, Local Division Manager, ABB Power Grids division India, “The achievement is a testimony to our customer commitment and comes at a time when India has resumed focus on high and ultra-high voltage transmission in line with development of large scale renewable energy projects.” ABB has also developed a 1,200 kV circuit breaker previously commissioned at the test station.
Siemens to acquire Mentor Graphics
Lapp Group buys CEAM and Fender
Siemens and Mentor Graphics recently announced that they have entered into a merger agreement under which Siemens will acquire Mentor for $37.25 per share in cash, which represents an enterprise value of $4.5 billion. This acquisition decisively extends Siemens' leading Digital Enterprise Software portfolio with Mentor’s well established electronics IC and systems design, simulation and manufacturing solutions. Speaking on this, Joe Kaeser, President & CEO, Siemens, said, “Siemens is acquiring Mentor as part of its Vision 2020 concept to be the benchmark for the new industrial age. It is a perfect portfolio fit to further expand our digital leadership and set the pace in the industry.” Elaborating further on the acquisition, Walden C Rhines, Chairman & CEO, Mentor Graphics, said, “Combining Mentor’s technology leadership and deep customer relationships with Siemens’ global scale and resources will enable us to serve the growing needs of our customers and will allow us to accelerate our vision of creating top-to-bottom automated design solutions for electronic systems.”
Lapp Group has recently acquired CEAM CaviSpeciali. The company hires 110 employees in Monselice, Italy, and is one of the leading European manufacturers of data cables for Industrial Ethernet and fieldbus network systems. Lapp has also acquired S C Fender Cables, a company employing 20 members of staff in ClujNapoca, Romania. Elaborating on this, Andreas Lapp, Chairman — Board of Lapp Holding, said, “The acquisition The acquisition of CEAM strengthens of CEAM strengthens Lapp’s Lapp’s leading role in industry-standard leading role in industry- data communication systems standard data communication systems.” Speaking further on this acquisition, Georg Stawowy, CTO, Lapp Holding, said, “The takeover will help Lapp to become the innovation leader in cable-based data communication systems in the field of automation.” Franco Magon, one of CEAM and Fender founders, emphasised that the Lapp Group and CEAM fit together not only in terms of technology, but also in their values, and added, “Ethics, innovation, performance and service - these values have been guidelines for CEAM, and they have brought our small family business together with the global player Lapp.”
A&D India | Dec’16-Jan’17
9
MARKET | NEWS
Automation India Week 2016 held in Mumbai ISA recently organised Automation India Week – 2016, a three-day roadmap and getting started with IIoT. This was followed by a presentation conference and exhibition on the latest developments in automation on the perspective on IIoT, Internet of Things, services and people, and the technology in Mumbai. The purpose of the show was to bring synergy on application of wireless technology in asset condition monitoring. The next automation technology for the varied presentation was on advanced wireless industry segments including power gas detection, which improves safety generation, food, life sciences, oil & gas, through asset integrity assessment and metal, infrastructure, robotics, increased coverage. Subsequently, the automobile and factory as well as session also covered topics, such as process automation domains. new developments in valve actuation, The first day of the conference pervasive sensing for smart plant with started off with the topic, ‘A value centric greener future, RACS optimisation approach to IIoT’. This was followed by technology and green energy. the CEO conclave where prominent CEOs The final day of the conference of the manufacturing sector shared their included a discussion on the human thoughts on ‘Make in India on IIoT’. Then, factor within a successful cyber security the ISA District 14 ISA’s progress and the and cyber security compliance for way forward were discussed. After this, The purpose of the show was to bring synergy on automation industrial systems. This was followed by there were sessions on the industrial technology for the varied industry segments a session on integrated power and internet, which is more than just an IT-OT automation collaborative platform, convergence, smart manufacturing, smart engineering and production. The bonding reality and possibility: IIoT integrated control rooms and trends in first day concluded with a presentation on engineering platform for Industry control room technology. The conference ended with a discussion on regulation 4.0, after which the ISA leaders meeting was held. and innovation in ambient monitoring and emerging opportunities in post COPThe second day of the conference began with a discussion on the 21 energy market.
Conference on smart manufacturing held in Shanghai
New partnership to advance IIoT technology
The eighth NAMUR (International user association of automation technology) conference was recently held in China, where over 160 participants proved of NAMUR’s continuing development in the country. The topic covered in detail at the conference was that of smart manufacturing. In addition to smart manufacturing, which plays a very important role in increasing the efficiency of operations in companies, safety topics, such as functional safety and explosion protection also attracted a lot of attention during the international conference. There were two workshops on smart manufacturing and functional safety, respectively, that were held in parallel to the main sessions. With this new setup, the conference participants had a better chance of exchanging ideas within the small working groups. Krohne, which had already been the sponsor of the NAMUR Annual General Meeting in Germany in 2015, sponsored this event as well. Together with NAMUR, Krohne also presented their expertise in increasing efficiency and functional safety. The next NAMUR China Annual Conference will be held on November 22 and 23, 2017.
NI has recently announced that SparkCognition is partnering with NI and IBM to collaborate on the Condition Monitoring and Predictive Maintenance Testbed. The goal of the collaboration is to deliver an unprecedented level of interoperability among operational technology and informational technology as organisations search for better methods to manage and extend the life of aging assets in heavy machinery, power generation, process manufacturing and a variety of other industrial sectors. Speaking on this partnership, Stuart Gillen, Director – Business Development, SparkCognition, said, “This collaboration between NI and SparkCognition powers the complex and intelligent processing of information to produce valuable insights.” Elaborating further on this, Jamie Smith, Director – Embedded Systems, NI, shared, “We are very excited that our platform can acquire the data and extract the features to drive SparkCognition analytics for IIoT solutions. Combined with the existing technologies in the testbed, the addition of SparkCognition helps present new ways in which we can help automate the process of turning sensor data into business insight.”
10
A&D India | Dec’16-Jan’17
The interface to Industry 4.0
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MARKET | INTERVIEW
“Sensor technology joins IoT” …says Deepak Aran, Country Manager, Contrinex Automation. In an interaction with Suchi Adhikari, he discusses the current trends in sensor technology and points out how the company caters to sensors that are able to withstand harsh outdoor conditions. Excerpts… What are the recent developments in sensor technology? The sensor world is now working on Industry 4.0, which is the technology of the future. Looking into the smart technology for faster monitoring, diagnosis and rectification, it is aimed to move towards the smart world where everything can be at one’s finger tips. The work is already in full swing and it will soon be visible in the automation world. How does your company model to Industry 4.0? What are the products being offered from Contrinex that support customers as they move towards Industry 4.0? Contrinex is a member of the consortium working on Industry 4.0 technologies and its various components and interfaces. We are offering our sensors with ‘IO-Link’ technology, which is an essential part of the Industry 4.0. The IO-Link facilitates communication between the various interfaces of this futuristic technology and makes the sensor intelligent and self-diagnostic. Sensors must be able to withstand harsh outdoor conditions. How does Contrinex cater to this demand? Contrinex provides a range of full Inox sensors with Condet technology, which are suitable for harsh outdoor conditions. The housings of these sensors are made out of a steel rod and are a single piece, including the sensing face. Other normal sensors have plastic face and are, thus, prone to mechanical damage or moisture ingress, etc. Contrinex Full Inox sensors come with a high sensing range when compared to normal sensors in same sizes. We also give sensors in other categories with IP69K protections, which ensure the reliable usage of sensors in harsh outdoor conditions.
12
Offering flexibility and long operating distances is key in sensor technology. What are your company’s offerings that meet these criteria? Contrinex offers various categories of sensors like ‘Classics’, ‘Extra Distance’, and ‘Extreme’, which give wide flexibility in terms of sensing range, sizes, construction and technology. These categories are offered to suit the various applications and requirements so that the proportion of cost and requirement can be maintained. Since functional safety plays an important role, what are the safety components being offered by your company? We offer a complete range of Safety Light Curtains for industrial safety applications where operator/machine safety is required like, presses, robots, etc. Contrinex offers both Type-2 and Type-4 category safety equipment to the industry. These safety light curtains can be used to safeguard the operator from accidents and will stop the machine if anything crosses the curtains. Similarly, these can be used to safeguard an area like robot sheds so that the robot can be stopped immediately if anyone enters the danger zone. Can you brief us on your company’s future plans for the Indian market in the short and long-term? Contrinex is known for its quality, reliability and innovation. This is the reason why we have many sensors, which are produced only by Contrinex. We plan to maintain this USP of providing the Swiss quality to ensure smooth operations at our customer’s end and grow in the Indian market. Also, we are working to educate our customers on Industry 4.0 so that they can understand the benefits of our sensors and prepare themselves for future sensor technologies. ☐
A&D India | Dec’16-Jan’17
Regenerative Converter D1000 3.7 to 560 kW Looking for a fully regenerative and/or clean power solution for your multi-drive or single drive system? Look no further. D1000 is your answer. Unlike passive rectifiers which can only supply power from source to load, the D1000 is capable of delivering power in both directions, and is most beneficial to supply multi-drive or single drive common bus systems that experience significant regeneration. Additionally, the D1000 system includes input harmonic filtering, achieving low distortion levels and improved power factor, which further reduces energy costs and stress on power systems. This clean power solution is achieved without the use of expensive multi-pulse components. Conventional System 18-Pulse Rectifier
Active Rectifier System Brake Transistor Unit DC Supply for Inverter Loads
Harmonic Filter Module
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Highlights • Compatible with all conventional drives having full power access to DC bus • Overload capability of 150% for 30 seconds, 200% for 3 seconds • 0.99 True Power Factor at full load • Ability to compensate for low voltage (boost function) • Overcurrent and Overheat Protection
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Typical Applications • Centrifuges • Paper winders • Film winders • Sawmill systems • Test stands
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C O V E R S TO R Y | T E C H N O L O G Y
INDUSTRIAL INTERNET OF THINGS
Maturity & user perspective in India
The Industrial Internet of Things (IIoT) has begun transforming the industrial sector, and technology users can dramatically improve both asset performance and operating performance with IIoT technologies. But what is the reality on the ground and is the industry exploring this opportunity? The feature suggests recommendations for companies that have not yet started active use of the IIoT, and useful insights for those that have.
14
Amruta Kanagali Analyst ARC Advisory Group India akanagali@arcweb.com
A&D India | Dec’16-Jan’17
T E C H N O L O G Y | C O V E R S TO R Y
IIoT Maturity Model Decision Making
Responsiveness and capabilities for IIoT opportunity
ARC Advisory Group conducted a web-based end user survey during 2016, to uncover the developments and understand trends in IIoT adoption, readiness, applications, and related challenges in India. Majority of the user responses were received from the oil & gas, automotive, chemical & petrochemical, and utilities industries. Others included pulp & paper, machinery manufacturers, food & beverages, and pharmaceuticals.
Why an IIoT maturity model? Organisations have started reinventing their processes, systems, and business models using existing and emerging technologies like the IIoT. With the right organisational culture, companies can leverage IIoT platforms and associated technologies to control costs, enhance efficiency, and improve the overall performance of both the plant and the enterprise. For most companies, the IIoT can be adopted in an incremental manner. To guide such companies, ARC has developed an IIoT maturity model, which helps them to understand where they stand right now, where they would like to get to, and the incremental steps needed to get there. Companies were asked about the maturity of their technical capabilities across the six dimensions, which include both plant level and enterprise wide factors. This model gives good indication of responsiveness of organisations’ processes and the capabilities for capitalising IIoT opportunity. The term IIoT may give a perception of ubiquitous connectivity, but it needs to be kept in mind that equipment intelligence, data infrastructure, analytics, systems and software, and new business models are equally important.
A&D India | Dec’16-Jan’17
Cybersecurity
Digital Information
Systems and Infrastructure
Business Processes Fixed Assets
Management & operational decision-making Decision-making is as much concerned with the organisational culture as with the technologies used. The maturity of decision-making styles can range from decisions based on intuition or workplace politics to far more integrated approaches that utilise data generated by customers or external events. More than 40 per cent of the companies have said that they collect data from various sources – such as internal operations, products, from partners and customers, and they use it rigorously to drive decisions. To maximise gains from IIoT, companies need to have a data infrastructure that can collate information from across the extended enterprise, and make it accessible to everyone in a consistent manner. Equally important is a change in decision-making culture; as timely decisions are needed to take advantage of IIoT generated time-critical data.
Use of digital information IIoT allows organisations to disseminate information more widely and efficiently. In a positive trend observed here, a majority of the companies have moved beyond spreadsheet analysis, and have achieved widespread data sharing and collaboration. By connecting previously stranded data, from smart sensors and industrial assets, with advanced applications and predictive analytics in the Cloud, the IIoT is becoming a strategic enabler to improve manufacturing performance. Moreover, more than one-third of users are taking advantage of Big Data, or at least have strong bidirectional information flow between the plant and the business. It is
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C O V E R S TO R Y | T E C H N O L O G Y
Big Data and predictive analytics widely deployed
6.7%
2-way information flow between plant and business
26.7%
Common data is shared across plants
24.0%
Digital control and time series data, with spreadsheets
28.0%
Little digital data, mostly paper based
14.7% Collection and use of digital information
seen that companies with these capabilities are more abundant in the early IIoT adopter category. Despite initial concerns, many companies now realise that, when properly implemented, internet and wireless technologies can provide appropriate security and availability of services across multiple plants and facilities. While production, asset management, and field service applications represent one of the largest sources of Big Data today, much of this data is unstructured. It must be transformed into meaningful and actionable information before it can be applied to areas like condition monitoring, analytics, or operational intelligence.
companies migrate to a more synchronised approach in response to increasing market demands and pressures.
Fixed assets used for production how intelligent & connected are they?
Through smart sensors embedded in equipment to stream real-time information, the IIoT can facilitate improved performance of large fixed assets by improving their productivity, eliminating unplanned downtime, and cutting maintenance costs. ARC anticipates asset performance and maintenance including remote machine monitoring to be among the early adopters of IIoT technologies. Moreover, as per the survey, close to 40 per Integrated business & production processes cent of the assets are instrumented for control purposes How well and how richly are production operations only, which presents a significant opportunity for upgrades. integrated with business needs and demands? At one ARC has researched asset maintenance and has extreme, processes could be entirely manually driven and, discovered that the traditional preventive maintenance only on the other end, they can be fully synchronised with works well for 18 per cent of assets, and the remaining 82 current business needs. The situation looks encouraging, as per cent of assets fail at random intervals. IIoT can improve a majority of the end users are aware of the need for this scenario by enabling predictive maintenance (PdM) integration between plant and the enterprise. Integrated alerts using data from intelligent assets and feeding it to processes can have a major impact on operating costs and advanced algorithms. More than one-third of respondents profitability by enabling close synchronisation between are already maintaining assets through predictive approach. demand and supply, and further reducing friction, lowering With advanced notice of an upcoming failure, necessary costs, and keeping customers satisfied. repairs can be scheduled, and parts can be replaced before Automated control systems (DCS, PLC etc), enterprise they fail. Besides, the spare parts inventory can be controlled, systems, and asset maintenance management platforms are resulting in huge cost savings. going to be the frontrunners for leveraging data from Connecting an asset to the overall ecosystem can provide connected devices. This will bring more convergence between significant benefits for a wide variety of ecosystem IT-OT layers, and better information sharing between plant participants; both within the plant, across the enterprise, and and enterprise levels. Over time, we are likely to see more even within the technology supplier’s organisation. OEMs
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A&D India | Dec’16-Jan’17
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C O V E R S TO R Y | T E C H N O L O G Y
Production processes are fully synchronized with business needs…
26.9%
Production processes somewhat synchronized
25.6%
Mostly driven by process control and safety system
25.6%
Production processes are visible to business systems and some partners
15.4%
Entirely manual operation
3.6%
Not Sure
2.8% Production processes in the organisation
can use this data to perform remote diagnostics and support. They can also use overall asset performance information to improve the design and manufacturing of the asset.
Systems & infrastructure used in the production organisation A modern, agile infrastructure that uses emerging technologies such as the Cloud, mobility, and advanced device connectivity will propel widespread use of IIoT. Most of the systems and infrastructure for production operations covered here are traditional. Many are not likely to have the flexibility and agility required to easily integrate into largescale IIoT applications. Also, with increasing data flow and connectivity demands, older technologies such as clientserver solutions would struggle to keep up. As per the survey, only 15 per cent of the users have adopted a next-generation IIoT Platform such as Cloud services or advanced device connectivity. In the latter case, users need to ensure that devices are able to link to the Industrial Internet. This requires connectivity that enables communication both from and to the device, and allows feedback from analytics back to the device. Moreover, understanding of operating conditions or market dynamics that drive companies to adopt a particular technology is important. For instance, industries such as oil & gas and power have geographically distributed assets, and are likely to leverage the internet and advanced cloud based applications for remote asset management to reduce maintenance costs. In the case of smart grids / micro grids, we see both industry majors and start-ups in India come up
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with innovative IIoT solutions for remote management and even control. However, industries in which market dynamics favour customised or localised production, such as food & beverages, the need for IIoT-aided agile and flexible manufacturing is higher.
Cyber security approach by organisations Cyber security professionals and business managers need to recognise the impact of technologies like mobility, IoT, and Cloud computing on cyber security strategy; and device new approaches to keep networks safe. Furthermore, taking full advantage of IIoT requires a more open and frictionless information sharing, and this increased connectivity demands a broader and robust approach to data security. A broader scope would include extending the scope of industrial cyber security to all devices within the complete IIoT infrastructure including traditional plants, smart devices, external systems, remote devices, and networks of all types. More emphasis is required on device-centric security and secure-by-design, as IIoT will be applied both within and outside the plants.
Organisations’ viewpoint on the IIoT The need to improve asset management including uptime, productivity, and equipment utilisation, is driving users to leverage IIoT. Users are now correlating these benefits with business metrics such as revenue, cost control, profitability, and risk management.
A&D India | Dec’16-Jan’17
C O V E R S TO R Y | T E C H N O L O G Y
Next-generation platform: cloud, mobile, Big Data, advanced analytics, device connectivity Some applications deployed 'as a service' in the cloud
6.8% 8.2%
Client-server applications, management and operators dashboards and reports
38.4%
Automation systems, historians, APC, HMI, specialty software Basic control systems
35.6% 11.0% Systems and infrastructure used
Capacity additions and expansions in refineries, chemicals, automotive, food & beverages, infrastructure including smart cities, smart grids, and various other process and discrete industries is expected to pick up in medium to long term; this presents immense potential for incorporation of IIoT, especially in Greenfield projects.
Are the capabilities in place to embrace IIoT? According to ARC, early adopters of IIoT applications demonstrate stronger capabilities in all the six areas discussed here. When we compare the three IIoT user segments, their decision-making approach, and to an extent, their production & business processes are well placed. However, companies which are yet to implement IIoT, need to develop capabilities in the areas of digital information flow, asset intelligence, systems and infrastructure, and cybersecurity. Connected systems and devices are in place in many plants, but only in pockets. According to ARC, discrete automation devices including PLCs and drives represent the largest number of potentially connectable devices by far. Apart from connectivity, companies need to develop their IT and OT infrastructure to capture OT data from disparate assets and collate it in a standardised global data model for seamless sharing of information. Moreover, with the use of IIoT network, plant data can be transmitted not only up to the enterprise level but it can also be shared with the extended value chain that includes suppliers, customers, and partners,
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thus enabling new business models and processes.
Top inhibitors of IIoT adoption • Lack of clarity on ROI: Suppliers need to determine and justify ROI to users • Lack of technology standardisation: IIoT solutions that are available have widely differing and competing standards • Security concerns: More supplier involvement is needed in sustaining security of all devices and systems
Key takeaways In conclusion, the following are some of the ways in which IIoT can be leveraged to achieve its maximum potential: • Awareness of the IIoT capabilities is the key to adding value to existing operations • The IIoT should solve business issues, not technological ones • Implementation of IIoT is not just limited to medium and large companies. IIoT projects can be taken up for specific areas of a plant/shop floor/supply chain to derive definite value • There is no single correct IIoT solution. Each company must decide which data is important and/or necessary, and what is the desired outcome. • Suppliers need to work on their pricing strategies, and offer innovative smart products and solutions that can be easily integrated with legacy systems ☐
A&D India | Dec’16-Jan’17
MANAGEMENT | INTERVIEW
“IIoT can be a key enabler for the ‘Make in India’ mission” …says Ashish M Gaikwad, Managing Director, Honeywell Automation India (HAIL), in this interview with Suchi Adhikari. He discusses the need for combining the power of IT with the manufacturing initiatives being taken in India to achieve its potential. Excerpts… What is the current potential of IIoT in India? How do you think the manufacturing ecosystem is supporting the growth of smart factories in India? The potential is large and untapped when it comes to IIoT in India. It will be through building on top of what already exists today in the manufacturing industry and building on new technologies, which will enable us to take advantage of the power of internet. Adoption of these new technologies with existing automation is leading to the development of new solutions, which were not possible before. Huge amounts of data are generated from the daily operation of the manufacturing plants. Using the new technologies, we can now gain better insights that favourably impact safety, security, reliability, efficiency and sustainability. Internet provides the connectivity, collaboration and context. Linking this to the internet has taken in-plant connectivity beyond the precincts of the traditional plant and linking it to the outside world – to multiple locations, and even the entire industrial ecosystem that can collaborate. Quintessentially, this is IIoT. India has an edge over other countries with its younger population being IT-savvy. Combining the power of IT with the initiatives being taken in manufacturing will open up opportunities in the country. The manufacturing
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ecosystem is also being developed and evolved by players in this industry. Companies, governments, universities and colleges, consumers and service providers are part of this ecosystem. Due to raised awareness levels, everybody is working towards similar goals, which will bring the momentum in creating this ecosystem. How do you think IIoT can help the ‘Make in India’ initiative become more successful? The intent behind ‘Make in India’ is to create more jobs – encouraging young people to associate with an organised sector. By using IIoT, people who don’t have access to capital or are located in different regions and not in big cities, can still have access to opportunities. Thus, IIoT can be a key enabler for the ‘Make in India’ mission by bringing people virtually together and by connecting the jobs with people. Can you suggest some measures that are required for increasing the adoption rate of advanced automation technology in the Indian manufacturing sector? Multinational companies help in easily bringing the learnings and new technologies from one part of the world to the other. Often, it so happens that some technologies are not yet fully
A&D India | Dec’16-Jan’17
INTERVIEW | MANAGEMENT
“By using IIoT, people who don’t have access to capital or are located in different regions and not in big cities, can still have access to opportunities” Ashish M Gaikwad
developed or are in their infancy or ideation stage. In such cases, customers become our partners in developing that ideation and creating a product or solution; thus, increasing the adoption rate of advanced technologies in this sector.
engineers leaned heavily on the electronics sector. This gives an idea of how IT has impacted our solutions and offerings.
In recent years, cyber security threat has become a growing concern for the industrial automation sector. What are the How can the potential of IT & software solutions enable latest security measures from Honeywell that help defend the process industries to be more efficient? industrial facilities from cyber attacks in India? Many industries that are not connected with IT are at a bit of With the progress on IIoT, the subject of cyber security has a disadvantage given that today, a lot more software is being become very crucial. At Honeywell, it is simply not an optional used, even by the otherwise traditional industries. There are issue any more. To address cyber security concerns, Honeywell many software tools and aids coming up that are making the has a solutions suite called Industrial Cyber Security Risk processes in most of these industries quite impactful. Thus, Manager. Risk Manager is a software that one can install on if software and IT is used, the company will be far more a server, which is connected to industrial automation. The efficient compared to the players in the same industry, who software is able to continuously monitor incoming threats. are not adopting it as fast. Often, it is physically impossible to monitor threats in a However, simply incorporating IIoT is not going to give manual way. Risk Manager can do this automatically across a the desired results. Companies need to ask how they can use very large network. It is also designed to monitor the industrial the power of internet connectivity beyond the restrictions systems and not just a generic IT system. that existed earlier, and the power of data analytics to gain insights from the experts to solve problems that otherwise How do you make sure that you are prepared with the were near-impossible to address. right technology and strategy to ensure the success of an automation project? What role does IT play in driving significant advances in As an automation service provider, we have the inherent processes, the industrial automation solution? Can you highlight which enable that the delivered solution and technology ensures developments in Honeywell in this area? safety, reliability and integrity of the overall process. Within In terms of advances in industrial automation solutions, no those safety boundaries, we find the optimal way of achieving longer are these industrial solutions of a proprietary nature. efficiency. Cyber security is another aspect, which is given Advanced IIoT systems have made all these solutions open and priority, ensuring that the deliverables of the solutions are safe available, not just globally, but even locally, for others to come and secure. In terms of the right technology, our company takes and service. Therefore, the cost of ownership, maintenance part in seed planting, also known as new products introduction. and running has been brought down significantly. IIoT has It surveys the current and future needs and ensures that the made an impact not only in terms of speeding up operations, technology level is also aligned with the upcoming automation but also in terms of doing things by meeting cost-constraints. projects. By analysing the trends in the right manner, we realised Currently, Honeywell has about 15,000 engineers, out that many industries would shift towards sophistication on IT of which almost half of them are software engineers. This and software. This, therefore, prepared us to serve the industry is in sharp contrast from a decade ago when the majority of with IIoT solutions for today. ☐
A&D India | Dec’16-Jan’17
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VIEWPOINT | MANAGEMENT
Enhancing human ergonomics with robots Currently, Industry 4.0 and IIoT are all set to unleash machine-machine and human-machine collaboration with smart manufacturing practices and intelligent automation systems. Will this lead to decrease of factory employment or will there be any change in the distribution of personnel between various operational/business roles? There are mixed opinions across industry sectors. Some believe that this will lead to machines so intelligent and able to coordinate themselves that they will completely replace human labour. While others are of the opinion that regardless of the complexity of the implemented algorithms, the interpretative skills and the decision-making characteristic of the human brain will always be necessary. The viewpoint section analyses ideas from industry leaders to hit the point of dilemma of the everincreasing sides of humans with machines. A read on… “Focussing on practical aspects in manufacturing”
P V Sivaram, Managing Director, B&R Automation India
What kind of manufacturing transformation do you see on the shopfloor in future, in the age of smart manufacturing and Industry 4.0? The autonomy is increased, firstly, by the degree of automation, and even more so, by machine-to-machine (M2M) communication. Leaving philosophical and psychological speculations aside, we will focus on the practical aspects of manufacturing. The fourth industrial revolution is not only about manufacturing, but also has many other aspects – commercial, marketing, business management, sociological aspects. However, a huge impact will be on manufacturing, which will include not only how a shopfloor is organised and run, but also what will be manufactured, how the decision-making will happen, how contingency and recovery plans will be devised and set into operation. Automation is delivering a two-folded journey. On one side, it automates the entire work process, and on the other, it substantiates humans with thinking machines. What is your take on this? Jobs can be mapped on two dimensions – variety and analysability. More variety states that it is less routine and needs flexible and agile thinking as well as learning on the fly. Low analysability states that it is more difficult to describe the actions needed to produce a result. It is difficult to prescribe a recipe or algorithm for execution. Therefore, it is clear that jobs, which have low variety and high analysability are easy to automate, whereas at the other end are the jobs, which are challenging. Will humans continue to play an integral role in production in the period of the fourth industrial revolution and smart manufacturing? How can workers be empowered to learn new skills to do more with technology? The drivers for Industry 4.0 and for IIoT are not the same. Even if closely related, they are not purely business results. There are compulsions from the political community arising out of globalisation, there are incentives for the scientific community and there are challenges of sustainability, food-safety, energy-efficiency, environment protection, etc. From the consumer community comes the demands for better products, higher customisation and cost-efficiency. Therefore, the business community faces the challenge to stay profitable. So, the march towards technological advancements will continue, and machines will talk to each other in languages and at a speed that humans cannot comprehend. The change in technology will not happen as a quantum leap, it is rather a change in many small steps.
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A&D India | Dec’16-Jan’17
VIEWPOINT | MANAGEMENT
“Automation is an enabler of human-efficiency improvement”
Arunkumar J, Associate Director— Automation & Electronics, Frost & Sullivan
What kind of manufacturing transformation do you see on the shopfloor in future, in the age of smart manufacturing and Industry 4.0? The shopfloor of the future will focus on reducing input for the same output and increasing output for the same input. Seamless interface and interconnectivity between diverse assets will determine transformation of the shopfloor and this is crucial for real-time performance management and customer centricity. The smart factory of the future will enable sustainable management of resources, reduce- time-to-market, ensure collaborative competitiveness and reduce risks. The shopfloor dynamics will also witness changes with the need for employee skills up-gradation to suit the new ecosystem. With an increasingly globalised manufacturing environment, Industry 4.0/Advanced Manufacturing will become a quintessential part of the manufacturing revolution in India. Automation is delivering a two-folded journey. On one side, it automates the entire work process, and on the other, it substantiates humans with thinking machines. What is your take on this? Automation is an enabler of human-efficiency improvement and not a replacement for humans. Challenges related to skilled workforce will drive manufacturers to adopt strategies, such as human-centred design, role-tailored software approaches to aid intelligence and ease the decision-making process. While human intelligence cannot be replaced, the focus will be on manufacturing approaches that allow humans to be more efficient. Artificial intelligence, simulator training and safety robots will find dramatic adoption. There are virtual reality-based training solutions that can facilitate workforce to do more with technology. Will humans continue to play an integral role in production in the period of the fourth industrial revolution and smart manufacturing? How can workers be empowered to learn new skills to do more with technology? Humans will be an integral part of the future of manufacturing. Advanced automation solutions and robotics will only increase the need for higher number of skilled workforce with an ability to manage these systems and ensure customer-centricity of the business. The need for unskilled or semi-skilled workforce may reduce. While the ‘Make in India’ programme targeted on enhancing India’s position as a global manufacturing powerhouse, there is also an important requirement to focus on enhancing the skill sets of the workforce. The empowerment of workforce can happen through a collaborative effort between the government, industry and associated industry bodies.
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A&D India | Dec’16-Jan’17
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VIEWPOINT | MANAGEMENT
“Transforming the manufacturing world”
Rajabahadur V Arcot, Automation Consultant
What kind of manufacturing transformation do you see on the shopfloor in future, in the age of smart manufacturing and Industry 4.0? Developments taking place in IT are all set to transform the manufacturing industry. Taking into account the profound implications of this transformation, the German Government’s Federal Ministry of Education & Research and Federal Ministry of Economics & Technology collaborated and prepared the report, ‘Recommendations for implementing the strategic initiative Industry 4.0’ with a view to get Germany future-ready for the emerging manufacturing era. Industry 4.0 is the symbolic reference to the evolving Fourth Industrial Revolution that will be profoundly influenced by IIoT and Cyber-Physical systems (CPS), data analytics, etc. IIoT / CPS will collect massive amount of data from all activities associated with industry and data analytics will trawl through the data and generate information that can be acted upon to drive decisions. Internet and cloud computing will act as automation platforms with artificial intelligence and robotics playing a greater role. Automation is delivering a two-folded journey. On one side, it automates the entire work process, and on the other, it substantiates humans with thinking machines. What is your take on this? The IIoT architecture to gain industry acceptance requires achieving significant progress in the development of open software and communication standards, which are still at conceptual stages. The German alliance Platform Industry 4.0 is among the many organisations that is taking initiatives on these areas. Platform Industry 4.0 has taken the lead in launching ‘Standardisation Council Industry 4.0’. The aim of this initiative is to initiate standards on digital products and to coordinate these standards at national and international level. While developing the IIoT platform and architecture, there is no need to present unsurmountable technical challenges; the true challenge is in establishing the value proposition for industrial companies that will enable them to justify funding. It is equally necessary to establish that the IIoT architecture, while ensuring modularity, inter-operability, expandability, reusability, portability, adaptability, and scalability, is also intrinsically cyber secure. Until recent times, the overall perception was that automation systems will essentially aid humans to be become more efficient and productive and, because they lack cognitive and perceptive skills, they were not perceived as a challenge to humans. However, these perceptions are rapidly getting challenged. Recent technological advances are making it possible to computerise and automate tasks that were considered as non-routine, only a decade ago. Will humans continue to play an integral role in production in the period of the fourth industrial revolution and smart manufacturing? How can workers be empowered to learn new skills to do more with technology? Some technological developments taking place will not only make many jobs redundant, but also significantly affect the current social norms and economic systems. Are we in a position to remain masters of our own destiny, is the question that arises in our mind.
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A&D India | Dec’16-Jan’17
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VIEWPOINT | MANAGEMENT
“Robotic intervention makes humans more efficient at work”
Yaduvendra Singh, Vice President & Global Head— Sales, Marketing & Solutions Group, GreyOrange
What kind of manufacturing transformation do you see on the shopfloor in future, in the age of smart manufacturing and Industry 4.0? Manufacturing involves a lot of repetitive processes. With industry 4.0, the shopfloor will have the capabilities to rapidly develop product prototypes and make the iterative changes. Prototyping will become viable as all stakeholders involved in the process (suppliers, manufacturers, and other service providers) will be situated in close proximity (manufacturing clusters). This will reduce the overall logistics cost and turnaround time. It also encourages intense collaboration as well as competition between the players. Automation is delivering a two-folded journey. On one side, it automates the entire work process, and on the other, it substantiates humans with thinking machines. What is your take on this? It is easy to automate processes that are mechanical and repetitive in nature, but machines cannot think like people. Robots are a combination of hardware and software that can execute most tasks that are repetitive, predictable, involve high volumes and do not need intellectual ability, interpersonal touch, or are hazardous in nature. Robots can perform these tasks at a much higher speed and accuracy. Therefore, these complement humans at workplace. It allows humans to skill up and take high-value jobs. Will humans continue to play an integral role in production in the period of the fourth industrial revolution and smart manufacturing? How can the workers be empowered to learn new skills to do more with technology? Robotic intervention only makes humans more efficient at work. In the last decade, there have been tremendous advancements in robotics and artificial intelligence technologies. When computers were introduced, globally people thought that they will take away millions of jobs. Instead, computers have only had a positive impact on the work scenario, creating smart jobs for humans and have made humans more efficient. Automation will help automate processes that are high-volume, repetitive, wearisome, and hazardous in nature, in the same time period, allowing a substantial job growth. While automation, there will be a high demand for these who conceptualise, design, program, manufacture, and repair those robots. We will also require skilled technicians to operate or monitor these robotics systems. To be smart and adaptive, robots need to be coached and watched over by humans. This again emphasises the fact that robotics will require highlyskilled programmers, technicians and operators. Compiled by: Megha Roy
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A&D India | Dec’16-Jan’17
S E M I C O N D U C TO R & E L E C T R O N I C S | F O C U S
Miniaturising IoT designs The article highlights the challenges that come with designing connected devices into increasingly smaller products, specifically antenna integration, and how system-inpackage modules can help As we wirelessly connect more and more devices to the internet, electronics engineers face several challenges, including how to package a radio transmitter into their existing device real estate and how to make increasingly smaller devices. They’re also striving to meet consumer demand for Internet of Things (IoT) products that are ergonomically easy to use and un-obtrusive to the environment. Size expectation is one of the most frequently asked questions when considering IoT devices, along with radio performance and price. Ideally, engineers would like to use IoT components that are as small as possible, have great RF performance, and are affordable. These characteristics do not
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typically converge in IoT component offerings, and that presents a challenge for solution providers. Fortunately, the size of a silicon die has been getting smaller and smaller over the years as the industry adopts new silicon manufacturing processes. The industry has been solving the space issue for IoT implementations by combining the MCU and RF front end into system-on-chip (SoC) configurations (i.e. making wireless MCUs available.) However, the trend toward SoCs has not solved the physics of the RF transmitter — the antenna. Antenna design is often left for a customer to sort out, or they may be guided to choose ready-to-use wireless modules with an integrated
A&D India | Dec’16-Jan’17
F O C U S | S E M I C O N D U C TO R & E L E C T R O N I C S
antenna. The space required for an antenna is a challenge that comes with designing small IoT devices. It needs to be efficient, while also enabling reliable wireless connections. For this reason, the following section highlights the specific concerns around antenna integration.
Why a SoC? When the first IoT boom started to blossom during the 2000s, the industry was called machine-to-machine (M2M), and the components offered for IoT connectivity were mainly GPRS modems, Bluetooth® serial cable replacement, or Sub-G proprietary radios. These designs had two main components for connectivity: the MCU and the radio modem. And the required space for basic IoT functionality was typically at its smallest — 50 mm on each dimension — meaning the devices where about the size of a mobile phone. When the silicon industry moved to processes where the required MCU and RF functionality could be packaged into the same die space, new possibilities for developers began to emerge. Now they could implement the functionality of an IoT device in same IC/SoC. The IoT component architectures shifted to wireless MCUs due the obvious benefits— engineers could design IoT devices with a single component and save significant space, but they could also save money because of the lower component costs. When selecting the architecture for modern IoT devices, it’s obvious that the SoC-based systems will lead the way thanks to their size advantage.
What about the antenna? How much space? The new era of highly integrated SoCs leaves developers with some questions: What about the antenna? How much space I should reserve for the antenna? What kind of antenna I should choose, or should I use a module with the antenna already integrated? The antenna question is complex at many levels as we need to consider not only size and efficiency but detuning questions as well, especially across designs that may have different housings but the same antenna architecture. It has been common to use PCB trace antennas, such as inverted-F, for IoT designs due their low bill of material (BoM)
A&D India | Dec’16-Jan’17
costs. But these printed PCB antennas have significant size requirements, normally in the range of 25 mm x 15 mm, ultimately making the resulting IoT devices enormous. These antennas have another downside if used in a module as well: They are sensitive to the detuning caused by the housing materials and require specific consideration in the end product assembly to work optimally. In SoC designs, antenna tuning is part of the normal design flow and requires a certain amount of expertise. In these designs, a printed antenna does not differ from other antenna types. The antenna manufacturers have been offering ‘chip antennas’ for quite some time to simplify design efforts, but there are size benefits as well. These chip antennas are offered mainly in two different forms: • Antennas that are not coupled to the GND plane and will require a relatively large clearance area (or that is free from the ground, traces, and components). Examples of such antennas are monopole and inverted –F type antennas. • Antennas that are coupled to the GND plane and require either a relatively small clearance area beneath the antenna or don’t require clearance area at all. Both of these antenna types have space requirements on clearance area and/or ground plane and PCB size. The required space for the RF part of an IoT design should also include the needed clearance area because no components or traces can be placed here. This means that when designers are doing size estimations for IoT devices, they need to pay attention to the necessary PCB dimensions for the antenna and the needed clearance areas, but they also need separation distances from the antenna with the edge of the housing. When making IoT designs the size of a coin cell battery, there is always a compromise with antenna efficiency. The smaller size we try to achieve, the less efficiency we can have for the RF performance. Devices less than 10 mm on each dimension begin to achieve performance in the 2.4 GHz band, giving users Bluetooth connectivity of approximately 10 metres with a mobile phone, which is acceptable for most personal IoT devices. However, when the dimensions are closer to 20 mm in each direction, the efficiency of RF increases significantly, giving
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S E M I C O N D U C TO R & E L E C T R O N I C S | F O C U S
These printed PCB antennas have significant size requirements, normally in the range of 25mm x 15mm, ultimately making the resulting IoT devices enormous
practical range of 20–40 metres with a mobile phone depending on the conditions. When dimensions reach 40 mm, the optimum efficiency of several antennas that tune with the ground plane size reach maximum performance. This means with the Bluetooth 4.2 protocol, a practical range between two identical devices is around 60–400 metres. When using 15.4 protocols such as ZigBee®, the range can be up to +500 metres in line of sight. So depending on the application and size targets, a designer needs to look at the antenna performance and efficiency in relation to PCB size, as most of the chip antennas use the PCB ground plane as part of the antenna configuration. In addition, the position of the antenna/module in the design is important, and designers need to consider the clearance areas, grounding for the optimum location of the module in the design.
What about the external antenna? According to statistics of Bluegiga modules in the design pipeline, for several different antenna packaging options, nearly 50 per cent of IoT customers evaluate the performance and feasibility of external antenna (antennas integrated into the housing example via U.FL connector). However, approximately only 10 per cent of these evaluated designs deploy the external
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antenna, and 90 per cent of the customers choose modules with a built-in chip antenna. What is the reason behind this? Why would engineers not widely deploy external antennas on their designs? The answer to this question has two main dimensions. Firstly, the mechanics of external antenna at the design is not design friendly; they look ugly and they break easily if the IoT device is dropped. These antennas also significantly increase the BoM and assembly costs. Also, when comparing the efficiency of the well-built RF design with chip antenna vs external antenna usage through a U.FL antenna connector, there is not a benefit to using an external antenna. The benefit of the external antenna is obvious if the housing of the device is metallic, forming a Faraday cage that makes it impossible for the RF signals to penetrate the device. Also, if the absolute best performance is required and assembly costs and mechanical designs allow for the usage of an external antenna.
How packed should the housing be? When engineering the IoT device with an antenna, the mechanics and housing play an important role in avoiding or causing antenna detuning. The RF radiation, when bursting out of the antenna, is impacted by the proximity of the
A&D India | Dec’16-Jan’17
S E M I C O N D U C TO R & E L E C T R O N I C S | F O C U S
Antenna clearance area, ground plane stitching, and position of the BGM121 SiP module from the PCB edges impacts RF Performance
materials. The antenna will detune if it touches the metal or even plastic. For this reason, the antenna needs to be separated from physical contact with housing plastic or metals. There are big differences in the types of antennas and their sensitivity to detuning. Monopole-type antennas are more sensitive than GND coupled antennas. Some of the latest packaging innovations of Silicon Labs’ SiP module solve the detuning issue because the antenna is already within the substrate and detuned to the proximity of the plastic housing. This sets designers free to place the SiP module freely on their designs, reducing the size of the devices significantly.
Possibilities of System in Package (SiP) Silicon Labs has combined its IoT SoC experience with Bluegiga antenna design experience by creating a SiP module that offers the benefits of a SoC module combined with an ultrasmall footprint. The total design footprint size, including the antenna clearance area, is slightly over 50 mm 2. This means that it leaves space for other components in the design, finally making it feasible to design truly compact IoT devices. The BGM12x SiP modules are designed for the smallest
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design footprint for Bluetooth low energy technology. Its 6.5 x 6.5 size offers complete implementation and includes an ARM® Cortex™- M4F core-based MCU, plenty of flash and RAM, an integrated antenna, and an ultra-small clearance area of 5.0 mm x 3.0 mm to enable high-performance applications. The SiP module also integrates all required passive components in practice, leaving the designer free from all RF-related designs worries if layout guidelines are followed. The SiP modules are ideal for wearables and home automation systems, and where the design of end devices needs to be slim and small, such as sports and fitness devices and wearables.
Best practices for size optimisation with SiP 1. Use a SiP based on an SoC with flash-based architecture for protocol updates and maintenance. 2. Use highly integrated and small SiP modules with small PCB clearance areas. 3. Use highly integrated SiP modules with antennas that do not detune in proximity of the housing. 4. Precisely follow given layout guidelines. Pay attention to the precision of clearance area size, SiP module positioning, and distance from PCB edges. ☐ Courtesy: Silicon Labs
A&D India | Dec’16-Jan’17
I MA G E CO URT ES Y: Beckhoff Automation
INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY
Automation technology with endless possibilities Automation technology functions are determined more and more with software. In addition to pure PLC applications, tasks from areas of motion and safety control, robotics and measurement technology are increasingly integrated into the application. More software also requires increased CPU power. The article talks about the many-core industrial server that is able to run the world’s largest automation applications. According to Moore’s Law, CPU performance doubles every two years. This trend will continue to apply in the foreseeable future. Although processor speed will not increase significantly, the number of cores per processor will continue to rise. The next step is the many-core CPU. Many-core industrial servers differ from ‘normal’ Industrial PCs (IPCs) in terms of their architecture. They are equipped with multiple processors,
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Dr Ing Josef Papenfort TwinCAT Product Manager Beckhoff Automation
referred to as “packages”, and each processor has a certain number of cores. Furthermore, many-core industrial servers differ in terms of their memory— the technology referred to as NUMA (Non Unified Memory Architecture) offers a separate individual memory unit for each processor. Currently, Beckhoff offers two Intel® Xeon® processors, each with 6, 12 or even 18 cores, integrated on one motherboard.
A&D India | Dec’16-Jan’17
TECHNOLOGY | INDUSTRIAL COMPUTERS & PERIPHERIES
Machines and production facilities consist of different function modules, which lend themselves to mapping via individual control programs running in parallel, i.e. a many-core architecture
Making full use of TwinCAT 3 performance An ever-increasing degree of automation, with more and more elaborate visualisation, leads to demand for higher computing power. Additional factors are new demands on modern machines, such as machine monitoring via condition monitoring and ever faster and more complex control algorithms to achieve appropriate process quality and, thus, product quality. Naturally, there is a drive to integrate these new requirements into the standard control, which in turn increases the demand for computing power and memory. In order to achieve optimum utilisation of the individual cores, setting and diagnostic functions must be made available that go beyond the allocation of tasks to cores. TwinCAT 3 offers both aspects. In addition, it also offers the possibility to use cores exclusively for the TwinCAT runtime. These so-called ‘isolated cores’ no longer run a Microsoft operating system. In this way, it is easily possible to separate the Windows processes from the real-time processes on a PC.
Possible fields of application for many-core industrial servers Let’s use an example to illustrate how the different cores of a many-core industrial server can be used. The example machine consists of three basic units: a ‘loader’, which loads the parts to be processed into the machine. Various modules
A&D India | Dec’16-Jan’17
(L0, L1 and LR0) are used in the example. The module LR0 is a loading robot. The basic machine for the actual parts processing also consists of different modules (M0 to M7, plus the CNC modules MC0/MC1). The manufactured components are then made available in a transfer unit for further processing. In addition to the T0 and T1 modules, e.g. for controlling of conveyor belts, a robot TR0 is used here. One could distribute everything to many industrial PCs. However, this would result in more communication overhead between the processors. In addition, diagnostics becomes more difficult, because the distributed data would have to be collected first. The software that runs on the different processors has to be managed, and interfaces have to be agreed. A powerful PC can be used to realise centralised control, while still leaving reserves for further expansion. The different modules can be distributed to the individual cores of the many-core CPU, for example. In this way, the modularity is maintained, while the benefits of central controller can also be used. With this control philosophy it is possible – today and in the future – to implement each of the different modular machine parts on a central PC-based controller. Naturally, a high-performance CPU can also handle visualisation. In some cases, it may not be necessary to use intelligent panel PCs, and a passive panel may suffice. This saves money and reduces the component variety. Since manycore CPUs can be equipped with high-performance graphics cards, they can also be used to execute advanced and ergonomic 3D or multi-touch applications with high performance. The easy integration of wearable devices is another advantage.
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INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY
PC-based control technology has always benefited from increasing PC performance, coupled with steadily falling component costs
Functionality increases with computing power Besides the possibility to run one or more PLCs in IEC 61131 with object-oriented extensions, motion control with point-to-point axes (PTP) is also integrated. A CNC or a robot can also be enabled quite easily. The eXtended Transport System (XTS) also benefits from high computing power. With a corresponding number of processor cores, the possibilities are endless. Machine performance improvements can be achieved with eXtreme Fast Control (XFC) technology from Beckhoff. It goes without saying that, in this case, more computing power is required. This is also true for image processing and condition monitoring. Both require a large memory area and a variety of complex algorithms. For the many-core industrial server, this is not a problem. In future, simulations will become much more important in automation engineering. A first step was taken with the integration of MATLAB®/Simulink® into TwinCAT 3.
Based on XFC technology, which consists of a powerful PC (for example, a many-core industrial server such as the C6670), EtherCAT as the fieldbus, TwinCAT as a solution for PLC, motion and scientific automation, and particularly fast I/O modules, it is possible to achieve extremely fast response times of less than 100 μs. XFC enables higher sampling rates for control loops, which usually leads to better control results automatically. In more conventional applications, such as control of a pneumatic cylinder – which occurs dozens of times on machines, faster response times can also enhance the overall machine performance. This comes about with minimum effort: simply reduce the cycle time and use special I/O components.
Summary
PC-based control technology has always benefited from increasing PC performance, coupled with steadily falling component costs. In today’s PCs, the primary way to achieve higher performance is to increase the number of cores. ManyPerformance enhancements core industrial servers, such as the C6670 – feature a higher Thanks to the increasing PC performance and the application number of processors and at the same time more cores on a of more and more processors and cores in many-core industrial board. Currently, configurations with up to 24 cores are servers, it is not only possible to accommodate dramatically available. This is supplemented by a much larger cache and increased functionality on a single central computer, the overall high clock rates. performance also increases continuously. Increasing computing Many-core industrial servers are capable of controlling power also allows task cycle times to be reduced considerably. complex machinery and equipment centrally. The performance Conventional PLCs have cycle times of 5–10 ms, while PC- of these computers is sufficient to run tasks in the fields of based controllers with cycle times of 1 ms or less have already scientific automation and simulation in addition to been available for quite some time. With high-performance conventional control tasks. Measurement technology, many-core computers and TwinCAT 3 software, cycle times are condition monitoring, energy monitoring, and many other expected to fall to a level of 100 μs or less. In addition to suitable functions can be implemented right alongside. Highsoftware to support these short cycle times, a high-performance performance many-core industrial servers can also handle fieldbus is required. EtherCAT is perfectly suited to get data into advanced and ergonomic human-machine interfaces. the central PC deterministically and with exceptionally precise Operating concepts such as wearable devices are integrated timing, even with high clock rates. very easily. ☐
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A&D India | Dec’16-Jan’17
IMAGE PROCESSING & MEASURING | TECHNOLOGY
Accelerating production of turbine blades An application story on the usage of laser scanning acquisition system that is used for QA and reverse engineering, which has helped Fine Forge to increase productivity and accuracy levels. Fine Forge is one of the leading steel die forging companies in India. Operating primarily in the power generation sector, Fine forge, an ISO9001:2000 certified company based in Hyderabad, specialises in the manufacture of turbine blades. Established in 1989, Fine Forge originally aimed to replace the need for imported turbine blades with locally manufactured components. With the Indian authorities pushing for more locally sourced and manufactured components, Fine Forge stepped up. Since becoming an established company in the energy sector, it has diversified, now supplying steel forgings for power, automotive industries and more.
Combining high accuracy and throughput The moving blades and guide blades, which occupy a large percentage of Fine Forge’s production are essential for
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the optimal functioning of steam turbines. The company is responsible for manufacturing up to 95 types of moving blades and 24 types of guide blades, all of which have differing, complex geometry. The company required a system that could make 3D scanning easy for the wide range of varying shapes and sizes. The blades, which are made from X20, X10 & X22 compositions of stainless steel, are developed and supplied to different customers for applications in the power and industrial sectors. Fine Forge previously used manual and destructive measurement methods, which were counter-productive, with data collection methods particularly time-consuming as well as the waste of expensive materials and parts. Fine Forge wanted to replace its manual methods and find a method that could introduce reverse engineering capabilities to help slash CAD design turnaround times. These points were the criteria before consulting an array of
A&D India | Dec’16-Jan’17
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IMAGE PROCESSING & MEASURING | TECHNOLOGY
The CMM operator sets up an inspection of the turbine blade with the LC15Dx laser scanner
CMM suppliers. It was detailed that a fast and accurate multisensor system that could facilitate QA and reverse engineering was required. After consulting other suppliers and searching the market, it was discovered that Nikon Metrology could provide the most full and comprehensive solution.
Increasing precision The multi-sensor ALTERA CMM with CAMIO, combines touch probing, SP25 continuous scanning and laser scanning, providing Fine Forge with a complete inspection toolbox. Regarding accuracy, the Nikon LC15Dx is closing the gap with tactile inspection systems, delivering the most accurate results possible for a laser scanner. Thanks to the optical chain design using a Nikon focusing lens, the scanner is able to obtain a probing error of just 1.9 μm. Not only does the scanner facilitate the measurement of complex shapes, but the LC15Dx does so with speed and precision, giving Fine Forge a formidable tool for all inspection and reverse engineering requirements. The SP25 is the perfect partner for the laser scanning probe. For difficult-to-access elements, such as internal features and diameters or in the case of only a few sections to measure, the tactile SP25 is the perfect solution. In CAMIO, changing the laser scanner and tactile probes is complete with just a few clicks of a mouse. After the installation of the Nikon system, the team at Fine Forge has expressed their satisfaction with the investment and the opportunities introduced. The multi-sensor CMM is equipped to deal with many challenges, helping to reaffirm Fine Forge’s status as a market leader.
Reverse engineering capabilities The productivity increase since the installation has helped
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the team to look for new possibilities and expand into different sectors. Vinod Reddy, Managing Director, Fine Forge, explained that with the installation of the Nikon system, they are now able to explore new possibilities in pipe fittings and heavy truck components. Vinod explains that the Laser Scanner has been a ‘phenomenal advantage’ for Fine Forge, as it has enabled easy migration from the power industry to heavy truck components and pipe fittings. Reddy continued to explain that many of the pipe fitting manufacturers never had the drawings for the parts, but the introduction of the LC15Dx, with its reverse engineering capabilities made exploring this market possible. Shortly after checking the materials and mechanical properties, the build was ready to begin. As the power industry has peaked, Vinod is happy to be able to seamlessly shift from one industry into another industry with their new reverse engineering capabilities. However, turbine blade manufacture does still remain part of the business today. The introduction of the laser scanner now enables the measurement of larger complex sheet metal blades, which wasn’t possible before.
The distinct advantage Previously, inspection of larger blades was dominated by competitors, but Fine Forge has now moved a step ahead. Many other companies in the region are still using probing, but the Nikon Laser Scanner gives Fine Forge the distinct advantage, making easy work of inspection tasks, providing a detailed analysis in the form of instant, easy-to-interpret results. Following the success of the Nikon installation, Fine Forge have been vocal about the improvements they have experienced and have been instrumental in the installation of Nikon systems at other manufacturers within the region. ☐ Courtesy: Nikon
A&D India | Dec’16-Jan’17
INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY
Optimising motion control system In today’s quarterly bottom-linedriven business environment, designers are pushed to design the least expensive solution that will serve the application right now. Asking honest questions and answering them fully is the best way to ensure that a new motion control system can continue to evolve along with the application’s changing requirements and continue to provide a return on investment for many years to come. Marissa Tucker Product Marketing Manager - Controls and HMI Parker Hannifin Mitali.Nair@Parker.com
Jim Wiley Product Manager Parker Hannifin Mitali.Nair@Parker.com
Historically, motion controllers, programmable logic controllers (PLCs), and industrial PCs were separate components in a control system with clearly defined functions. With the rise of programmable automation controllers (PACs), motion controllers are increasingly difficult to distinguish from PLCs. Programmers are building custom applications on PCs to create decentralised control schemes that command a wide array of sub-control devices, including motion controllers, drives, vision systems, etc. The trend of merging traditionally separate control components can add confusion and complexity to the task of designing a new machine or expanding the functionality of an existing one. Luckily, with a bit of knowledge of the different control architectures and knowing the right questions to ask, designers can quickly identify which control scheme will be best for their application. Programmable logic controllers: Essentially, a PLC is a
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ruggedised control device made up of a microprocessor, memory and a variety of peripherals. PLCs typically use IEC 61131-3, an industry standardised set of programming languages, including Ladder Diagram. Ladder logic, a language that reads the same as the electrical diagrams maintenance crews are already familiar with, makes the PLC a popular choice. Traditional PLCs typically rely on peripheral devices, such as smart drives and standalone motion controllers to provide advanced functionality. A potential drawback of this motion control architecture is the need to maintain separate programs for each device. Smart drives and standalone motion controllers often use proprietary languages, canceling out the benefit of using an IEC 61131-3 PLC in the first place. Industrial PCs: Using an industrial PC increases flexibility, giving users the freedom to communicate to any device using either pre-built APIs or by writing their own communication
A&D India | Dec’16-Jan’17
TECHNOLOGY | INDUSTRIAL COMPUTERS & PERIPHERIES
Easy accessible mass storage drives increase serviceability
drivers. This freedom leads to the creation of novel applications using smart subsystems that may not have been intended or initially designed to work together. Standalone motion controllers, in the form of smart drives or multi-axis controllers are examples of smart subsystems. Motion controller manufacturers typically provide an API that allows the developer to send motion commands to the controller— limiting the need to learn a full, separate language. Beyond increased flexibility, these applications have several benefits over traditional PLC systems. The HMI (human machine interface) is built right into the control application itself, reducing the need for additional devices for visualisation. In addition, a single programming language can be used to control all subsystems. This single application can also be a major downfall as the machine ages. Motion controllers: It offers designers highly specialised functionality for controlling and coordinating the movement of motors within a machine. A range of form factors are available as motion control providers have developed solutions based on smart drives, PCI cards, Ethernet and just about every fieldbus ever created. Centralised or distributed solutions offer machine designers nearly endless possibilities for crafting a system that best fits their needs in terms of performance, size and cost. In general, motion controllers rely on a proprietary language that is tailored to fit motion commands. Programmable Automation Controllers: PACs are the merging of PLCs, PCs, and motion controllers into a single device. Rather than requiring a separate standalone motion
A&D India | Dec’16-Jan’17
controller, PACs provide multi-axis motion trajectories over a bus—such as EtherCAT—while drives close the local PID loop around the motor. This architecture not only allows the entire system to be programmed with IEC 61131-3, but also within a singular development environment—reaping all the benefits of standardised programming. Maintenance is significantly reduced as drives can now be queried by the PAC to determine the failure mode. Rather than needing to open up a machine to gain access to data either through manual multimeter readings or direct connection to subdevices, all the information can be accessed by connecting to a single PAC. When choosing a PAC, it is important to select a bus system that will allow flexibility when choosing devices as well as withstand the test of time. For example, the Parker Automation Controller uses EtherCAT as its main fieldbus and also offers support for EtherNet/IP, OPC client/server, Modbus TCP, PROFINET, and PROFIBUS, ensuring longevity and compatibility with the most popular industrial devices now and in the future.
Universal application questions After understanding each system architecture and their pros and cons, it’s critical to weigh a variety of considerations to avoid ending up with a less-than-optimal motion control solution. Armed with the right questions to ask before beginning the specification process, the designer can avoid making the wrong control choice: • How is the application likely to evolve over the next 20–25
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INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY
Direct machine mount industrial PCs with IP65 protection
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years? Consider what new functionality/subsystems are likely • to be required/desired. Take the time to assess whether the solutions you’re considering have the flexibility to allow integrating new devices/subsystems readily. Will the system require centralised, deterministic control scheme? This is common in industrial applications where a single PAC is in control of an entire system. Or does the design require a combination of multiple, decentralised smart devices, such as optical lab instruments, in addition to motion control? What communication protocols offer the greatest flexibility and longevity? There are so many choices. It is important not only to select a bus that works best for your system (for example, EtherCAT is best for high-speed motion control), but also a bus that is proven, widely used, • and growing in installation. How will space constraints dictate system architecture and component choices? Must the system be compact enough to sit on a benchtop or can it span many meters? For instance, Ethernet-based bus systems can transmit data over extended distances, whereas traditional motion controllers are limited by the quality of digital and analog • signals and are limited to smaller ranges. What existing integration and programming resources are available? Many organisations are reluctant to take the time to acquire a new skill set and third-party services may be used in the future to maintain a machine. The choice of programming language is critical in determining how quickly an organization or maintenance crew can diagnose, change, and develop an application.
Common design errors Designers that don’t take the time to determine the best control scheme or choose components too quickly without asking these critical questions have the potential for serious consequences further down the road. It is important to know and avoid these common design mistakes:
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The tail wagging the dog: When a controller is selected first, with insufficient regard for the application, it constrains the designer’s choices, leading to longer and more expensive development cycles. The controller is often selected first when the designer either defaults to a controller he or she is familiar with or “falls in love” with a controller gussied up with all the latest bells and whistles. This forces the designer to use components that may not be ideal for the application but that work with the controller selected. As a result, the designer may need to find workarounds to get a system to operate correctly, increasing development time. Similar problems can arise when a designer doesn’t take the time to understand all that the application entails. No place to grow: When new functionality requirements emerge, the wrong controller can mean great difficulty in expanding or extending the system. Without careful consideration of how a motion control system is likely to evolve over its lifetime, it’s far too easy to select a controller (such as a traditional controller based on I/O) with limited ability to accommodate new devices or functionality. Penny wise, pound foolish: Selecting an inadequate controller for a given application to save a little money now or failing to plan for future necessary expansions of an application all but ensures a less-than-optimal return on investment. Selecting the wrong controller in the early stages of system development will demand additional design time and could force the designer to employ less efficient components to allow the poorly chosen controller to work. As the machine matures and requires maintenance, it may be difficult or impossible to keep it running, especially if the programming language used was proprietary or no longer commonly used, especially if the original designer has moved on to another organization. If expansion is required to add a feature or device to extend the system’s lifespan and usability but the control bus used is no longer available, the system may have to be redesigned from scratch instead, costing significant development time and resources. ☐
A&D India | Dec’16-Jan’17
G E A R S & M OTO R S | T E C H N O L O G Y
Laser cutting head The FiberCut laser cutting head by Laser Mechanism cuts metal like butter, accurate and fast. The proper gap between laser head and workpiece is controlled by maxon DC motors and planetary gearheads. An application story... Advanced laser beam solutions are used in all aspects of industrial automotive applications, including cutting, welding, drilling, scribing, surface treatment, and other processes. In addition, these solutions can be used with every type of laser, such as CO2, Nd:YAG, and fibre lasers. Laser Mechanisms (Novi, Michigan) is a regular innovator in this industry, producing components that enhance performance, increase safety and provide flexible capabilities, while maintaining ease of use, reasonable costs and greater overall effectiveness. One of the company’s recent innovations is the FiberCut™ series of laser cutting heads.
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Providing clean cut The FiberCut laser processing head collimates and focuses a laser beam to provide a clean cut along metal surfaces. This three-dimensional cutter is light weight to minimise the inertia seen by the supporting robotic arm. The FiberCut nozzle also senses the required tip standoff distance from the workpiece (using Laser Mechanisms’ patented sensing technology) and automatically maintains that distance, providing a high accuracy cut as the cutter moves around the 3-dimensional metal part.
A&D India | Dec’16-Jan’17
T E C H N O L O G Y | G E A R S & M OTO R S
Precision at high speeds
Application benefits
There are three FiberCut heads in the series—a straight The speed of the FiberCut head can reach 200 mm per second head, a right angle head and a compact head. All three use a even though the maximum travel of the head—in an up and down maxon RE-max 29 brushed DC-motor to the tip standoff motion—is only 25 mm. How this works is that the lower part of function, and each system also uses a maxon produced GP22 the head moves up and down to maintain a constant standoff (19:1) planetary gearhead. According to Gerry Hermann, distance between the laser and the metal being cut. Springs are Senior Electrical Engineer, Laser Mechanisms, “Speed is the used to push the head out, while the motor is used to pick the most important feature we needed and high speed automation head up. Some additional features of the FiberCut laser cutting forces the need for accuracy at those speeds.” head include an adjustable focus lens for focus-to-tip adjustment The heads attached to most robot arms are used in the and a cam-operated drive system with axial crash protection. The manufacturing lines of the automotive industry. The lasers heads work with all leading fibre-delivered laser systems up to 4 are used to cut out large body panels for cars and trucks, as kW with wavelengths of 1064/1080 nm. All the wiring and assist well as smaller support components, such as undercarriage gas lines are internally plumbed to avoid snags and breaks. mounts and structural components designed for overall Each head in the series includes a sealed beam path and a strength and safety of the final automobile. To keep up with design that is engineered for the factory floor environment production lines, creating such components as undercarriage associated with automotive manufacturing, which is essential mounts needs to be efficient. for the 24/7 operations of the automotive industry. The main Furthermore, accuracy is a key for assembly purposes. The enclosure is purged with a dry air source to keep the inside clean. maxon RE-max 29 brushed motor offers high performance This is important so that debris doesn’t get into the optics or into density for its size, which is the main reason laser mechanisms the motor chamber. Along those lines, the maxon motors used selected them. The additional benefits include durability and in the device does not produce particles that could damage the long life. Due to the company’s ironless core design, which optics or cause a maladjustment to the tip standoff control. results in low electrical erosion between the brushes and Additional motor features include quiet operation. ☐ Courtesy: Maxon Precision Motor India commutation segments, the motor lasts longer. Advt
A&D India | Dec’16-Jan’17
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M A N U FA C T U R I N G I T | A P P L I C AT I O N
The sweet side of simulation At Nestlé, the research, design, and manufacturing that goes into producing one perfect bar of chocolate candy is a mesmerising process, not entirely different from the spectacular world of Willy Wonka’s chocolate factory. A lot of thought and quite a bit of simulation goes into perfecting the process. An application story on Comsol’s multiphysics simulation used by Nestlé that helps perfect the chocolate production. Engineers at Nestlé’s Product Technology Centre in York, UK (PTC York), work, among other things, on the research and development of three different products — a chocolate depositor for making candy bars, a wafer baking plate and an extruder, used to cook and sort cereals at the same time. At PTC York, which is home to the research and development of Nestlé’s confectionery products, engineers rely on multiphysics simulation to optimise and streamline the production process.
Chocolate R&D Candy bars, such as Kit Kat®, Aero®, Crunch, and solid milk chocolate bars are produced using a chocolate depositor that
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fills a mould with molten chocolate. Chocolate enters the depositor via an arm at the top and exits into a mould through each of the nozzle tips. “Ensuring that the amount of chocolate in every bar is consistent means that the flow rate and pressure of the chocolate exiting each nozzle must be the same,” says William Pickles, Process Engineer, Nestlé. “Not only do we need to make sure that each chocolate bar is the same weight for cost effectiveness and standardisation, but we are also committed to guaranteeing that the calorie information on the package is correct as well. This allows us to deliver products with exact nutritional content that fit in with our customers’ balanced diets,” he adds further. In order to achieve this standardisation,
A&D India | Dec’16-Jan’17
M A N U FA C T U R I N G I T | A P P L I C AT I O N
COMSOL Multiphysics® simulation showing the magnitude of chocolate flow in the depositor’s nozzles and flow channels
the uniformity in flow and pressure between each nozzle tip must be precise to within a narrow margin. To achieve this consistency, Nestlé uses a combination of modeling and simulation tools. The chocolate depositor was first designed using SOLIDWORKS® software and the geometry was then imported into the COMSOL Multiphysics® simulation software for analysis. Simulation was used to perform fluid flow optimisation, test mechanical stress, and analyse the thermal properties for a particular geometry. As per Pickles, every chocolate manufacturer has its own special recipe that produces chocolate with unique characteristics. “We were able to fully model the nonNewtonian behaviour of Nestlé’s signature chocolate by setting up a simulation where an experimental curve relating the shear rate to the shear stress of the fluid was imported into the software. This way, we were sure that we were modeling chocolate with the same fluid properties as the real product.” Using simulation, the team identified areas of high and low flow rates and determined the differences in flow between each of the depositor needles. Numerical probes in the flow channels and at the tips of the nozzles were used to analyse conditions at certain locations of the geometry. “By optimising the depositor design, we were able to achieve a flow rate through each of the nozzles that is consistent to within a tenth of a percent of the desired value,” adds Pickles.
Simulation saves crunch What would a Kit Kat® be without the well-known snap of the wafer baked inside? When baking a wafer, uneven heating can cause different moisture concentrations within the wafer, ruining its crunchy texture or even causing it to spontaneously snap. The wafer baking process at Nestlé uses two baking plates that compress the batter between them. During baking, the plates are passed above a series of about 40 flames. “We are using simulation to optimise the baking plate design by looking at the flow of hot air below and around the plates to ensure that we have an even temperature profile across the plates’ surfaces,” describes Pickles. “Our aim for this study is to correct burner power and orientations to give the best wafer, while simultaneously reducing the amount of fuel we use.” The flames underneath the baking plates were
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modeled as jets of hot air, where heating proceeds via convection. “We were able to validate our model against baking plates used in experiments, and we found our simulation results were in very good agreement,” opines Pickles. The results also show how warmer spots occur due to increased heat conduction through the bolts holding the baking plates together. The next step will be to optimise this design to distribute the heat as evenly as possible across the top of the plate and minimise temperature peaks.
Cooking while extruding Cereals such as Cheerios®, Trix®, Nesquik®, and many others are made at Nestlé using an extruder. “The hightemperature extruder used at Nestlé to make certain types of cereals works by forcing dough through a die. The pressure and friction created during this process causes the dough to cook through viscous heating. Extruders are common because they are a compact and cost-effective way of manufacturing products,” avers Pickles. He further adds, “For our design, we needed to make sure that the viscometer housing could withstand the high pressure within the device.” In the original extruder design, the pressure was too high for the viscometer housing to withstand. “We redesigned the housing, which helped to reduce the pressure. We were then able to make sure that the die design didn’t exceed the yield stress so that the viscometer could safely be housed inside it,” he vouches. Additionally, simulation was used to check that the displacement of the extruder was consistent, as varying displacement of the device would cause the cereal being produced to have uneven shapes and sizes.
Towards healthier products At Nestlé, simulation is a big part of the design process, from producing chocolates to wafers to cereals and everything in between. Concludes Pickles, “We are confident in the results obtained from our simulations, and we know that they can be trusted to help us produce the best and safest designs possible. This in turn allows us to consistently deliver tastier and healthier products.” ☐ Courtesy: Comsol
A&D India | Dec’16-Jan’17
EVENT | REPORT
Addressing facets of a Connected World The recently held 13th edition of NIDays conference at Bengaluru addressed the different facets of a ‘Connected World’, while discussing the future of self-driving cars, virtual reality and connected intelligent systems. In addition, the event also witnessed the latest version of LabVIEW. A post event report… National Instruments, the provider of systems that enable engineers and scientists to solve the world’s greatest engineering challenges, recently hosted the 13th edition of NIDays – an annual conference on graphical system design – in Bengaluru. The event was attended by over 500 engineers, scientists, and experts from industry and academia who discussed the trends, opportunities and challenges that lie in the future of connected systems. At the seminar, NI India launched the latest version of its
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Maria Jerin Features Writer maria.jerin@publish-industry.net
flagship product, LabVIEW 2016, with enhancements in acquiring, processing and managing data from remote data acquisition systems. NIDays offered 21 technical sessions and tutorials along with a wide range of products and application demonstrations. Speakers and exhibitors from various industries joined the event. The diverse set of panelists shared their ideas on trends in communication systems, embedded electronics, security and automated test systems that address the challenges and opportunities for the next generation of connected systems.
A&D India | Dec’16-Jan’17
EVENT | REPORT
Event highlights
To accelerate engineering skills development in India, NI also hosted its annual Engineering Impact Awards 2016 aimed at recognising the most innovative projects based on NI software and hardware and NIYANTRA awards 2016 recognising the best graphical system design created by budding engineering students.
Addressing the media at the event, Jayaram Pillai, Managing Director – IndRAA, National Instruments, said, “Over the last 18 years in India, we have built a strong ecosystem of partners, proficient developers and successful customers and this ecosystem has enabled our customers to innovate. It’s inspiring to see the amount of innovation and true technological Engineering Impact Awards advancements at this year’s NIDays. The continuous dedication NI’s annual technical application contest – Engineering and leadership I’ve seen from the engineering community is Impact Awards, enabled NI customers to showcase innovative awe-inspiring and I’m excited for the future of engineering.” Commenting on the success of the event, Ajit Gokhale, projects based on NI software and hardware. The contest this Senior VP—Global Marketing, National Instruments, said, "As year had a total of 40 teams and the winners got a chance to the world becomes more and more connected, the immense participate in the Global Engineering Impact Awards held in amount of data available today provides the engineers and Austin annually during NIWeek. This year, Captronics won in the 'Application of the Year' scientists with a wide variety of insights, but getting the right insight can be a challenge! We continue to help our customers and 'NI Alliance Partner of the year' categories. They developed stay ahead of the curve through our platform-based approach an application to determine the location of a bullet on a target and cutting-edge technology advances in application areas system using NI cRIO. National Aerospace Laboratories won such as the Internet of Things (IoT) or the development of 5G in the 'Systems Category' for their design and development of networks by creating tools that help engineers solve real world structural health monitoring system comprising of SyncVIEW, DiagnoseVIEW, QuickVIEW© for aircraft composite challenges, accurately, efficiently and rapidly.” structures. Jawaharlal Nehru Technological University, Hyderabad won in the 'Academic Category' for developing a Accelerating productivity closed loop control of three phase inverter voltage using NI NI’s tools have proven to be instrumental in the success of LabVIEW FPGA and cRIO. a lot of Indian customers and their applications. This year, NI added various new products to the list of these tools aimed at NIYantra Awards accelerating the productivity of engineers and researchers In order to foster the spirit of innovation in engineering working in the areas of IoT, 5G, industrial automation, etc. Some of these tools enable applications that previously seemed students and expose them to the essence of experiential education through a contest, NI hosted its annual student too ambitious because of their complexities. The new range of products launched at the event includes: design contest NIYantra 2016. This contest, held over a • High-performance PXI instrumentation for processing period of six months, helped the undergraduate engineers design their project ideas and convert them into working and sensing at the edge • MIMO Application Framework, which provides wireless models using NI hardware and software. This year, NIYantra 2016 witnessed submissions from researchers with a fully open reference solution to more than 950+ teams, out of which 18 teams made it to the accelerate 5G prototyping • Early access technology platform for TSN, which delivers finals. The results of the competition were announced at mechanisms to create distributed, synchronised, hard NIDays 2016. Sri Eshwar College of Engineering won the NIYantra 2016 awards for creating an innovative path real-time systems over standard Ethernet • NI Hardware-in-the-Loop (HIL) Simulator, which helps detector designed for visually challenged. Teams from Vivekanand Education Society's Institute of Technology and drive down the cost of test for customers • Software-centric NI PXI Digital Pattern Instrument used by KJ Somaiya College of Engineering were the runners-up. The semiconductor characterisation and production test team from Kumaraguru College of Technology was also recognised for their efforts. ☐ engineers to drive down the cost of their tests
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A&D India | Dec’16-Jan’17
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EVENT | REPORT
“Accelerating development process” …says Jayaram Pillai, Managing Director – IndRAA, National Instruments, in this interaction with A&D India during the recently held NIDays 2016. He discusses NI’s platform in providing solutions to meet real-world engineering challenges by redefining Industrial Internet of Things. Excerpts… NIDays 2016 witnessed the addition of new channel wires to LabVIEW 2016? Can you brief us more on this? Can this be integrated into the older version of LabVIEW software? The channel wire, a new feature in LabVIEW 2016, simplifies the programming involved in data transfer between parallel loops, such as the common producer/consumer pattern. Available on both desktop and real-time versions of LabVIEW, the channel wire method helps improve code readability and reduces development time. Channel wires abstract complex data transfer patterns to help users develop applications that run correctly with fewer mouse clicks and fewer corner cases to debug. Channel wires will be supported in the subsequent releases. However, the users of older versions of LabVIEW would need to resort to conventional methods such as queues and variables to obtain similar functionality. Can you highlight the role of NI in automotive vehicle testing? What are the latest offerings in this domain to accelerate the vehicle development process from concept to production? NI tools are used by various automotive OEMs & suppliers for rapid control prototyping, hardware-in-the loop testing, invehicle test & logging, infotainment test, test cell measurement & control and end-of-line testing. In each of these cases, NI tools accelerate the development process by providing an open & customisable hardware and software platform. At NIWeek this year, we announced turnkey HIL simulators built on an open, modular architecture for automotive and aerospace embedded software testers. These HIL simulators combine real-time operating system and FPGA technology offered onboard the PXI and CompactRIO platforms. With the advent of autonomous vehicles, automotive engineers worldwide are working on mmWave radar technology for implementing Advanced Driver Assistance Systems (ADAS). NI’s new 2nd generation Vector Signal Transceiver (VST) boasts a 1 GHz instantaneous bandwidth, with a programmable FPGA at the back, to help automotive test engineers develop HIL test systems for cutting-edge automotive radar technologies.
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How NI can help the Indian factories by providing a platform for their journey towards Industry 4.0? ‘Smart Factories’ or Industry 4.0 focus on the latest techniques, designs and equipment to make modern manufacturing efficient, organised and structured. NI, along with a vast partner network, collaborates with many industry players to help build connected, intelligent systems that ensure the quality of the product and the information being transferred to significantly accelerate the development process & make the overall process more efficient. Indian customers, too, have access to these NI platforms, which have the capability to acquire, analyse and present Big Analog data, which includes data from light, radio frequency signals, vibrations and temperatures, etc, thereby, enabling a smarter, operator-centric production environment for the futureready factories. At NI India, we continuously strive to make these platforms easily accessible and we also wish to leverage this level of insight and deep knowledge of the technological advances to help Indian customers. Can you brief us on your company’s short-term and longterm plans for the Indian market, especially its role in the industry-institute collaboration? Our company’s long-term plans remain aligned with our company’s mission to provide versatile platforms to scientists and engineers. Our short-term plans aim to align with ‘Make in India’ program through collaborations and partnerships with various industry and institute associations. NI India and IEEE India, recently signed an MoU to collaboratively work on professional skill development programs that address the need for proficient engineers for the evolving Indian high tech industry. NI India also launched the NI India Business Incubator Program to provide increased access to NI technology, technical training and support to the shared local communities like domestic small and medium-sized enterprises (SMEs), academic incubation centres and startups. ☐
A&D India | Dec’16-Jan’17
NEWS | TECHNOLOGY
Process control in the cloud
Industrial PC
B&R offers a cloud-based process control system called APROL that offers maximum flexibility with maximum security. With data and reports generated by the process control system available anywhere in the world, geographically dispersed teams can collaborate with remarkable efficiency. APROL can be installed on virtual machines offered by any well-established cloud hosting company. A local APROL installation performs preprocessing and compression, so that only significant data is transmitted to the cloud Cloud-based APROL solutions database. This approach, which is based on the concepts of fog and edge computing, helps keep data transfer costs to a minimum. APROL supports the MQTT, AMQP and OPC UA protocols. A number of local APROL nodes can send data to the central cloud-based APROL installation. Reports from the business intelligence solutions in local and cloudbased installations can be opened via a REST API. The system architecture with local APROL nodes and one cloud installation ensures plant security making APROL's business intelligence functions available via the cloud.
Beckhoff offers ultra-compact C6015 Industrial PC that is designed for universal use in automation, visualisation and communication tasks, as well as in EtherCAT-based applications. It opens up new application areas for IPC technology, especially those with pronounced cost or space restraints. Fully suited to industrial applications, the multi-core IPC measures just 82 x 82 x 40 mm, demonstrating the extensive scalability of PC-based control technology from Beckhoff. The IPC is only one third the size of The ultra-compact C6015 IPC the C6905, previously the smallest control cabinet IPC in the company’s portfolio. Price savings of approximately 25% also place the device well below the previously least expensive x86 PCs from Beckhoff. With these features, automation, visualisation and system-wide communication in small and mid-size applications can be implemented in a cost-effect manner with minimal footprint. Thus, the compact device opens up areas of use where PC-based control technology has not been used thus far, or where motherboards are commonly integrated as expensive custom solutions.
B&R Industrial Automation | Pune Email: shyam.padwal@br-automation.com | Tel: +91-20-41478999
Beckhoff Automation | Pune Email: info@beckhoff.co.in | Tel: + 91-20-40004800
Brake motors
Trio for the Industry 4.0 lifelines
Emerson Industrial Automation offers a new range of Leroy-Somer FFB brake motors developed around the ‘Flexible concept’. This robust, innovative concept offers an extensive range of options associated with safety and variable speed as standard, thus, making the FFB brake motor ideal for a multitude of applications. With the latest generation IMfinity® induction motor from Emerson, the FFB brake motor is based on a tried and tested design, ensuring it can withstand the most severe stresses Leroy-Somer FFB brake motors encountered in handling applications. Its mechanical and electrical design is based on recognised expertise in industry, civil engineering and lifts, making it highly reliable and extremely robust. The FFB brake motor can be integrated in most fixed or variable speed applications quickly and easily. Its modular encoder adaptation principle makes it a versatile motor, suitable for the simplest to the most demanding variable speed applications. The total control of the noise level, for both pick-up and engagement, make the FFB brake motor one of the best of its generation.
HARTING Technology offers M12 Power, PushPull Signal and preLink® module for the Industry 4.0 lifelines: power, signal and data. This trio operates in accordance with approaches for the industry of tomorrow and the miniaturisation and modularisation trends. With 63 V and 16 A, the M12 Power with L coding offers enough power for energy-hungry applications and it will further allow customers to dispense with 7/8'' solutions in the future as well. The PushPull Signal M12 Power featuring the new 20-pole design takes the same clear step towards miniaturisation. Additionally, it offers twice as many contacts in the same space as previous signal connectors, be connected in the field, while at the same time, field devices have to become more and more compact. The modular preLink® system for Ethernet applications up to 10 Gigabit rounds out the trio. It is the first to separate the previously permanent connection of cable and connector into two modular units comprising a cable and connector that can be recombined any number of times.
Emerson Industrial Automation | Chennai Email: tr.sathishkumar@emerson.com | Tel: +91-44-66918400
A&D India | Dec’16-Jan’17
HARTING India | Chennai Email: balaji.sundaramurthy@HARTING.com | Tel: +91-9600096645
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TECHNOLOGY | NEWS
Modular linear axes system
Sensor for adhesive & sealing applications
igus has developed a construction kit for its drylin ZLW axes, with which the customers can individually assemble their own solutions. In this modular system, width, rail distances and length of the axes can be adapted quickly and easily. Due to the low profile of the toothed belt axes, even small installation spaces are sufficient for this. In drylin ZLW modular system addition, users can order the cross beams, rails and carriages made of aluminium or stainless steel. The latter is of particular interest for applications in the food industry, due to the majority of components being made from stainless steel, this is unique when considering standard 'off-the-shelf' items. A maximum service life is possible in combination with liners made of iglidur E7. The linear guides can be supplied with the igus motor or connected to the customer, which enables a variable motor integration to the right and left of the axis by means of solid and hollow shafts.
ISRA Vision offers new BeadMaster sensor that checks the quality of the adhesive bead even during application. Its high level of precision means that desired tolerances can be adhered to, guaranteeing immaculate, reliable adhesion of car bodies and other unfinished parts. The robot-guided in-process application is perfectly suited to a wide variety of adhesives and surfaces: stationary or mounted on a robot, BeadMaster reliably measures all the important parameters of adhesive and sealant layers – even on BeadMaster sensor glossy substrates. It inspects all types of adhesives in any colour and on all substrates with a single sensor version. The 360° inspection field surrounding the application nozzle enables the inspection of even complex components. The results are provided online in the form of live images or as higher-level error statistics. The sensor’s high flexibility is based on its innovative software. Its GigE interface allows image data to be transmitted rapidly, while the multitouch user interface is highly intuitive and convenient to use.
igus (India) | Bengaluru Email: vinayak@igus.in | Tel: +91-9341136381
ISRA Vision India | Mumbai Email: info.india@isravision.com | Tel: +91-20-2674-1000
Diaphragm operated poppet valve - 2/2
Waterproof solar cables
Janatics India has launched brass body valve diaphragm operated design for high flow applications. The recommended medium is air. If the medium is water, the purity level is to be considered. The diaphragm operated poppet valve - 2/2 is available in the range of sizes: 1/4, 3/8, 1/2, 3/4 & 1 inch. The maximum operating pressure is 10 bar. The diaphragm design results in high flow up to 11800 lpm, which can be suitable for Diaphragm operated poppet valve - 2/2 many applications, such as process industries, food & packaging industries, machine tools and SPMs, etc. The valve is 2/2 way design with high flow characteristics. The valve can be used for continuous duty cycle. The valve is available with wide range of coil voltage with IP65 protection. The company is a leading manufacturer of wide range of pneumatic products like air cylinders, directional control valves, airline valves, air preparation units and accessories. It has been consistently focusing on development of new products and has more than 17000 models in its range.
Lapp India has introduced its first permanently waterproof solar cable under the ÖLFLEX® SOLAR series. OLFLEX® SOLAR waterproof series is an electron beam cross-linked solar cable, which is durable and weatherresistant for use in photovoltaic systems. Its optimised cable design and the constantly high insulation resistance ensure that it will still function reliably even after being in water for long time. The cable is now also available with relevant TUV and ÖLFLEX® SOLAR series the latest EN certification. When photovoltaic cables are exposed to dampness over a long period of time, it can lead to decreased performance and insulation resistance. The ÖLFLEX® SOLAR waterproof series is a safe alternative – particularly in areas which are prone to flooding, or where cables are installed underground in protective conduits where water, heat and moisture can accumulate. Its feature include weather/UV-resistant acc. to HD 605/A1, Ozone-resistant according to EN 50396, halogen-free and flame-retardant, good notch and abrasion resistance and proven electron beam cross-linked quality.
Janatics India Pvt Ltd | Coimbatore Email: janatics@md2.vsnl.net.in | Tel: +91-422-2672800
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Lapp India | Bengaluru Email: info@lappindia.com | Tel: +91-80-47405222
A&D India | Dec’16-Jan’17
NEWS | TECHNOLOGY
Thickness measurement sensor
Visualisation software
Micro-Epsilon has developed new thicknessSENSOR that opens up diverse application possibilities in terms of non-contact thickness measurement. The sensor works extremely precisely combined with ease of use and a compact design, measuring without contact and, therefore, wear-free. The fully assembled system enables easy integration without requiring any complex sensor alignment. Due to its compact design, the system can also be easily thicknessSENSOR implemented in a confined installation space. This new entry-level sensor class enables high precision thickness measurements accompanied by an unmatched price/performance ratio. The thicknessSENSOR is used for thickness measurement of strip and plate material such as metals and films. The material thickness is detected according to the difference principle. Two laser triangulation sensors are fixed opposite to each other on a stable frame and measure against the material surface without making contact. The evaluation unit integrated into the frame calculates the thickness values and outputs these via different interfaces. The intuitive web interface provides the new thicknessSENSOR with unique ease of use.
Phoenix Contact has new Visu+ Express software that provides an easy introduction to the visualisation of typical operating and monitoring tasks. The visualisation software is available free of charge and is particularly suitable for HMI applications. The adapted and simplified user interface provides users with an easy introduction to the engineering. With such a small learning curve, beginners achieve quick results. This saves both time and money. The software covers all the functions typically required in HMI applications. Visu+ Express software These include comprehensive graphics options, integrated event and alarm management, data logging, trend display, and even recipe management. Thanks to the OPC Classic interface and numerous direct drivers, the visualisation software can be linked to controllers from Phoenix Contact and other leading controller manufacturers. Visu+ Express is scalable and fully upward compatible with Visu+ software. The familiar user interface and transfer of projects mean that users can easily switch to the standard software. Compared to the Express software, Visu+ provides a much wider range of functions.
Micro-Epsilon | Pune Email: pragnesh.mori@micro-epsilon.de | Tel: +91-20-2674-1009
Phoenix Contact India | New Delhi E-mail: works@phoenixcontact.co.in | Tel: +91-11-3026-2700
Linear modules
Modular power distribution systems
SCHUNK has developed ELP linear modules with a low-maintenance 24 V linear motor drive where commissioning it is very easy. Within SCHUNK's mechatronic modular system, the series top off the segment of easy-to-use mechatronic alternatives. Entire pick & place and feeding tasks can now be solved just as easily electrically as it has been with pneumatic modules. The drive, controller, and unique autoteach technology are ELP linear modules completely integrated into the compact module. To commission it, one has to connect the axis using standard plugs (M8/M12), and set the end position mechanically using an Allen key. The speed of retraction and extension can be regulated according to the add-on weight by means of two rotating switches. Therefore, it is not necessary to possess mechatronic know-how or space in your control cabinet to use the linear module. An integrated LED display in the axis indicates the status of the teaching process. Between two and five strokes are normally all it takes before automatic programming is complete.
R STAHL offers hazardous area power distribution systems now based on modular design. Lighting and power distribution solutions, trace heating and socket distribution boards can now be precisely configured, requested and offered more easily and much more quickly. In many cases, customers will benefit from faster deliveries as a result of time saved in the planning and engineering stage. All performance characteristics and certifications of the modules are precisely documented. The customers will find they can dispense with one engineering phase altogether: based on the specified purpose, ambient conditions, loads, wiring parameters and fuse on the supply line, Power distribution systems R STAHL is able to supply ready-to-use power based on modular design distribution boards that comply with EN/IEC 61439. Like all R STAHL products, the new modular solutions feature a lowmaintenance design and good usability. They are available with a wide variety of breakers. Suited for all climates, GRP or stainless steel R STAHL distribution cabinets withstand extreme conditions in an exceptionally broad temperature range from -60 °C to +135 °C.
SCHUNK Intec India | Bangalore Email: info@in.schunk.com | Tel: +91-80-4053-8999
A&D India | Dec’16-Jan’17
R STAHL (P) LTD | Kancheepuram Email: sales@rstahl.net | Tel: +91-44-30-600-600
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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 2017 IMPRINT
Automation & Drives
Publisher / Chief Editor ShekharManufacturing Jitkar Efficient
shekhar.jitkar@publish-industry.net Senior Features Writer Megha Roy megha.roy@publish-industry.net Features Writer Maria Jerin maria.jerin@publish-industry.net Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net
» Pharma & Packaging The Indian pharmaceutical market has already crossed the 100,000 crore mark. With this in the background, the next edition will feature the latest automation case studies catering to the emerging requirements of this industry. It will also focus on the latest technologies in packaging automation and the latest innovations in this domain.
» Drives & Components Today’s drives offer a broad range of control modes, features, options, and packaging, as well as global voltages and many power ratings. The upcoming issue will feature the 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.
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HANNOVER MESSE 2017 Hannover Messe 2017, the world’s leading show for industrial technology will take place on April 24-28, 2017. With the theme ‘Integrated industry – creating value’, this five-day exhibition will highlight the benefits of Industry 4.0. There will be 7 concurrent events - Industrial Automation, MDA (Motion, Drive & Automation), Digital Factory, Energy, ComVac, Industrial Supply, and Research & Technology. The next issue will present the highlights of the event.
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Apex Dynamics . . . . . . . . . . . . . . . . . . . . . 57 ARC Advisory Group India . . . . . . . . . . . . . . 14 B&R Industrial Automation . . .Cover,6,7,8,24,61 Beckhoff Automation . . . . . . . . . . . . . . . 38, 61 Comsol . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Contrinex Automation . . . . . . . . . . . . . . .27,12 Delta India Electronics . . . . . . . . . . . . . . . . . 3 Emerson . . . . . . . . . . . . . . . . . . . . . . . .8,61 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 26 GreyOrange . . . . . . . . . . . . . . . . . . . . . . .9,30 Harting Technology . . . . . . . . . . . . . . . . . . 61 HMS Industrial Networks . . . . . . . . . . . . . . . 43 Honeywell . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hummel Connector Systems . . . . . . Back Cover ICP Das Co . . . . . . . . . . . . . . . . . . . . . . . . 45
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Ifm electronic India . . . . . . . . . . . . . . . . . . . 11 Igus (India) . . . . . . . . . . . . . . . . . . . . . 2, 8, 62 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 InnoVista Sensors . . . . . . . . . . . . . . . . . . . . 19 Intelligent Motion Technology . . . . . . . . . . . . 31 Inteltek JV . . . . . . . . . . . . . . . . . . . . . . . .4,49 ISA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ISRA Vision . . . . . . . . . . . . . . . . . . . . . . . . 62 Janatics . . . . . . . . . . . . . . . . . . . . . . . .21,62 Kuebler Automation . . . . . . . . . . . . . . . . . . 41 Lapp India . . . . . . . . . . .Back Inside Cover,9,62 Maxon Precision Motor India . . . . . . . . . .25,50 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . .5,63 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 51 Moxa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Murrelektronik India . . . . . . . . . . . . . . . . . . . 55
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page NAMUR . . . . . . . . . . . . . . . . . . . . . . . . . . 10 NI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 56 Nikon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Novus Produtos Electronicos . . . . . . . . . . . . . 1 Parker Hannifin . . . . . . . . . . . . . . . . . . . . . 46 Phoenix Contact . . . . . . . . . . . . . . . . . . . . . 63 Pilz India . . . . . . . . . . . . . . . . . . . . . . . . . . 29 R Stahl . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Renu Electronics . . . . . . . . . . . . . . . . . . . . . 37 SCHUNK Intec India . . . . . Front Inside Cover,63 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . 59 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Silicon Labs . . . . . . . . . . . . . . . . . . . . . . . . 32 Weidmuller Electronics India . . . . . . . . . . . . . 35 Yaskawa India . . . . . . . . . . . . . . . . . . . . . . 13
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A&D India | Dec’16-Jan’17