VOL 06 | OCT-NOV 2013 | ` 100 www.AandD24.in
A U T O M AT I O N & D R I V E S
MEGATRENDS IN AUTOMATION
Capturing the winds of change
FOCUS Automotive industry P. 36, 40 Machine tools P. 44 ROUND-TABLE Sensors for the future
Dr James Truchard
President, CEO & Co-founder, National Instruments
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E D I TO R I A L
Driving automation Automation has the potential to be more objective, more repeatable, more accurate and quicker to respond. But even then, the most obvious driver fuelling automation remains the cost and availability of labour, especially in countries like India. If we consider a pure cost analysis, any manufacturing plant needs to weigh the cost to acquire, train and retain labour against the cost of purchasing and maintaining automation systems. In industrialised nations where labour is scarce and expensive, this analysis is increasingly favouring automation as the preferred solution, but in case of developing countries such as India it may not. With increasing globalisation activities, India too is feeling the need to have global competitiveness, which is making Indian industry look for alternatives to alleviate their reliance on operators while maintaining high product quality and production line efficiencies. But to uphold a balanced proposition between the labour cost and the automation cost, the automation technology is used in Indian industry mostly in batches and not in a complete package. With the speed and efficiency of communications today, the value of maintaining high product quality has increased. At the same time the value of automation is rising, but the cost of automation is falling. Thus, the equation is rapidly shifting in favour of automation. So, manufacturers are developing new technologies, starting with those that offer the greatest value and the fastest payback for their customers. A&D India has been reporting on not just the developments in the automation and robotics sector, but also on new technologies and innovative solutions for varied application needs of the industry. This issue comes again packed with the contents that will help you get your wheels whe running.
DRAW WIRE SENSORS Measuring ranges from 50mm to 50m Customer specific OEM‘s Very compact sensor design Output: encoder, potentiometer, current, voltage Simple to install and easy-to-use
INDUCTIVE SENSORS Wear-free and maintenance-free More than 250 different models Measuring ranges from 1 to 630mm Compact sensor design Environmentally stable (dirt / moisture)
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 Managing Director Honeywell Automation India
A&D India | Oct-Nov 2013
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 Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants
Proven technologies Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
www.micro-epsilon.in MICRO-EPSILON | 94496 Ortenburg / Germany Phone +49 85 42/168-0 | info@micro-epsilon.com Representative for India: IPS Integrated Process Systems | 600 004 Chennai 3 Phone +91 44 24981786 | www.ipsindia.in
CONTENTS
Market
Management
10
28
NEWS “INNOVATION COMES FROM TARGETED
Interview with Somshubhro Pal Chowdhury, MD, Analog Devices India
20
36
Interview with Dr James Truchard, President, CEO & Cofounder, National Instruments
APPLICATIONS”
18
Automotive industry
EMERGING MARKETS REMAIN THE KEY INVESTMENT AREA
16
Focus
“DEVICE MANUFACTURERS NEED
AUTOMOTIVE CARRIAGES ON THE MOVE
An article on a major automotive manufacturer which used wireless I/O and advanced control for its EMS conveyor 40
SHAPING THE FUTURE OF AUTOMOTIVE
MULTI-CONNECTIVITY”
MANUFACTURING
Interview with Umesh Sakle, CEO & Country Manager, Hilscher India
A read into the various benefits of using intelligent networked automation for increased profitability
“CONSISTENT AND STRUCTURED APPROACH TO DESIGN”
Interview with Mayur Agarwal, Business Development Consultant, Honeywell Process Solutions
Machine tools 44
Market Trends 22
THE FUTURE OF INDUSTRIAL AUTOMATION
An article discussing the roadmap of the automation industry in the future
Round-Table 32
SENSORS FOR THE FUTURE
Industry experts in discussion on the technology developments and trends in the sensor market
ROBOTICS & HANDLING 48
Moving towards a potential win A brief insight into the market forecast for industrial robotics
70
Showcasing new age technologies Event report on 11th annual NIDays 2013 held in Bengaluru
MACHINE TOOL AUTOMATION
The article highlights machine tools that have reached a very high standard in terms of machining power, accuracy, speed, robustness and cost efficiency
CONTENTS
Advt
Technology
Cover Story 26
CAPTURING THE WINDS OF CHANGE
66
EDUCATION & TRAINING
Getting your humanware ready
The article analyses and suggests measures to make the most of the current trends in automation for a sustainable and profitable future
The article stresses the need to build human competency for future automation & instrumentation industry requirements
ROBOTICS & HANDLING 52
56
Taming the robot A development story on how B&R boosted robot safety to a level that allows humans and robots to work hand-in-hand
72
Innovative milling robot
73
TECH TALK
New Products
Cabling solutions for automotive applications
76
An insight into cabling solutions for crane and drag chain applications
A case study on the development of a milling robot as a special purpose machine
Protection from arc flash
77
The article deals with arc resistant equipment that can help protect employees working on or near energised equipment
78
MANUFACTURING IT 60
3D modelling A look into the use of Siemen’s 3D modelling software by Vishwakarma Engineering Works
62
74
SENSORS & ENCODERS
Redefining the future
Spring loaded terminal blocks; Output circuit protection relay; Precision regulators; Power supply units Standardisation & automation software; CAN repeaters; Brushless motor; Industrial wireless access point Compact AC drives; Pressure transmitters; Online colour measurements; Frequency inverters
A look at the latest innovations introduced in the Indian market by leading sensor manufacturers
Shortening product development time
Columns
A case study on how Tetra Pak CPS uses CD-adapco’s STAR-CCM+ for computer aided engineering
07 Editorial 08 Contents 80 Highlights - Next issue 80 Company index
Advt
MARKET | NEWS
Carnival of innovation GE Technology recently hosted Tech Mela 2013, a two-day technology wind regime, end-to-end solutions for extraction, transportation and use extravaganza showcasing innovations, in Bangalore, from 5 to 6 October of oil & natural gas, to various offerings in breaker solutions for the 2013. With an attendance of over electrification industry. The GE 4,500 employees and family members appliances stall boasted a 3D printer from the R&D centre it showcased in action and GE Global Research products and technologies from highlighted futuristic technologies various GE businesses located at the like contactless power transfer, John F Welch Technology Centre. It battery integrated and wind turbines. varied from a ‘Tunnel of Innovation’ GE ITC also took the opportunity to where GE Healthcare took the audience showcase some of the great through the different stages of life and initiatives at the centre, including the healthcare needs associated with community service projects that are each, the magnificent CF6 engine that engaged in, wellness initiatives rolled took pride at the GE Aviation stall, to out by GE’s corporate wellness the demonstration of GE program Health Ahead and GE Transportation’s railway signaling Tech Mela 2013 showcased products and technologies from various GE Women’s Network for advancing the businesses located at the John F Welch Technology Centre solutions on a model track. careers of diverse employees. The Energy businesses GE Power & Water, centre’s cultural club, DRC also Oil & Gas and Energy Management showcased their technologies in the entertained the audience with a flash mob and a concert by the in-house sectors that varied – from wind offerings customised for the Indian low rock band. > MORE@CLICK ADI03305 | www.AandD24.in
Tech Talk on Field Device Integration (FDI)
B&R & Alstom present POWERLINK
ISA Bangalore hosted a Tech Talk on 31 August, 2013, by Prasanjeet Padhy, Senior Engineer, R&D, ABB. The five major automation foundations, including the FDT Group, Fieldbus Foundation, HART Communication Foundation, PROFIBUS & PROFINET International and OPC Foundation have developed a single common solution for Field Device Integration (FDI). Implementation of the extended scope was supported by seven major supplier companies — ABB, Emerson Process Management, Endress+Hauser, Honeywell, Invensys, Siemens and Yokogawa. FDI technology is expected to provide a common solution for managing information of intelligent field devices for the various tasks associated with all phases of its lifecycle, configuration, commissioning, diagnostics and calibration. This makes different solutions for different devices obsolete. FDI is a truly unified solution that addresses end user requirements across the spectrum. It is focused on device integration for process automation. The goal of FDI is to provide a common solution based on device integration technologies EDDL (Electronic Device Description Language) and an FDT based DTM (Device Type Manager).
The Eleventh India Forum, hosted by the ARC advisory group in Hyderabad, attracted over 230 delegates, including thought leaders and decision makers from key industrial segments, end users and technology solution providers. As a technological leader in the automation industry, B&R and its customer Alstom were invited to present on the topic of real-time deterministic, redundant networking for power plants using POWERLINK. Alstom uses B&R technology and the Rajeev Sharma, VP & MD, Alstom open Ethernet POWERLINK protocol Power Automation & Controls as a communication backbone to addresses at the Eleventh India optimise plant efficiency. Over the Forum years, the use of Ethernet in power plants has evolved from shared, bridged and switched networks to deterministic real-time Ethernet one thousand times faster than traditional fieldbus technology. “As an open communication protocol based on standard Ethernet, POWERLINK is wellprepared for future evolutions,” said Rajeev Sharma, VP & MD, Alstom Power Automation & Controls.
> MORE@CLICK ADI03306 | www.AandD24.in
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> MORE@CLICK ADI03307 | www.AandD24.in
A&D India | Oct-Nov 2013
MARKET | NEWS
Control Techniques celebrates 40th anniversary Control Techniques recently celebrated its 40th anniversary. The company, which is headquartered in the UK, was originally founded as KTK on 4 October 1973. “I am proud to be leading this fantastic company. I would like to thank all employees, past and present, for the hard work that they have put in over the past 40 years to make Control Techniques the global success story. Last year, Control Techniques had launched Unidrive M, the first Control Techniques has manufactured, family of drives that is dedicated engineered and designed centres in specifically to the manufacturing the UK, the US, France, China and automation market. I believe that India, as well as sales operations in our ongoing commitment to over 100 countries technical innovation will ensure Control Techniques’ continued success,” said Enrique Miñarro Viseras, President, Control Techniques. Control Techniques has manufactured, engineered and designed centres in the UK, the US, France, China and India, as well as sales operations in over 100 countries. Currently, the company employs about 1,971 people. > MORE@CLICK ADI03308 | www.AandD24.in
Alstom inaugurates its competence centre Alstom has recently inaugurated the digital substation automation competence centre in Pallavaram, Chennai. The competence centre is a cornerstone of Alstom’s commitment to the development of the Smart Grid in India and will showcase its leading smart grid technologies. It is expected to strengthen Alstom’s know- The competence centre is a will showcase its leading smart grid technologies how in digital substation automation technology and support its strategy to develop the substations of the future.“Energy utilities worldwide are experimenting with new smart grid systems, adding a new layer of digital equipment into their existing infrastructures to interconnect all assets. “The inauguration of the digital substation automation competence centre is a milestone for Alstom from a global perspective, and represents our commitment to pursue R&D and deployment of smart grid technologies in India,” said Patrick Plas, Senior VP — Power Electronics & Automation, Alstom Grid. The development of a fully digital substation is vital to the transition from conventional electrical grids to smart grids. > MORE@CLICK ADI03309 | www.AandD24.in
Merging plans Fieldbus Foundation and HART Communication Foundation has announced in member services and support.” The Fieldbus Foundation and HART their willingness to merge the two organisations into a single industry Communication Foundation have worked extensively together in the past foundation dedicated to the needs of and have a long history of cooperation. For intelligent device communications in the example, the two organisations have worked world of process automation. The Chairmen together on the development of common of these two organisations—Dr Gunther international standards such as Electronic Kegel, Fieldbus Foundation and Mark Device Description Language (EDDL) and Schumacher, HART Communication recently, the development of the Field Device Foundation—issued the following statement Integration (FDI) specification. The merger on behalf of their boards of directors. “We offers significant potential to harmonise believe combining the resources and many aspects of the two protocols, making it capabilities of each foundation into a single easier for end users and suppliers to organisation that will provide significant implement the technology and obtain the full Dr Gunther Kegel, Chairman & Board of Director; Larry benefits of each technology in plant benefits to both end users and suppliers. For Obrien, Global Marketing Manager & Rich Timoney, operations and maintenance. In preliminary end users, a single organisation that President & CEO, Fieldbus Foundation in FF Technology discussions, Richard J Timoney, Fieldbus combines the power of both Fieldbus Conference at Automation 2013 Foundation and Ted Masters, HART Foundation and HART Communication Foundation would provide a full solution that Communication Foundation, added that many addresses every conceivable aspect of field communications and intelligent synergies already exist and the decision will provide momentum for a device management for the process industries. For suppliers, a single major step forward in the evolution of intelligent devices and the world of organisation would create efficiencies in resource utilisation, consistency industrial communications. > MORE@CLICK ADI03310 | www.AandD24.in of processes and procedures, and would deliver significant improvements
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A&D India | Oct-Nov 2013
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MARKET | NEWS
VDMA engineering summit The 2nd VDMA Engineering Summit was held on 30th September, 2013, at and Germany and the increased bilateral trade between the 2 countries Taj Vivanta, Bengaluru. Around 110 members attended this prestigious that crossed 17 billion euros in 2012. This was followed by the address event. After a successful debut in of M Maheshwar Rao, Commissioner, Pune last year, the summit was Industrial Development & Director, held in Bangalore offering a Industries and Commerce, who platform for exchange in elaborated on the skilled labour engineering sector and expand the problem that India has been facing network within VDMA members. and the measures that has been The summit started off with a taken by the Karnataka government welcome message from Rajesh to counteract these problems. Nath, MD, VDMA India. Nath Ulrich Ackermann, Managing mentioned that the exports of Director — Foreign Trade Division, German machinery to India VDMA Frankfurt, elaborated on the touched 3.2 billion euros in 2012. growth of Indo-German relationship The 2nd VDMA Engineering Summit was held on 30th September, 2013, at over the years. He stated that India With this the exports of German Taj Vivanta, Bengaluru was Germany’s 20th largest trade machinery to India have increased partner in 2011 (Statistisches by 7 times in the last 12 years. The exports of machinery from India to Germany attained a figure of around Bundesamt, 2012), the previous year witnessed India climbing up the 500 million euros indicating an increase of 5 times in the last 12 years. ladder finishing as 10th largest partner in the mechanical engineering The Chief Guest, Joern Rohde, Consul General, Federal Republic of sector. > MORE@CLICK ADI03311 | www.AandD24.in Germany, Bengaluru, reiterated the strengthening bonds between India
SPS confirms 2014 edition with 75% of booth space
Red Lion panel meters win control design
SPS – Industrial Automation Fair Guangzhou has officially confirmed its Red Lion Controls, the global experts in communication, monitoring and 2014 edition. The fair will be hosted at the China Import and Export Fair control for industrial automation and networking, was recently recognised Complex in Guangzhou from 3 to 5 for its industry-leading panel meters by Control Design Readers‘ Choice March, 2014, where leading Awards 2013. This is the 13th domestic and overseas suppliers consecutive year that the readers will showcase the latest of Control Design have selected SPS – Industrial Automation Fair advancements in automation Red Lion as the top provider of Guangzhou will be hosted at the China technology. At the 2013 edition, 448 panel meters in the industry. Import and Export Fair Complex in exhibitors from 15 countries and “Being recognised by our customers Guangzhou from 3 to 5 March, 2014 regions had participated. With the for the 13th time in a row in the face increasing demand for automation of fierce market competition reaffirms our determination to continually technology, especially in China’s manufacturing sector, the 2014 fair is develop the best industrial automation solutions in the industry,” said Jesse Benefiel, VP - Product Management, Red Lion Controls. To expected to achieve an even higher figure in exhibitor recruitment. “We had reached some great heights for our niche sector in 2013, and I determine this year’s winners, Control Design had sent questionnaires to believe we will continue this momentum into 2014. For the next edition, approximately 15,000 magazine subscribers who work directly with we expect to attract over 500 exhibitors from around the world, and industrial automation and control products. The questionnaire included utilise 35,000 sqm of exhibition space,” said Louis Leung, Deputy an unaided ballot in which participants were asked to identify the General Manager, Messe Frankfurt. Approximately 75% of booth space vendors that came to mind in response to the questions. Respondents has already been reserved by top firms such as Autonics, Beckhoff, had to pull Red Lion’s name from memory or experience, further validating the company’s products and services. Contrinex, Higen Motor, Kacon, Mecano, Sanyo Denki and Ushio. > MORE@CLICK ADI03312 | www.AandD24.in
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> MORE@CLICK ADI03313 | www.AandD24.in
A&D India | Oct-Nov 2013
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MARKET | INTERVIEW
‘Innovation comes from targeted applications’ Somshubhro Pal Choudhury, Managing Director, Analog Devices India, shares his insights on the recent technologies emerging in the industrial automation and control industry, and the challenges in automation & instrumentation, during an interview with Srimoyee Lahiri What is the size & potential of the industrial automation and control market in India? In the process control and industrial automation space, the hardware equipment market in India is approximately $1.5 billion. It does not include electricity generation automation equipment, which is captured under the energy domain. The overall market includes turnkey projects. Presently, the software market is larger than the equipment sales. Opportunity for the process control and industrial automation sector is huge, as India has barely scratched the surface. The market is likely to grow at 10-12% CAGR for the next few years, almost double the rate of GDP. Which are the emerging market trends shaping up in industrial automation and control segment? Innovation in this industry typically comes from targeted applications and less from application of latest technologies. Wide ranging sensors for measuring various ranging parameters in the field and touch screen interfaces are growing. Another unique characteristic of such automation is decades of reliability and shelf life of the equipment. From a communication perspective, industrial Ethernet is getting much more prominence compared to RS-485 that have been used for generations. Wireless MBus, SubGHz Zigbee, 6LowPan and are other wireless sensor protocols are emerging. With myriad of communication protocols in use, conversion of one protocol to another is a major requirement to make the system more flexible and evolve to work with newer and more standardised protocols. Another area where activity has been witnessed is the machine vision technology in the shop floor to look and flag for defects in production. Mounted digital cameras on the assembly line can check a high resolution image of the unfinished or finished product and compare against a known good image to highlight and provide alert on defects during the production.
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This can also be used as a screening tool. Improving energy efficiency at the factory level, with accurate measurement of energy in real time, power factor measurement and ways to improve it, time of use metering, effective temperature control, energy management systems and energy efficient machinery are some of the latest trends in the industry. Which challenges lie in the Indian manufacturing sector in terms of automation and instrumentation? Cost of automation is one big reason why small to medium size Indian manufacturers have slowed down to take up automation and justify their ROI. The good news is that Indian manufacturers, who are adopting automation now, do not have legacy systems in place like their counterparts in more developed manufacturing intensive economies. Therefore, Indian manufacturers need to go for the latest standard based technologies. What is your agenda for 2013-3014? To help Indian manufacturers and designers go to market faster, we are working on more ready solutions in the form of reference designs and ‘circuits from the labs’. We are doing regular and targeted webinars & seminars to educate our customers on the technology and solutions available with us in these domains. We are also doing matchmaking between the customers and Indian design houses if they want to partner for quick technology development to reach market faster. In 2013-2014, our goal is to gain market share. We will add field application engineers and sales staff to augment our coverage with our customers, add system specialists as and when required and leverage the large design team we have in our Analog Devices India product development centre in Bangaluru. ☐ > MORE@CLICK ADI03314 | www.AandD24.in
A&D India | Oct-Nov 2013
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MARKET | INTERVIEW
‘Device manufacturers need multi-connectivity’ Umesh Sakle, CEO & Country Manager, Hilscher India, briefs on the strategic plans of the company in India, technology trends in industrial communication and how Indian firms are open to experimenting the hi-tech industrial communication technology with more functionality. Excerpts from his interview with Shekhar Jitkar… What are your strategic plans for the company, as you take over as the CEO of the company? Adaptation to the customer needs with swift expert response is very important to succeed in India. My aspiration is to help Indian people use hi-tech industrial communication products. Unfortunately, India being a very cost sensitive market, our strategy for the next few years is not the profit, but penetration of our products in the market so that Indian customers will benefit from our low cost & technologically advanced gateways, embedded modules, PC cards, net analysers & other communication solutions. Industrial communication technology is going beyond the traditional industrial automation solutions from fieldbus systems to technologies based on the Ethernet. What are the trends today? From traditional discreet wired control systems to de-centralised control systems such as fieldbus, industrial communication technology is moving towards distributed intelligence using industrial Ethernet. Fieldbus is still the dominating technology but all network development and news are focused on industrial Ethernet which is replacing common fieldbuses and there are different standards in the world for Ethernet like Profinet, Ethernet/IP, Modbus TCP, etc. Hilscher deals with technologies that cover a very broad range from CANOpen, CC-Link & DeviceNet to Profibus & Profinet. Which are the fast-moving technologies in India? As far as Hilscher is concerned, apart from the sales of our standard protocol solutions, we also provide customised solutions as per the customers’ requirements. With this, we offer R&D, programming & customisation support as we want to simplify technological maze for our clients to help them in attaining results in a faster and smarter manner. The market for industrial communication is very fragmented and there will be
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no single standard protocol neither today nor in future. Training is an important element in such hi-tech industrial communication field. How does Hilscher take care of the training for its customers, in India and globally? Products, technologies and service at the leading edge of industrial communication technology is our requirement. We want to be measured by the success of our customers with their competitive products. Being a world leader in hitech industrial communication our staff of R&D engineers, sales & application engineers must have wide and deep product knowledge. They always must be prepared to support customers. For that, we invest a lot in training and education of our engineers. Together with our customers we have to develop hi-tech industrial communication solutions. Therefore, a close partnership with our customers is very important globally as well as locally. We train engineers & sales team from India at our headquarters in Germany for technical support and innovative use of our products. After this traineeship they return to India and impart the same training to our distributors & customers in India. Do you find Indian firms open to experimenting hi-tech industrial communication technology with more functionality? How is your experience so far? In India, device manufacturers need multi-connectivity to serve a wide range of automation applications and vertical market segments in order to grow business. Multi-network connectivity being an entry ticket into the global automation, Indian firms are quiet open to experiment our hi-tech industrial communication solutions and this trend is increasing day-by-day. ☐ > MORE@CLICK ADI03315 | www.AandD24.in
A&D India | Oct-Nov 2013
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MARKET | INTERVIEW
‘Consistent and structured approach to design’ Mayur Agrawal, Business Development Consultant, Honeywell Process Solutions, discusses the various benefits of design solutions for the process industry, during an interaction with Sumedha Mahorey
Please elaborate on the benefits of design solutions for the process industry. Today, every process industry needs to optimise their process designs to achieve more reliable and stable operations. Such companies should quickly identify optimum designs with minimum risk of rework to remain competitive and maximise business performance. At times, process engineers are challenged with making timely decisions to meet the business objectives of designing and operating efficient, safe and profitable plants. Additionally, the industry also faces challenges with regards to project cost savings, risk management, engineering time saving, reducing reengineering, etc. Design solutions can help mitigate these challenges. With process design solutions, users can reduce engineering costs as it provides a common environment to manage consistent use of data and models. It also helps mitigate risks associated with project execution and reduce feedstock waste (or rework), resulting in millions of dollars in savings. The design solution saves 95% of an engineer’s time with easy-to-maintain optimisation solutions as well. Which are the latest technology trends shaping up in this domain? Lifecycle modeling solution is a powerful methodology that demonstrates how an investment in simulation software that can provide comprehensive coverage throughout the entire lifecycle of a plant, from Front End Engineering Design (FEED), to operator training, to operation optimisation can be utilised for maximising the returns. A key enabler for sharing process modeling information across disciplines is a set of well integrated tools which allow users to seamlessly expand models at each stage of the plant lifecycle to meet their specific needs. The selection of compression system configuration is
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also one of the key decisions made during the concept design stage of new processing facilities. The compression system configuration not only impacts initial project capital expenditure but significantly influences the overall system performance, availability, operating costs and flexibility throughout the life of the facility. Which demand trends are emerging in the design solutions market for process industries? Some demand trends identified through Honeywell Voice of Customer program include the customers’ need to be able to select optimum process and control design through use of steady state and dynamic simulation; customers’ need of selection of unit operations that enable them to efficiently construct models of the required fidelity for the processes under consideration; customers’ need to design flare system facilities based on industry and company standard protocols. Please highlight the challenges and opportunities for implementation of design solutions in India. Market opportunities by implementing design solutions can be summarised by certain challenges that the process industries face. These are project cost savings and risk mitigation – assessing the effect of the different process alternatives early in the project lifecycle will have significant impact in the project economics. Also, allowing engineers to quickly and easily determine the cost implications of their process design choices will reduce the number of hours spent on evaluating expensive process configurations and validating data to support decision trade-offs. ☐ > MORE@CLICK ADI03316 | www.AandD24.in
A&D India | Oct-Nov 2013
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Image courtesy - Siemens
MARKET | TRENDS
The future of industrial automation Since the turn of the century, the global recession has affected most businesses, including industrial automation. Here are the author’s views on the directions in which the automation industry is moving Because of the relatively small production volumes and huge varieties of applications, industrial automation typically utilises new technologies developed in other markets. Automation companies tend to customise products for specific applications and requirements. So, the innovation comes from targeted applications, rather than any hot, new technology. Over the past few decades, some innovations have indeed given industrial automation new surges of growth. The PLC – developed by Dick Morley and others – was designed to replace relay-logic and generated growth in applications where custom logic was difficult to implement and change. The PLC was a lot more reliable than relay-contacts, and much easier to program and reprogram. Growth was rapid in automobile
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Jim Pinto Technology futurist, international speaker & automation industry commentator jim@jimpinto.com
test-installations, which had to be re-programmed often for new car models. The PLC has had a long and productive life, since last three decades and has now become a commodity. At about the same time, another surge of innovation came through the use of computers for control systems. Minicomputers replaced large central mainframes in central control rooms, and gave rise to DCS, pioneered by Honeywell with its TDC 2000. But, these were not really ‘distributed’ as they were still relatively large clumps of computer hardware and cabinets filled with I/O connections. The arrival of the PC brought low-cost PC-based hardware and software which provided DCS functionality with significantly reduced cost and complexity. There was no
A&D India | Oct-Nov 2013
TRENDS | MARKET
“The promise of remote-controlled automation is finally making headway in manufacturing settings and maintenance applications” Jim Pinto
fundamental technology innovation here rather, these were innovative extensions of technology developed for other mass markets, modified and adapted for industrial automation requirements. On the sensor side were indeed some significant innovations and developments which generated good growth for specific companies. With better specifications and good marketing, Rosemount‘s differential pressure flow-sensor quickly displaced lesser products. And there were a host of other smaller technology developments that caused pockets of growth for some companies. But few grew beyond a few hundred million dollars in annual revenue. Automation software has had its day, and can’t go much further. In the future, software will embed within products and systems, with no major independent innovation on the horizon. The plethora of manufacturing software solutions and services will yield significant results, but all as part of other systems. So, in general, innovation and technology can and will reestablish growth in industrial automation. But, there won‘t be any technology innovations that will generate the next Cisco, Apple or Microsoft. We cannot figure out future trends merely by extending past trends; it’s like trying to drive by looking only at a rear-view mirror. The automation industry does not extrapolate to smaller and cheaper PLCs, DCSs, and supervisory control and data acquisition systems; those functions will simply be embedded in hardware and software. Instead, future growth will come from totally new directions.
New technology directions Industrial automation can generate explosive growth with technology related to new inflection points: nanotechnology and nanoscale assembly systems; MEMS & this includes
A&D India | Oct-Nov 2013
nanotech sensors (tiny, low-power, low-cost sensors) which can measure everything and anything; and the pervasive internet, machine-to-machine (M2M) networking. Real-time systems will give way to complex adaptive systems and multi-processing. The future belongs to nanotech, wireless everything, and complex adaptive systems. Major new software applications will be in wireless sensors and distributed peer-to-peer networks – tiny operating systems in wireless sensor nodes, and the software that allows nodes to communicate with each other as a larger complex adaptive system. That is the wave of the future.
The fully-automated factory Automated factories and processes are too expensive to be rebuilt for every modification and design change – so they have to be highly configurable and flexible. To successfully reconfigure an entire production line or process requires direct access to most of its control elements – switches, valves, motors and drives – down to a fine level of detail. The vision of fully automated factories has already existed for some time now. Customers order online, with electronic transactions that negotiate batch size (in some cases as low as one), price, size and color; intelligent robots and sophisticated machines smoothly and rapidly fabricate a variety of customised products on demand. The promise of remote-controlled automation is finally making headway in manufacturing settings and maintenance applications. The decades-old machine-based vision of automation – powerful super-robots without people to tend them – underestimated the importance of communications. But today, this is purely a matter of networked intelligence which is now well developed and widely available. The large, centralised production plant is a thing of the past. The factory of the future will be small, movable (to where
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MARKET | TRENDS
Real-time systems will give way to complex adaptive systems and multi-processing
the resources are, and where the customers are). For example, there is really no need to transport raw materials long distances to a plant, for processing, and then transport the resulting product long distances to the consumer. Today, those things are available globally.
Hard truths about globalisation The assumption has always been that the US and other industrialised nations will keep leading in knowledge-intensive industries while developing nations focus on lower skills and lower labour costs. That is changed now. The impact of the wholesale entry of 2.5 billion people (China and India) into the global economy will bring big new challenges and amazing opportunities. Beyond just labour, many businesses (including major automation companies) are also outsourcing knowledge work such as design and engineering services. This trend has already become significant, causing joblessness not only for manufacturing labour, but also for traditionally high-paying engineering positions. Innovation is the true source of value, and that is in danger of being dissipated â&#x20AC;&#x201C; sacrificed to a short-term search for profit, the capitalistic quarterly profits syndrome. Countries like Japan and Germany will tend to benefit from their longerterm business perspectives. But, significant competition is coming from many rapidly developing countries with expanding technology prowess. So, marketing speed and business agility will be offsetting advantages.
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The winning differences In a global market, there are three keys that constitute the winning edge: r Proprietary products: developed quickly and inexpensively (and perhaps globally), with a continuous stream of upgrade and adaptation to maintain leadership. r High-value-added products: proprietary products and knowledge offered through effective global service providers, tailored to specific customer needs. r Global yet local services: the special needs and custom requirements of remote customers must be handled locally, giving them the feeling of partnership and proximity. To implementing these directions demands management and leadership abilities that are different from old, financiallydriven models. In the global economy, automation companies have little choice â&#x20AC;&#x201C; they must find more ways and means to expand globally. To do this, they need to minimise domination of central corporate cultures, and maximise responsiveness to local customer needs. Multi-cultural countries, like the US, will have significant advantages in these important business aspects. In the new and different business environment of the 21st century, the companies that can adapt, innovate and utilise global resources will generate significant growth and success. â&#x2DC;? > MORE@CLICK ADI03317 | www.AandD24.in
A&D India | Oct-Nov 2013
FlexiPanels
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C O V E R S TO R Y | T E C H N O L O G Y
CAPTURING THE WINDS OF CHANGE With the megatrends in automation sweeping across the global markets and radically changing the business landscape, companies need to adapt and modify their business processes to reap the benefits and emerge as winners in the future
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G Ganapathiraman Country Manager ARC Advisory Group, India RamanG@ARCweb.com
A&D India | Oct-Nov 2013
T E C H N O L O G Y | C O V E R S TO R Y
Megatrends in automation are altering the way businesses Meanwhile, PLM tools are revolutionising engineering with are conducted globally. The automation landscape is shaped by their holistic approach to products, systems design and ability a convergence of largely internet and IT-based enabling to do simulation testing in a virtual environment. DCS technologies. This convergence is likely to remove many technology has also evolved and emerged as more flexible and existing constraints to help transform the way manufacturers extensible with the merging of IT, increasing use of standards, and other industrial enterprises operate and collaborate, both building the system around Ethernet and more collaboration internally and across their extended value chain. In 2011, between business and production management functions. automation companies globally saw good growth, but the Advanced process control and real-time optimisation are other subsequent eight quarters showed a decline in growth. This is emerging automation trends. The range of APC applications has increased and it has become more practical & adaptive, largely attributed to the global slowdown. Megatrends that are changing the direction of automation and no longer needs an ‘expert’ to keep it tuned. Digital have emerged, Ethernet has become and helping companies to succeed in a competitive market networks include intelligent devices (ID) and the Internet of Things all-pervasive and process Fieldbus standards – Foundation (IoT); predictive analytics for big data; cloud computing and Fieldbus, Profibus-PA and HART have a market stronghold. services-based solutions; virtualisation 3D simulation; The demand for intelligent instruments and software to mobility-enabled applications; and remote operations/asset manage assets (PAM, APM, EAM) is also projected to grow. Today, most major automation suppliers are supporting management. As new technologies and new ways of doing things surface, virtualisation in one form or another, predominantly for PC more companies feel the need to use the solutions and more and/or server virtualisation. Virtualisation also lowers cost of employees throughout the enterprise want more and better ownership, empowers disaster recovery for critical production decision-support tools. From top to bottom, the industrial processes and reduces hardware failures due to its space is becoming much more dynamic. Manufacturers need high-availability architecture. System deployment and disaster to recognise (or even better, anticipate) rapidly changing recovery leverages virtualisation technology to quickly get situations in order to take appropriate measures in time to systems back up and running when computers fail. 3D virtual make a difference. It is evident that in the competitive technology allows plant engineering and operations groups to marketplace, operations management is the battleground and create comprehensive and accurate virtual environments that represent the complete physical plant/facility. These are used the winner is the one who provides better service. to help plan operational procedures, train operators and maintenance technicians and meet health and safety Machine automation trends requirements; all within a computer-simulated 3D environment. Some of the major trends emerging in machine automation Increasingly, planners also take advantage of this advanced include streamlining production processes and improving the technology to improve their scheduling activities. Another visible trend is wireless technology. The prospect bottomline. Hardware is becoming ‘smarter’ and self-configuring, with faster networking capabilities and of adding wireless devices to the process automation built-in diagnostics. This has reduced downtime and increased architecture is a compelling one from the perspective of productivity as well. Mechatronics is another emerging trend tangible business benefits and incremental operational which integrates mechanical hardware, electronics and improvements. Process industry customers are increasingly software, leading to more standardised machine sub-assemblies. aware of the potential inherent in applying wireless to business
A&D India | Oct-Nov 2013
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C O V E R S TO R Y | T E C H N O L O G Y
Hardware is becoming ‘smarter’ and self-configuring, with faster networking
Courtesy: Hannover Messe
capabilities and built-in diagnostics
challenges ranging from improved process performance, reliability, and efficiency to conformance with government mandates.
and novel ways to exploit organisational weaknesses. A broad strategy that anticipates change and includes ongoing vigilance is the only real defence. To prevent cyber-attacks, automation and IT need to be closely coupled.
Cyber security Workforce mobility The fallout of rapid progress in automation is the threat to cyber security. With organisations becoming more dependent on network connectivity through mobile systems and other emerging platforms, security of operations is critical for business continuity and delivery of services. The growing complexity of organisational operations, numerous applications, global architecture, and all-pervasive nature of cyber threats make security more difficult to achieve. The appearance of the Stuxnet malware in 2010 dramatically changed the general attitude toward cyber security for industrial automation systems and equipment. Post-Stuxnet, it has been a demonstrated fact that malware can be deployed by countries as a weapon of war, as well as by hackers, malicious or otherwise. Such weapons may be extremely difficult to develop, but are also very difficult to trace to an individual, group, or country. They may also prove widely effective against ‘soft targets,’ meaning industrial devices and systems that are relatively insecure. Industrial cyber security standards and regulations have generally been developed by vertical industry organisations. A wide variety of systems and equipment are deployed in critical automation and control applications (DCS, safety shutdown systems, PLCs, SCADA systems, drives, intelligent relays, industrial Ethernet switches, etc). Vertical industry experts have the specific domain expertise to comprehend how to prioritise and protect their specific types of assets from cyberattack. Every industrial organisation needs to address the growing challenges of protecting its plants and facilities from cyber intrusions. Implementing a good security technology infrastructure is essential, but not a complete answer. Persistent hackers and cyber criminals will always find new vulnerabilities
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The emergence of people-centric collaboration technologies and social networking is an important trend as business dynamics are changing and the workforce is getting betterconnected. Mobility has also blurred the lines between home and office. The era of connected devices is already upon us. In 2012, there were more than 10 billion Wi-Fi-connected devices, with projections for more than 50 billion devices to be connected by 2020. This will include more than 5 billion smartphone and internet users, most cars, and many home appliances. Free or inexpensive mobile platforms will dominate the market. Intelligent devices and IoT have broad ramifications for industry, particularly for asset management, process management, remote operations management, safety and security, and supply chain applications. This is just one side of the story. With the advancement of technology and workforce mobility, another important angle emerges – the retirement of the ‘Baby Boomers’ (those born between 1946-62) and the entry of the Millennials. According to an ARC report, “The Millennials are a generation of digital natives that adapt quickly to new technology with a penchant for experiential learning over extensive training and manuals.” The retiring generation, the ‘Baby Boomers’, has certain characteristics that will be missed when they leave the workforce – mainly experience and knowhow. Due to this impending loss of experience, companies will need to put a combination of technologies, processes, and training in place to allow the new generation, the ‘Millennials’, to be effective. The middle generation, the ‘Gen Xers’, will also be impacted and, in many organisations, will be expected to fill leadership roles.
A&D India | Oct-Nov 2013
T E C H N O L O G Y | C O V E R S TO R Y
CLOUD DEPLOYMENT MODEL Private cloud
The cloud infrastructure is provisioned for exclusive use by a single organisation comprising multiple consumers (e.g. business units). It may be owned, managed, and operated by the organisation, a third party, or some combination of them, and it may exist on or off premises.
Community cloud
The cloud infrastructure is provisioned for exclusive use by a specific community of consumers from organisations that have shared concerns (e.g. mission, security requirements, policy, and compliance considerations). It may be owned, managed, and operated by one or more of the organisations in the community, a third party, or some combination of them, and it may exist on or off premises.
Public cloud
The cloud infrastructure is provisioned for open use by the general public. It may be owned, managed, and operated by a business, academic, or government organisation, or some combination of them. It exists on the premises of the cloud provider.
Hybrid cloud
The cloud infrastructure is a composition of two or more distinct cloud infrastructures (private, community, or public) that remain unique entities, but are bound together by standardised or proprietary technology that enables data and application portability (e.g. cloud bursting for load balancing between clouds).
SOURCE: NATIONAL INSTITUTE FOR STANDARDS AND TECHNOLOGY â&#x20AC;&#x201C; USA
Information-driven companies are moving to a culture and business model in which all decisions are made based on Cloud computing is a new computing model that features analysis of process and business process data. Throughout the the intensive use of remote computing services (processing, organisation, these companies employ software to collect, storage, networking, and software). Cloud architectures are contextualise, visualise, and analyse data to gain new insights. particularly useful for scaling up computing tasks that can be Armed with new insights, organisations can anticipate changes parallelised. Though relatively new in the commercial/ and drive better business results. The culture of an industrial space, it already has tremendous industry patronage information-driven company is based on real-time analytical-, as it has been developed to support internet applications of data-, and information-based decisions. major software and internet firms such as Google, Amazon, Information-driven companies employ advanced analytics Apple and Microsoft. throughout their value networks, business processes, and Cloud represents a new model for IT, challenging an decision-making to support corporate initiatives such as organisationâ&#x20AC;&#x2122;s established IT practices in every area; new energy management and sustainability programmes; global platforms, new services, new deployment, licensing, and growth initiatives; and innovation in product, process, systems, support models. Cloud forces an IT organisation to examine and business models. They also employ advanced analytics each application within its portfolio and reevaluate the way the throughout the supply chain in design & engineering, application is currently deployed and supported. From a production, and with partners and customers. Interest in business standpoint, the cloud model offers several potential analytics and business intelligence (BI) software has surged advantages over the traditional IT service model, including over the last few years. Leading software providers offer full rapid deployment, elasticity, reduced capital investment, and analytics suites for enterprises to use to monitor, analyse, and increased access and mobility across a global enterprise. manage a wide range of business activities. Manufacturers use The cloud model can form part of the answer to the huge analytics in a number of applications. They benefit by applying explosion of smartphones and tablet devices that now confront analytic techniques to support continuous improvement IT organisations. Since cloud services are by nature external to initiatives, plant performance monitoring, decision support, an enterprise, the gap that develops between internal and predictive maintenance, generating KPIs, process control, and external capabilities becomes less relevant for cloud-based quality control. Analytics can also be used to identify and applications. While there are other solutions for mobility correct production anomalies, improve control, and make problems, cloud-enabled location-independent support for continuous improvements. user mobility is one potential advantage of cloud services. With megatrends in automation sweeping across the global markets, radically changing the business landscape, companies which adapt to these winds of change will reap the benefits and Information-driven companies emerge as winners in the long run. â&#x2DC;? Today, there is a glut of information and companies who > MORE@CLICK ADI03318 | www.AandD24.in can filter, record and easily access this information will succeed.
Cloud computing
A&D India | Oct-Nov 2013
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MANAGEMENT | INTERVIEW
‘Emerging markets remain the key investment area’ Discussing at length, how cyber physical systems have enabled integrated decision-making across the enterprise, Dr James Truchard, President, CEO & Co-founder of National Instruments (NI), in this conversation with Sumedha Mahorey, points out the roadmap & benefits of open systems and NI’s focus on emerging markets As per Industry 4.0, do you see cyber physical system as the Can you elaborate on the evolution of cyber physical system backbone of the next industrial revolution? since the incubation of Industry 4.0 concept? Presently, many technologies have converged. Today, we have One of the key ideas based on the cyber physical system that outstanding information technology infrastructure in terms of has been put forward in Industry 4.0 is that historically certain the cloud, internet, computing power, etc available locally in advanced control algorithms, analysis and measurements the form of servers. We have also added front-end capabilities are accessible, within a small number of companies. Now, for data acquisition, analysis and control. So far, we can scale with open systems, the availability of algorithm, technology, across an enterprise, use big analog data that is required from software, and with a platform-based approach, for almost any the systems to make better decisions, make more efficient technical problem, we can develop algorithms as any specialist use of energy, initiate better components with less failure somewhere in the world can apply his expertise to the platform rate, in other words, make the work processes more efficient, and make the right solution available. adding value throughout the whole chain of manufacturing This can really change the perspective on what’s proprietary till the customers’ end. These new age processes have also technology and what’s open & available across the globe. For enabled the flow of information from the customer in terms example, with this platform-based approach, iOS has enabled of feedback which helps in integrated decision making across 1 million different applications. We see the same trend for the enterprise. cyber physical systems. Engineers will use these platforms to
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A&D India | Oct-Nov 2013
INTERVIEW | MANAGEMENT
“With open systems, any specialist somewhere in the world can apply his expertise to the platform and make the right solution available” Dr James Truchard
create thousands of applications that serve a diverse range of industries. Which is the top trend that has emerged from the cyber physical concept? The top level is currently using information throughout the whole process, from the front line, i.e. acquisition of material to construction of the products throughout the backend service, including bringing in the feedback from the customer with real-time information integrated throughout the whole process.
Basically, at the core we leverage Moore’s law to give us more performance, capability, higher speed, acute measurement and so forth. Our investment is to make technology available to scientists and engineers. To do that we have to stay on the top of the technology curve, stay up with Moore’s law and make software space compatible as we scale it. In our demonstrations during NI days in India, we have showcased how we have moved from one processor to another, one operating system to another in the customer’s application range. This is the philosophy that we have and it takes a great deal of investment to give customers the benefit of ‘convenient use’.
With over 700 attendees, how significant is NI Days for the Any global investment plans in the offing? Indian market? We are constantly looking at what we can do. We have done The most important thing that we do is to educate engineers on quite a bit of expansion over the last couple of years and will the present opportunities that they have in solving problems. continue to be looking at where we need to expand and invest. That is why we work with over 7000 universities around the The emerging markets remain the key investment area as we world and around 600 in India. Education is a very important have seen the fastest growth for our products in these regions. part of our operations, and we want to make that information We will continue to invest in these emerging markets. available, train engineers on how to use these tools, so they can be most productive. NI Days is one of the key initiatives where How is NI aligned to the future roadmap of Industry 4.0? we stress on education, and showcasing new solutions. Our first goal is to make certain that our technology addresses some of the key needs in that space – Wi-Fi technology, ability With new launches and new product portfolios in your to work in the cloud with analysis and complication, the ability domain, which demand trends are you witnessing globally? to aggregate multiple sites, so that one can make decision to We have been quite successful as we have evolved our vision control over distributed networks and also have the algorithm from virtual instrumentation to graphical system design, where available to address advanced complex needs. we are doing some of the most advanced measurements for RF & communication applications as well as general purpose As the leader at NI, what is your agenda till 2015? data acquisition. We are now getting into implementation of In the time frame till 2015, we will be very focused on educating next generation systems using our technologies as the base, for engineers and scientists on our vision for graphical system example, CompactRIO, or BST PXI system for implementing design and cyber physical systems using our technology, and how it can be applied for solving specific problems in R&D, in very complex next generation systems. testing of products, and in newer areas. ☐ With innovation coming in with every product, how has > MORE@CLICK ADI03319 | www.AandD24.in been investment in R&D worked out?
A&D India | Oct-Nov 2013
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MOAUNNADG-ETA M EBNL TE | RMOAUNNADG-ETA R M EBNLTE
Sensors for the future With multiple sensor categories gaining traction amid the current recessionary times, this feature analyses the various new age applications and technologies that are making the rounds in the Indian sensor segment and suggests the themes of future developments in this domain. As per recent reports, the Indian sensor market is growing rapidly with the fastest growing segments being gas sensors, image, accelerometers and position sensors. Continuous technological innovation and increasing application areas for these new age sensors are pushing their demand in the market. With this in the backdrop, the sensors market is expected to grow at the CAGR of 14% till 2018. Analysing the current technology trends that are satisfying the need for innovative products and futuristic technologies in the Indian market are industry experts – Johann Salzberger, Managing Director – Marketing and Sales, Micro-Epsilon; Ravi Agarwal, Director, Pepperl+Fuchs (Factory Automation); Sunil Hasabnis, Managing Director, Baumer India; Bipin Jirge, Managing Director, ifm electronic India Pvt Ltd; Deepak Aran, Country Manager – Sales & Marketing, Contrinex Automation Pvt Ltd; Deenar Patil, Senior Manager – Key Accounts, Schmersal India; and Vikrant Agashe , Sales Manager – Sensors & Components, Gefran India.
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
Technology landscape Globally, the sensor technology has changed from purely electrical transducers to mechatronic-based systems. Commenting on this, Salzberger notes, “This means, today sensors are equipped with more electronics and integrated intelligence, micro-computers and software. In terms of measurement principles, the importance of optical, laser sensor systems and vision technology is constantly increasing.” In today’s scenario, every sensor company is also focusing on smart & miniaturisation technology coupled with designs amenable to modern production techniques that ensure least human error and improve overall product reliability. There is also a growing trend towards developing industry specific sensors. Highlighting this, Hasabnis says, “Advanced sensing technologies are offered for edge, positioning, profile measurement & sensing applications at higher speeds & accuracies which were not possible till date. Some latest design
A&D India | Oct-Nov 2013
M A N A G E M E N T | R O U N D - TA B L E
“The future trend will be towards more integration, miniaturisation and intelligence”
Johann Salzberger, Managing Director – Marketing and Sales, Micro-Epsilon
trends include Internet bus communication; analogue output; modular & flexible designs and IP rating up to IP 69K.” Adding to his thoughts, Agarwal points out, “There seems to be a paradigm shift along two streams. Traditional domain of industrial sensing is seemingly pushing for sensors to be smarter and communicating. Not only are the sensors being expected to measure absolute value of the parameter but also to effectively communicate it into the network. This is also impacting diagnostics, interoperability and machine/process/ network design and management. In the embedded technology, MEMS which relates to motion and orientation sensing is doing wonders.”
Market demand-supply position by 2015 The demand is increasing for automation, safety & control devices as users now demand more safe solutions. Asserting this, Patil avers, “By 2015, the market demand will increase as the machines are getting smarter with minimum wiring between control system and field sensors. Now, control devices for cranes/hydraulics press machines can be controlled remotely, safely and efficiently.” Sharing his views, Hasabnis avers, “Market demand and supply position address and meet the changing customer profile. On one hand, demand for automation & sensing products is increasing even under difficult economic conditions in sheer volume terms. However, other side of the same trend is increasing pressure on price and number of ‘me too’ products offered at ridiculously low prices. On the positive side, there is increasing trend towards global standard suppliers by all the major global OEMs and end users.” Adding further he says, “The trend towards 2015 is definitively that technology gap among different manufacturers will narrow and great companies will get more distinguished by value addition they offer rather than just the product & price.” Adding to this, Salzberger says, “The future market will need more sensors in general and more sophisticated sensor solutions in particular. In the field of displacement measurement different sensor technologies will be required, because there is no universal measuring principle which can solve the whole variety of measuring tasks. There will be a trend to more integration, more miniaturisation and more intelligence.”
Factors influencing technology developments New age industrial and consumer products consistently
A&D India | Oct-Nov 2013
“Speed, reliability and consistent performance in an application are the governing factors for proven solutions” Ravi Agarwal, Director, Pepperl+Fuchs (Factory Automation)
“The future of wireless technology will much depend on the reliability they can offer in the field” Sunil Hasabnis, Managing Director, Baumer India
“By 2015, the market demand will increase as the machines are getting smarter with minimum wiring between control system and field sensors” Deenar Patil, Senior Manager – Key Accounts, Schmersal India
throw challenges for manufacturing and automation. Elaborating on the market factors that are influencing sensor technology developments, Agarwal explains, “Speed, reliability and consistent performance in an application are the governing factors for proven solutions. The cutting edge designs are pushing for detection and measurement.” On similar lines, Aran says, “Major influencing factors are the latest communication protocols of automation, environmental conditions of sensing applications and the economy. Technocrats want sensors which are compatible with latest communication protocols, sensors with high accuracy, able to work in high temperatures, pressures and all sorts of environment like underwater, space, etc and at competitive prices.” As per Agashe, the influencing market factors include competitive differentiation. He notes, “Over the past few years, a number of developments in the industrial sector have facilitated low-cost sensor solutions. Reduced operating costs, enhanced performance and a high return on investment all drive technology development.” Summarising the factors for new product development, Hasabnis says, “Product versatility
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R O U N D - TA B L E | M A N A G E M E N T
“The technology trend being adopted by the sensor industry is towards smaller, faster, and cheaper solutions” Vikrant Agashe, Sales Manager – Sensors & Components, Gefran India
for different applications; compact size; low-cost manufacturing cost; reliability & one box design; exactly engineered products; better cost to performance ratio; shift towards robust technologies such as magnetic; wireless technologies; and user-friendly internet connectively for monitoring control and configuration of the sensor, are the major factors influencing the sensor technology developments.” Thus, as per Jirge, with the Indian market accepting appropriate automation levels in many industries, as the market develops further, the demand or the acceptance for higher technology sensors will only increase. This will lead to development of complex sensors at more affordable price points with the growing market.
Sensors gaining market traction
“Sensors are becoming more intelligent & capable of taking decisions locally ” Bipin Jirge, Managing Director, ifm electronic India
“2015 will see more requirement of special sensors, though standard sensors will continue to enjoy the current status as automation basics will remain the same”
Deepak Aran, Country Manager – Sales & Marketing, Contrinex Automation
So, with multiple reasons for new technology development, which type of sensors will be gaining traction in the current market scenario? Answering this, Aran points out that apart distant but are already a future in the making.” Aran notes, from higher expectations from inductive and photoelectric “There is limited response to smart sensors due to various sensors, a lot of interest and thrust is seen on RFID Identification reasons like adaptation to existing system, environmental sensors. Elaborating in brief on the topic, Agashe asserts, “The interference, etc. But the future of these sensors is definitely future of sensors is highly dependent on sensor technologies bright. These sensors will eliminate many problems related to such as microelectromechanical system sensors, wireless hard wired connectivity when the technology is improved and sensor, radar and many more. Hasabnis adds, “Inductive proven further.” On the other hand, Agashe believes, “Highsensors with extended sensing distance; smart vision sensors capacity wireless sensor networking is still an emerging with integrated programming and software; smart diffused technology. The existing systems need enhancements in terms with background suppression photo electric sensors; advanced of real-time performance. As the technology is new, the cost is measurement sensors; linear & inclination sensors used for too expensive to adapt.” Making his point, Hasabnis suggests, position sensing; position & speed sensing in one unit; and “The future of wireless technology will much depend on the programmable sensors in field of colour mark are some of the reliability they can offer in the field. Smart technologies such sensors which are gaining traction in the current market as sensors without reflectors, tape encoders which offer easy scenario.” Also, as per Jirge, position and fluid parameter retrofitting and much accurate feedback are much in demand. sensors are gaining more acceptance, while for Agarwal, photo In other words, market prefers technologies that are advancing sensor and ultrasonic technologies are turning out to be more in linear continuity over the past product line.” Adding his coveted solutions in the current market scenario. thoughts, Jirge says, “As on today, we have not seen large scale use of wireless sensors, but as the battery technology improves, we will certainly see more and more sensors going wireless.” Future roadmap of smart technologies With the sensor market rampantly scaling up on the With many companies introducing the ‘smart’ factor into technology & innovation front, and the demand for various sensors and wireless sensor networks, how does the future categories of sensors going up amid sluggish growth in the roadmap for these new age sensors look like? Answering this, manufacturing sector, the growing momentum of the Indian Agarwal suggests, “Although the adoption has been slow due to sensor market is likely to continue during the inherent needs of such platforms, they are here to stay. Sensors 2015-16 period. ☐ necessarily would need to and are already becoming smart. > MORE@CLICK ADI03320 | www.AandD24.in Industry 4.0 and cyber physical systems are no more very
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A&D India | Oct-Nov 2013
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PCB relays Industrial relays Relay interface modules Sockets and accessories
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AUTOMOTIVE CARRIAGES ON THE MOVE An article on a major automotive manufacturer that boosted uptime and reliability using wireless I/O and advanced control to ensure safe and productive operation of its Electrified Monorail System (EMS) conveyor 36
A&D India | Oct-Nov 2013
AUTOMOTIVE | FOCUS
In the education capital of India, Pune, a market leading optimise reliability and uptime of the EMS conveyor system manufacturer of utility vehicles built a modern Greenfield and deliver real-time communication with Programmable facility from the ground up with state-of-the-art equipment. Automation Controllers (PACs) and Inputs/Output (I/O) At the heart of the plant is the Electrified Monorail System modules for enhanced conveyor control. (EMS) conveyor, designed to deliver reliable, safe, quiet and Yantra Automation began the challenge of designing a efficient transportation of the vehicles from one work station complex wireless communication system for the assembly to another along the assembly line. The EMS runs throughout manufacturing line; an ambitious goal in a large-scale project the entire length of the Trim, Chassis and Final assembly involving multiple carriers in continuous motion along the (TCF) line of the vehicle in the general assembly shop. The overhead electric monorail system. Together, the team selected light truck manufactured in this facility is transported by a a Rockwell Automation control solution supported by ProSoft wireless EMS conveyor. The TCF line is considered the final Technology wireless Ethernet communication. The challenge stage in production, where components are added to the was to create a seamless and reliable communication system vehicle including ‘trim’ components such as windshield glass between each carrier and the controller as they move and seats, as well as operational components such as the throughout the plant. engine and wheels before final vehicle testing.
Implementation Control and communication automation For consulting, specifying and planning of this project, the manufacturer worked with Yantra Automation, in conjunction with their local Rockwell Automation Account Manager and with system integration company, Precision Automation Robotics India Limited (PARI). The team worked closely to develop the best overall solution for this sophisticated project. This being a new system and a Greenfield plant, they were not bound by constraints associated with some of the older monorail systems found in manufacturing plants. Thus, they were able to design a sophisticated system that easily conformed to the goals of the project and the manufacturer’s commitment towards flexible and lean manufacturing. Its aims to eliminate communication issues and concerns associated with rigid copper bus bars and brush collectors commonly used for communication with EMS carriers. To
A&D India | Oct-Nov 2013
PARI was commissioned for the design and implementation of the specific assembly line. PARI is a turnkey integration company specialising in top-to-bottom conveyor system design, controls & communication automation and robotics for automotive industry in India. PARI has designed the full vehicle assembly line to operate in real-time on the EtherNet/IP control network, using several Rockwell Automation ControlLogix PACs and supporting peripherals on the shop floor, including I/O and variable frequency drives. The decision to go with ProSoft Technology industrial hotspot radios was made primarily because of their industrial hardware and solid reputation for supporting Rockwell controls and communication interfaces seamlessly, in addition to the ease of operation. Movement of the EMS carriers for transporting vehicles through the different stages of assembly is handled over a wireless EtherNet/IP network. The control system consists of
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FOCUS | AUTOMOTIVE
The EMS runs throughout the entire length of the Trim, Chassis and Final assembly (TCF) line of the vehicle in the general assembly shop
one ControlLogix PAC on the conveyor and one ControlLogix PAC on engine decking system for body marriage. The conveyor PAC is hardwired to two ProSoft Technology Master radios while the Engine Decking PAC is hardwired to a third Master radio. The conveyor PAC is wirelessly connected with 33 individual carriers along the EMS, while the Engine Decking PAC is connected with 3 engine carriers. Each independent EMS carrier has a local control panel with Rockwell Automation I/O and a variable frequency drive (VFD), with a ProSoft technology access point acting as repeater to establish wireless communication between the main control panel equipment and their respective PAC. The carrier radios communicate with each other and with Master radio. This EMS application time is critical, so each repeater radio is connected with its parent Master radio at all times to avoid switching delays as communications change from one Master radio to another while the carriers are in motion. The Master radio in each conveyor PAC has two Omni antennas with a splitter to deal with multipath fading effect. The architecture fully supports seamless roaming by the carriers.
Benefits After some initial challenges with line-of-sight issues which were resolved by adding another Master radio and elevating their locations, the system is now able to provide
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real-time communication between the EMS carriers and the PACs on the assembly plant floor, including real-time I/O status for conveyor movement control. The system also enables wireless synchronisation between the floor-mounted engine trolleys and the overhead EMS carrier, for the smooth decking of the engine. The benefits that the manufacturer was able to avail were the ability to control EMS conveyor and the engine decking carrier in real time and synchronising the VFDs with the Engine Decking Carriers. Eliminated complex wiring/cabling and cat tracks for communication cable. It obtained seamless and robust communication between the PACs and the I/O .
Conclusion The project went live in November 2009. Since then, the manufacturer has seen an increase in uptime, reliability and consistency in production output, enhancing their commitment towards lean manufacturing. With the success of the Rockwell Automation control and ProSoft Technology communication solutions, five similar applications consisting of both EMS conveyor system and material handling in the vehicle assembly shops are being installed. â&#x2DC;? Courtesy: Rockwell Automation > MORE@CLICK ADI03321 | www.AandD24.in
A&D India | Oct-Nov 2013
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T O M OT OT I V E I N D U S T RY | F O C U S A U TO
SHAPING THE FUTURE OF AUTOMOTIVE MANUFACTURING The automotive manufacturing industry needs to focus more on the intelligent networked automation that creates a synchronised environment for seamless production of vehicles on the production line. This helps the industry continue operating profitably against the changing economic backdrop
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Nitin S Nair Chief Manager, Automotive Vertical Siemens Ltd nitin.nair@siemens.com
A&D India | Oct-Nov 2013
F O C U S | A U TO M OT I V E I N D U S T R Y
Global Automotive experts have forecasted that the Material flow to the line is synchronised; production attention of the automotive industry over the next ten to information available to the operator is relevant to the current fifteen years will be focused on the shift of automotive business vehicle at his station, quality gates have the right check towards Asia (China & India), the global demographic change, parameters programmed for the incoming vehicle and robots/ the demand for greater sustainability and the ever growing machines have the right programs for the planned operations proportion of alternative propulsion systems. If they are to on the incoming vehicle. All this ensures optimum interlinking continue operating profitably against this changing backdrop, between all the different automation components within the automakers will have to continue to step up their endeavors. production process and maximises productivity through the The major challenges for automotive manufacturers are: Siemens developed totally integrated (TIA) concept. With its r How to shorten the intervals between new model and TIA Portal, in 2011, Siemens has created a central engineering variant launches? platform which is now being adopted by an ever increasing r How to reduce the total cost of ownership? number of key players throughout the automotive industry. r How to have flexible manufacturing lines with short model The TIA Portal concentrates all the relevant applications and changeover times? tools in a standardised and intuitively operated user interface. r How to improve plant availability? Collation of all the relevant data in a standardised database r How to reduce energy costs? eliminates the need for multiple input and data matching.
Fewer hours per vehicle
Lesser time to market
The automotive industry has traditionally played a trendsetting role in terms of improving productivity. With an hour of production time in the automotive industry costing up to $100,000, automakers still continue to concentrate their efforts on driving down the number of operating hours needed to produce a vehicle and on increasing plant availability. This is achieved by continuous improvement in production times on the manufacturing line by reduction in all types of wastes on the line such as idle times, unnecessary material flow, storage on the manufacturing line and other non-value added work. In order to achieve this reduction in wastes, it is necessary that accurate information is available quickly at the point of decision-making on the manufacturing line. This improvement is brought about by intelligent networked automation on a manufacturing line which is dynamically interlinked with PLM & ERP systems. The vehicle manufacturing schedule based on the incoming orders is available from the ERP system. The process & component bill of materials for various models and variants are made available from the PLM system. With these inputs, the intelligent networked automation creates a synchronised environment for seamless production of vehicles on the production line.
Time is a key competitive factor in the launch of new vehicle models and variants. Globalisation and social change are speeding up the cycle of market trends. The response of automakers is to extend their product ranges and target ever shorter product launch times. The Siemens PLM software allows product variants and their influence on production to be simulated at the computer. In addition, processes which have traditionally been performed in sequence are now increasingly running in parallel. For instance, many manufacturers are already busy planning their production facilities while the product is still under development. Use of the TIA Portal facilitates the increasing parallelisation of product design, plant engineering and commissioning by allowing virtual engineering on a single platform. With this integrated plant engineering, the planning teams can verify various manufacturing scenarios with multi models in the digital factory, thus giving them the flexibility to produce multi models in different mixed batches on the real manufacturing line which is finally set up. Also helping to improve flexibility in the automotive industry is the Siemens industrial identification portfolio. Using radio frequency identification (RFID), products and components can be seamlessly tracked through the entire procurement, manufacturing and shipping process. Assuming
A&D India | Oct-Nov 2013
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A U TO M OT I V E I N D U S T R Y | F O C U S
Siemens PLM software allows product variants and their influence on production to be simulated at the computer
a key role in this process is the RFID data carrier which remains with each vehicle through every one of its many production stages. As part of a just-in-sequence production process, this allows automakers to produce different vehicle and equipment variants on the same production line without problems, and to comply with individual customer specifications.
by up to 40 per cent, or alternatively by implementing electric drives which can be used as required in conjunction with Siemens frequency converters, permitting up to 70 per cent reductions in the energy consumption of fans, pumps or compressors. Additional energy saving potential can be leveraged through the identification and compensation of load peaks and the coordinated shutdown of plant sections during idle periods using the PROFIenergy data interface. By taking an integral approach, Siemens is able to keep a Energy saving with a concept watchful eye on the entire process and value chain, offering Energy consumption is a significant environmental and not just products but also competent advice. On the subject of cost factor in automotive production. Added to this is the energy saving, automotive customers may rely on a team of need to comply with statutory requirements relating to energy- experts ready to offer the benefit of their energy, automation efficient production and reduced carbon emissions. The ISO and technology-specific expertise. 50001 energy management system standard sets out to define internationally applicable parameters for reducing energy Fit for the future costs, greenhouse gases and other environmental impacts. The world of automotive industry is fast changing, The energy management software B Data from Siemens is tailored precisely to the implementation of wide-ranging alongside the development of combustion engine; the requirements. It records the status quo of all the energy and emphasis is set to shift increasingly towards alternative material flows such as water, electrical energy, pressure or propulsion methods. Electric and hybrid vehicles in particular steam required in production and in all ancillary processes. are making rapid advances and will become an established The different consumption levels are allocated based on actual feature on our roads within the next ten to fifteen years. Three usage, and documentation is drawn up. Using key performance focal challenges facing the industry will be to develop new indicators (KPI), B Data delivers a solid basis for decisions lightweight construction concepts, find ways of reducing the relating to energy optimisation. For automakers, even the cost of producing lithium ion batteries, and fine-tune the implementation of a few simple measures such as leak manufacture of electric motors. Siemens is ready with a series detection or even load distribution will make use of the energy of smart concepts for the automation of new production management system worthwhile. In this way, energy savings processes. Here too, the spotlight is on integral and efficient between five and ten per cent can already be achieved even solutions based on the Totally Integrated Automation concept. without any additional investment. This effect is compounded The use of new approaches opens up scope for simple, costby the implementation of additional measures such as the use efficient and modular-based vehicle production. â&#x2DC;? of modern energy-efficient motors from the Siemens > MORE@CLICK ADI03322 | www.AandD24.in environmental portfolio which can reduce energy consumption
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A&D India | Oct-Nov 2013
M A C H I N E TO TO O L S | F O C U S
MACHINE TOOL AUTOMATION This article highlights machine tools that have reached a very high standard in terms of machining power, accuracy, speed, robustness and cost efficiency which has led to high productivity
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Shriniwas Vidwans Area Manager â&#x20AC;&#x201D; Sales GĂźdel India shriniwas.vidwans@gudelindia.com
A&D India | Oct-Nov 2013
F O C U S | M A C H I N E TO O L S
Automation has provided the desired and extended system functionality well beyond existing human capabilities
Machine tool analysis is the result of common evolutionary efforts made by generations of engineers to understand the manufacturing of machines from a more scientific point of view, i.e. to consider the main factors influencing the productivity of manufacturing cells and to gain mathematical models to describe performance with suitable precision. In this way, concept optimisation and trouble-shooting for existing machines can be realised with more sophistication than by trial-and-error strategies. Manufacturing cells are combinations of machine tools, industrial robots and transfer devices for efficient and automatic part production with a high degree of precision and reliability.
Rigid automation: Generally used for custom-engineered, special-purpose equipment to automate a fixed sequence of operations. It is mainly used for high production rates and inflexible product designs. Recoverable automation: Equipment designed to accommodate a specific class of product changes and is particularly used in batch production and medium volume. Flexible automation: It is designed to manufacture a variety of products or parts used mainly for low production rates or varying product design and demands.
Features
Need for automation
The features of manufacturing cell include gantry robots to generate relative movements between part and tools or storage devices. Part and tool transfer requires high-path velocities with moderate accuracy, while processing requires slower but very precise movements. The control units generate the set-point commands for the gantry robots, it helps to communicate with other cell parts (e.g. via fieldbus or cell bus) and the operator (via human-machine interface â&#x20AC;&#x201C; HMI). The graphical user interface (GUI) is used to control virtually the position of end-effector of the gantry mechanism.
The requirement for automation includes economic advantage through increased productivity with reduced labour uncertainty and costs. Automation initiates improved accuracy & repeatability with consistency of quality parameters; it is suitable for mass production with better material handling and also helps to reduce WIP. The potential areas of automation consist of loading and unloading of parts; in-process gauging (to enhance quality assurance); deburring of parts machined; adhesive dispensing requirements (3-axis manipulation); assembly operations and
A&D India | Oct-Nov 2013
Selection
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M A C H I N E TO O L S | F O C U S
Manufacturing cells are combinations of machine tools, industrial robots and transfer devices for efficient and automatic part production with a high degree of precision and reliability
replace human labour in hazardous conditions. Gantry robots are an efficient alternative for the automation of machine tools. Access to the machine is maintained loading from the top. This will make the shop floor space free for other activities with the help of utilising the space above the machine. The linear axes support operating, programming and training at the machine. This is of particular importance to set up the processes and observe the activities.
Challenges Automation involves machines, or integrated groups of machines, that automatically perform required machining, forming assembly, handling and inspection operations within the cell. Through sensing and feedback devices, these systems automatically make necessary actions. The integration of automation system into cellular arrangements with machine tools to process families of component parts where the system performs tasks right along with one or more human beings is very efficient. The automation can perform part loading and unloading, as well as material processing (like joining). The real mechatronic challenge is the machine tool manipulator. While almost all other parts are bought from specialised suppliers, the design and optimisation of the
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manipulator remains the key competence of machine tool manufacturers. It is still the physical feasibility of the manipulator that defines the level of productivity which can be reached by a manufacturing cell. In order to prevent time-consuming and ruinous trial-and-error prototype developments, suitable analysis methods like feasibility study, proper cycle time calculations etc are required which optimise design as far as possible in the concept phase and identify problems in the running system for effective trouble shooting. In most of the cases, automation has provided the desired and extended system functionality well beyond existing human capabilities. The role of human operator has changed dramatically. Instead of performing tasks, the job has turned into monitoring over the system. Also the robot manipulator design is becoming challenging due to the increasing need for path accuracy and velocity. To craft appropriate automation for the machine tools that will result in maximum yield includes terms like accuracy — related to target manufacturing deliverance; consistency — related to part orientation as per process sequence, in line gauging processes etc and repeatability — related to part positioning. ☐ > MORE@CLICK ADI03323 | www.AandD24.in
A&D India | Oct-Nov 2013
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Moving towards a potential win The recently released IFR study ‘World Robotics 2013 - Industrial Robots’ estimates that by 2016 the annual supply of industrial robots will reach more than 190,000 units. A brief insight into the market forecast… “The robotics industry is looking into a bright future!” stated Dr Shinsuke Sakakibara, President, IFR, on the occasion of the publication of the study ‘World Robotics 2013 - Industrial Robots’. “In 2013, global robot sales will increase by about 2% to 162,000 units. The IFR Statistical Department expects that between 2014 and 2016, worldwide robot sales will increase by about 6% on average per year. In 2016, the annual supply of industrial robots will reach more than 190,000 units.”
2013: Demand will vary among the regions and the industries In 2013, the demand of the automotive industry will start to slow down in certain markets after three years of continued increasing robot installations in the traditional as well as the
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emerging markets. The electrical/electronics industry will increase robot investments in production automation as well as in retooling for new production processes. A further increase of robot orders from other industries is also expected, particularly from pharmaceutical, food & beverage, metal and machinery industries. Growth of robot sales is expected in North America, Brazil, the Republic of Korea, China, in most of all other South East Asian markets as well as in most of the Central and Eastern European markets, and in Turkey. Robot sales to Japan will decrease due to the continuing weak economic position of its electrical/electronics industry. Also, in Germany a decrease in robot sales is likely after the significant robot investments of the automotive industry over the past three years. The United Kingdom is in a similar situation and will also have a reduction
A&D India | Oct-Nov 2013
H S Fa
m a r k e t | R o b ot i c s & H a n d l i n g
in robot installations in 2013. Due to the continuing tight economic situation, robot sales will either decrease or stagnate in Italy, France and Spain. However, due to the more complex robot systems entering the market, the increase in turnover might be higher, just as in 2011 and 2012.
Promising prospects for 2014-2016 The IFR Statistical Department estimates a further growth of robot installations between 2014 and 2016 by 6% on average per year. “The growth is based on huge potentials of further penetration of the industrial segments like electronics or food and on the on-going industrialisation of the emerging countries. But there are even additional growth potentials in the future based on breathtaking advanced and innovative technological developments”, commented Dr Andreas Bauer, Chairman, IFR
Industrial Robot Suppliers Group. “These technologies are opening doors to completely new applications for robots. Impressive for me are the developments regarding humanrobot cooperation and opportunities that are provided in new fields for automation, especially in areas where no robots are currently used.” The challenges and opportunities include cost-efficiency requirements which drive higher levels of automation globally; energy-efficiency and new materials requirements, e.g. carboncomposites, require retooling of production; growing consumer markets require expansion of production capacities; decreasing life-cycles of products and increasing variety of products require flexible automation; technical improvements of industrial robots that will increase the use of robots in the general industry and in small & medium-sized companies, e.g. easier to use robots for simple applications, collaboration of
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R O B OT I C S & H A N D L I N G | M A R K E T
“There are even additional growth potentials in the future based on breathtaking advanced and innovative technological developments” Dr Andreas Bauer, Chairman, IFR Industrial Robot Suppliers Group
robots with human workers; improved quality requires sophisticated high-tech robot systems; and robots improve the quality of work by taking over dangerous, tedious and dirty jobs that are not possible or safe for humans to perform. “Whilst these challenges are not insignificant, they are also far from insurmountable. In fact, our industry and governments around the world have already made significant progress in addressing them. They represent exciting opportunities for us and should be embraced to the fullest extent,” stated Per Vegard Nerseth, Head – ABB Robotics, Switzerland.
Booming robot market: China Between 2005 and 2012, sales of industrial robots to China have increased by about 25% on average per year and reached 23,000 units in 2012. This supply does not include sales of local Chinese robot manufacturers. At the joint event of the IFR and the Chinese Robot Industry Alliance (CRIA), the IFR-CRIA CEO Round Table at the CIROS trade show in July 2013 in Shanghai, it was reported that in 2011, local Chinese robot suppliers sold about 2,000 units and in 2012, 3,200 units. The Taiwanese company, Foxconn Electronics (enterprise Hon Hai Precision) is producing robots for their own use in their manufacturing plants in China. These robots are not counted in the statistics because the information on the installed number of the so called ‘Foxbot’ robots installed in mainland China is rather vague. The numbers differ between total 10,000 and 30,000 units over the last years. Taking into account the above mentioned information, the total number of robots installed in China in 2012 was between 28,000 and 35,000 units. Hence, China was already the largest robot market in 2012. China will continue to have a substantial economic growth rate in the coming years. Strong investments in automation will continue in order to increase productivity and to establish more eco-friendly production processes. China is one of the most rapidly growing and largest consumer markets in the world with an emerging middle class escalating the demand for consumer goods, medical care and high quality lifestyle, all great reasons for pushing the manufacturing sector to automate.
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“While the automation challenges are not insignificant, they are also far from insurmountable. In fact, our industry and governments around the world have already made significant progress in addressing them” Per Vegard Nerseth, Head – ABB Robotics, Switzerland
Besides modernisation of the existing production sites, various types of industries are building new production sites in order to gain market share in this huge consumer market. The potential for automation in the Chinese manufacturing industry is still huge. Compared to highly automated countries like Japan, Korea and Germany with robot densities in the manufacturing industry between 270 and 400 industrial robots per 10,000 employees, the robot density in China is comparably low with about 20 robots. To reach such a level of robot density, about one million new robots would have to be installed in the coming years in China. In China, the faltering economic growth in 2013 may somewhat affect robot investments. In 2013, the robot supply of foreign companies will increase by about 5% to 10% to about 25,000 units. And from 2014 to 2016, robot sales from non local robot suppliers will again gain momentum and increase between by 15% on average per year reaching about 38,000 units in 2016. Chinese robot manufacturers will increase their robot production in the near future, and robot suppliers from abroad will increase assembly of robots in China. Taking in account that China is already one of the biggest markets but is still in the beginning phase of utilising robotics, the Chinese market will offer huge potentials for installation for local and foreign robot suppliers in the coming years. ☐ Courtesy: IFR (International Federation of Robotics) > MORE@CLICK ADI03324 | www.AandD24.in
A&D India | Oct-Nov 2013
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R O B OT I C S & H A N D L I N G | A P P L I C AT I O N
Taming the robot Industrial robots have witnessed increasing usage in automated production lines. Until now, these have been isolated in cells to ensure the safety of those working in the proximity. Using TÜV-certified function blocks, B&R has now boosted robot safety to a level that allows humans and robots to work hand-in-hand Following the footsteps of their machine colleagues, industrial robots are assuming more and more responsibility in modern production lines. The most widely used type is an articulated arm robot with six electromechanical axes of movement. B&R has taken it upon itself to make industrial robots so safe that they can work hand-in-hand with humans, liberated from the confines of safety gates and enclosures. The safety requirements for industrial robots and robotic systems and their integration in workplace environments with human workers are defined in ISO 10218. Among other things, these standards specify the maximum strain to which the human body is permitted to be subjected. These defined upper limits ensure that humans working alongside robots are not exposed to any serious danger. As a general guideline it can be said that a safe limited force of up to 150 N, a reduced speed of
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Dr Gernot Bachler Technical Manager - Motion B&R
up to 250 mm/s and automatic stop capabilities ensure that any collisions will be harmless.
TÜV-certified safety The traverse paths followed by the tools and grippers used by industrial robots to perform their tasks are the product of highly complex axis movement patterns of multi-jointed machines. It is important that safe monitoring of speed accounts not only for each individual axis, but also for the robotic system including the tool center point. The first step towards B&R’s goal of expanding robot safety was taken in 2011 with the creation of the function SLS at TCP (Safely Limited Speed at the Tool Center Point). This SafeROBOTICS library contains TÜV-certified parameter and
A&D India | Oct-Nov 2013
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R O B OT I C S & H A N D L I N G | A P P L I C AT I O N
A TÜV-certified function block provides monitoring of the tool centre point. The parameters used to do this are standardised and loaded from a table containing the respective values. This is a versatile solution that can easily be used with different kinematic systems without requiring recertification
function blocks for use in B&R’s safe programming environment. These function blocks are used to program safety control applications that run on SafeLOGIC controllers. Safety applications read data regarding the status, position and velocity of individual axes and apply transformations to calculate the actual velocity at the tool centre point, which in turn is compared with the specified safe values.
Safe motion control SafeMC is an integrated standard component of all ACOPOSmulti servo drives from B&R. These drives boast a typical error detection and response time of 7 ms – about a tenth of the time possible with relay safety circuits – which shortens the stopping distance by a factor of 100. On drives equipped with B&R’s safe motion control feature, both the reading of the safety-related data and the execution of the safety functions are performed directly on the drive. Data is carried safely over the fieldbus-independent, safety-oriented transfer protocol known as openSAFETY.
A highly efficient solution In the first version of the SafeROBOTICS solution, the software module in charge of monitoring utilised a kinematic model parameter block, which can be configured for all commonly used types of robots. This had a significant disadvantage, however, as the resulting safety application had to be certified separately for each type of robot. To spare its customers this expense and inconvenience, B&R developed a more efficient solution based on a standardised block of kinematic modeling parameters. Its advantages include
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standardised parameter blocks that can be applied to any conceivable kinematic chain with up to 11 revolute and prismatic axes, regardless of the specific values they contain. Transformation parameters also permit modeling of mixed configurations where the robot itself is mounted on a linear portal axis or rotary table. The parameters can also handle constructions where multiple axes are coupled mechanically. In these cases, rotating Axis 4, e.g. changes the orientation of Axis 5. One of the advanced features of SafeROBOTICS is a new function block designed to manage the additional degrees of freedom in complex systems. This function block verifies the plausibility of stored parameters. All of this makes SLC at TCP an easy-to-use safety block, especially when users take advantage of the preinstalled parameter blocks for standard robot types provided by robot manufacturers.
Users are optimally supported Users are free to select whatever type of control works best, be it the robot controller from the manufacturer of the kinematic chain or integration in an overall control system. This is possible thanks to the open and bus-independent safety protocol, openSAFETY. The only requirement is providing safety-related position data and the ability to drive, safe to handle responses. Users of SafeROBOTICS do not need to know how the path curves and velocities are calculated. This is handled by integrated transformation functions. With this optimal support, they are free to focus on their core activities. Since the invention of the electro-mechanically driven six-axis articulated robot, 40 years ago it has never been so easy to let man and machine work together safely. ☐ > MORE@CLICK ADI03325 | www.AandD24.in
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R O B OT I C S & H A N D L I N G | T E C H N O L O G Y
Innovative milling robot A case study on the development of Stäubli RX170 hsm, a milling robot by Riexinger GmbH to satisfy the plastics and piping specialist Kubra GmbH’s requirement of a special purpose machine for the production of drainage chamber bases If a company that specialises in manufacturing customised machinery goes for an alternative solution, then it will have a valid reason – in this case, the Stäubli RX170 hsm. This innovative milling robot, working away within a cell supplied, by plant manufacturer Riexinger, ensures abundant flexibility in the complete machining of large plastic parts. The five-axis robot also scores in terms of maximum availability and short cycle times. Established half a century ago, Riexinger GmbH & Co KG operates on a global scale, specialising in plant and machinery for the processing of all types of plastics. When one of their customers, plastics and piping specialist Kubra GmbH, enquired about plant for the production of drainage chamber bases, Riexinger’s initial idea was to construct a special purpose machine. In the case of the deep-drawn parts made of polyethylene which have a diameter of 1 m, machining the external contour and the pipe connections is part of the process. Reliable and consistently reproducible processing of these chamber bases is essential for their
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subsequent use in drainage and sewage systems. In the search for appropriate alternatives, Otto Angerhofer (former CEO of Manz and now a consultant for Riexinger) came up with a persuasive concept – the robotics specialist knew of the new Stäubli RX170 hsm milling robot and informed the Riexinger designers about this innovation.
The job in terms of flexibility “In fact, the robotic solution turned out to be just the job,” says Markus Theobald, Managing Director, Riexinger. “With its operating range of nearly 2 m and the freedom of movement afforded by a five-axis model, the Stäubli robot can easily reach any working position on the large plastic parts. So, we had found the perfect machine for this application and now only had to supply the system peripherals.” The realisation went smoothly and quickly, and soon the machining centre for chamber bases proved its worth in terms of flexibility and easily met all other customer specifications
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R O B OT I C S & H A N D L I N G | T E C H N O L O G Y
RX170 hsm milling robot is intended precisely for applications such as fast and accurate processing of plastic and composite materials
with regard to cycle times and quality. The machining centre is currently handling chamber bases in various versions with pipe connections of between 110 mm and 315 mm but all with an outer diameter of precisely 1.0 m. The chamber bases arrive at the machining centre as deep-drawn parts made of polyethylene or polypropylene, with their outer contours and pipe connections as yet unformed. The job of the milling robot is to remove excess plastic material and thereby ensure a consistent outer radius. The five-axis robot is further tasked with the precise machining of the different pipe connections. The switch from one variant to the next is performed by the plant operator pressing a couple of buttons on the robot control console. Because the plastic material is easy to cut, the milling robot can go about its work in dynamic fashion. The Stäubli machine is equipped with a high-precision milling spindle supplied by Fischer Precise. To facilitate uninterrupted complete machining, the cell is equipped with an automatic tool changing station. Operating the robot is easy to learn and can be a lot of fun. No matter how many new variants may follow, the end user is well equipped for all eventualities with the Riexinger system. “The system is set up for maximum variation,” adds Theobald. “Loading and unloading of the robot cell takes place manually. The Stäubli RX170 hsm milling robot then takes complete charge of machining the chamber base. Thanks to its enormous range, the five-axis robot readily copes with all the many possible designs and - by comparison with a CNC machining centre - guarantees almost unlimited flexibility.” Here, the RX170 hsm autonomously selects the optimum cutter for each machining process. The quality of work done by the robot is in no way inferior to the result that might be expected from a machining centre handling this same application. Because the plastic material is easy to cut, the RX170 hsm can go about its business in dynamic fashion, thereby reducing the cycle time for machining a chamber base to less than two minutes. The machined surfaces pass all tests in terms of fit and quality, ensuring that no rework is required.
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Although Riexinger actually specialises in special-purpose machinery, Theobald is excited about the use of the milling robot. “In the Stäubli RX170 hsm, we have a turnkey plug-andplay solution that works absolutely reliably. By contrast with the time-consuming and expensive construction of a dedicated machine, the robot solution makes huge savings in terms of engineering costs. In addition, we have an integrated system with a significantly more manageable level of complexity, which in turn means higher availability, plus we also benefit from almost unlimited flexibility.”
Milling with a robot Stäubli’s newly developed RX170 hsm milling robot is intended precisely for applications such as fast and accurate processing of plastic and composite materials. It introduces a new element of freedom and flexibility into the production line and is able to process large workpieces rapidly with facility. In terms of performance too, the RX170 hsm is ideal for machining plastic parts: its repeatability is ±0.04 millimeters, which falls well within the requirements for the processing of the chamber bases. The Stäubli robot operates reliably in any working position within its two-metre range. A lot of professional expertise has gone into the making of this robot. The entire power supply as well as the spindle cooling and lubrication are contained within the arm. This represents a compact and highly reliable solution. Stäubli engineers also designed a new upper arm and a special wrist in which the sixth axis is replaced by a milling spindle. Here, Riexinger opted for the exceptionally high-quality Fischer Precise milling spindle. As the end customer operates the robot cell on a three-shift system around the clock, Riexinger quite logically uses only the best components available on the market. ☐ Courtesy: Stäubli > MORE@CLICK ADI03326 | www.AandD24.in
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
3D MODELING An application story on the use of 3D modeling software — Solid Edge by Vishwakarma Engineering Works to make design changes quickly and easily Although 2D drawings had been the primary design deliverable for many years, Vishwakarma Engineering Works (VEWorks) found that there were drawbacks to a 2D approach. If there was a design change, 2D drawings could not be easily updated in a timely manner. Changing complex assemblies involved considerable drafting hours. Engineers faced pressure to revise the drawings, which was not only time-consuming, but also arduous. Moreover, VEWorks often is tasked with producing a prototype to be approved by customers before getting the goahead for production. “The conventional way of designing in 2D was an impediment. It was time-consuming & often human errors would surface during the manufacturing stage. Our production orders are usually for small batches in varying sizes. Any change in dimension requires updating the entire assembly. This is more common when we are manufacturing process equipment,” says Jay Patel, CEO, Vishwakarma Engineering Works. The solution was to convert to a 3D design process.
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Choosing Solid Edge VEWorks chose to implement Solid Edge® software, with synchronous technology, from Siemens PLM Software, a specialist in product lifecycle management. The synchronous technology of Solid Edge® software enables a company to accelerate design, make changes faster and improve the re-use of imported data. Patel elaborates, “One meeting with Siemens PLM Software was sufficient for our management to understand the advantages Solid Edge had to offer. The biggest advantage with Solid Edge is that it offers far better editing and updating capabilities than any of its competitors. It is backed by support that is among the best in the industry. Siemens PLM Software also offers a comprehensive range of product development solutions that can be easily integrated into our growing organisational structure.”
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
Making changes is easy The company’s objectives included a faster design process that would allow for changes to be made rapidly without extensive time spent updating 2D drawings. This would help VEWorks produce sample parts or components as quickly as possible, enabling the company to provide samples to customers for review and approval. VEWorks’ objectives were met. The synchronous technology functionality of Solid Edge enables designers to make changes quickly ‘on the fly’ without concern for modeling history. This helped VEWorks eliminate the time-consuming and error-prone problem of having to constantly revise 2D drawings. VEWorks now designs more
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from a conceptual standpoint. Patel explains, “Using Solid Edge, we design products based on mere concepts and client input without any specific drawings or samples, then we manufacture the designed assembly in the volumes required by our customers.” The organisation’s staff received software training and shortly after implementation, the software was being used for all of VEWorks’ design and drafting needs. “We expect to be able to manufacture products faster than our competitors & look forward to upgrade our engineering solutions to further improve our products,” says Patel. ☐ Courtesy: Siemens PLM > MORE@CLICK ADI03327 | www.AandD24.in
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
Shortening product development time Computational Fluid Dynamics (CFD) is a proven tool for the detailed design of equipment and plants. The main advantage of numerical simulation is the three-dimensional flow information that can be generated to explore optimisation possibilities. Here is a case study on how Tetra Pak CPS uses CD-adapcoâ&#x20AC;&#x2122;s STARCCM+ to carry out this process. Specialised engineering and simulation software are important innovation tools. At Tetra Pak Cheese and Powder Systems (CPS), basic engineering (collecting key data from a process) and detailed engineering (designing and optimising the pipelines and individual components of a plant) are carried out via computer-aided engineering (CAE). The result is a digital representation of the plant, ideally as a 3D CAD model. With CAE, it is now possible to virtually perform
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Hans-JĂźrgen Bittermann Dipl-Ing (qualified engineer) Freelance specialised journalist Lambsheim
experiments that previously required elaborate laboratories or pilot plants, making it easier to compare alternatives, perform marginal analyses and therefore, support the optimisation process.
CAE at work The fact that CAE offers an efficient and cost-effective way
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
to optimise equipment and plants proved decisive in convincing Tetra Pak to use this tool. This is because their customers, who are operators in the food industry, place a great deal of value on continual improvement — their goal is always to produce better products in increasingly smaller plants while reducing their production, operating and service costs. One of the tools Tetra Pak CPS relies on is STAR-CCM+ from CD-adapco. “We actively use STAR-CCM+ for design optimisation, troubleshooting & research and development projects,” said Alfred Jongsma, Manager — Research & Development, Tetra Pak CPS. The company had a very good experience using this tool in a wide range of areas, such as investigating non-newtonian fluid flow in evaporation, minimising the loss of pressure in
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falling film evaporators, optimising the separation efficiency in separators, optimising the air flow in a spray dryer and analysing the recovery of waste heat at the dryer outlet, among many other applications.
Spray dryer — the goal is dry milk The spray dryer is based on the principle of surface enlargement in which liquid products, such as milk or whey, are atomised into fine droplets through a flow of hot air, whose temperature ranges between 150°C and 250°C. The droplets, which are dried during their falls, are only exposed to the airflow for 0.5 to 1 second. The operator can only achieve a high-quality solid product
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
STAR-CCM+ provides the world’s most comprehensive engineering simulation inside a single integrated package
retaining a small particle size with the smallest possible droplet size distribution. Its size depends on the drying time (fall time) and the desired size of the droplet/particle. “A typical spray dryer has a volume of 700 m3 (diameter: 8.5 m; height: 20 m), processing 5 t milk or whey an hour and using 5 MW of power. The energy efficiency lies between 40 and 65% – that makes every step towards optimisation worthwhile,” said Jongsma. The significant parameters of a spray dryer are chemical composition and the initial concentration; the temperature of the hot air flow; mixing properties of the droplets and air; flight path and the agglomeration properties. The quality of a simulation relies on the accuracy of the model; how realistic the relevant physical, chemical and technical processes are numerically described. In addition, to ensure a quick turn-around, the simulation set-up and execution should be easy, intuitive and efficient. STAR-CCM+, with its unrivaled meshing technology, high-fidelity physics and user-friendly interface, meets all these requirements. “I could not put a scale to it, I am very satisfied with the package itself, the workflow and the support that is given. There are of course limitations in what one can describe (in terms of physics) through CFD at the moment, but I see a steady growth in capabilities of the STAR-CCM+ solution. The increased capabilities are made possible by the research efforts of numerous institutes around the world and it seems this trend is not coming to an end any time soon,” said Jongsma. “In general terms, I can state that by actively using CFD we have greatly improved our understanding of the complex physics in spray dryers. We now know more about the conditions that are favourable for spray dryer operation. The
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objective here was to optimise the spray dryer output and minimise fouling. Fouling limits the running time of a spray dryer; after several weeks it needs to be cleaned. It appeared that the factors that minimise fouling also favourably affect the capacity. The factors that were optimised are the air flow into the system and the way the liquid is introduced (by highpressure spray nozzles).” The benefits to the customer include improved production capacity, powder quality and a longer period of time between necessary cleaning of the spray dryer.
STAR-CCM+ STAR-CCM+ provides the world’s most comprehensive engineering simulation inside a single integrated package. More than just a CFD solver, it is an entire engineering process for solving problems involving flow (of fluids or solids), heat transfer, and stress. While this might sound complicated but it is actually very functional and easy to learn, confirmed Jongsma. “It is demonstrated time and again even on the basis of relatively simple models, computer-controlled simulation leads to astonishing results. The unique way in which STAR-CCM+ is set up means the learning curve is really short. Creating a mesh, performing the simulation, and analysing the results take place in a single interface. The fact that post-processing can be carried out while the simulation is running, is very helpful in arriving at a converged solution.” ☐ > MORE@CLICK ADI03328 | www.AandD24.in
A&D India | Oct-Nov 2013
Image courtesy: Hannover Messe
E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y
Getting your humanware ready Suggesting measures to build the knowledge base for the automation industry, this article deals with the current status of educational infrastructure and hiring methods while stressing on the need to build human competency to cater to future automation and instrumentation industry demands. Manufacturing has had its share of innovation with the introduction of industrial automation systems that brought about speed, agility, efficiency and productivity. If one compares the decade prior to 80â&#x20AC;&#x2122;s with 90â&#x20AC;&#x2122;s and now, the growing dependence on the need for productivity, growth, sustainability and the need to be lean & competitive is clearly seen. Productivity levels are at an all-time high, and in the 2000s, with the convergence of IT, productivity growth, peaking was faster than that in the 1990s. We are close to that moment in
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Debashish Ghosh Retired Industry Marketing Specialist dgrockwell@hotmail.com
manufacturing history when we will perhaps be able to talk to our machines and our machines will understand our instructions and even carry them out. We will see some amazing innovation and big advances which will include improvements in vision; sensing systems, fine motor control and more autonomous robots. As some advanced economies recover from this Great Recession, hiring in manufacturing may accelerate, and some nations may even raise net exports. Manufacturers will continue to hire workers, both in production and non-
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T E C H N O L O G Y | E D U C AT I O N & T R A I N I N G
Image courtesy: Hannover Messe
Some automation companies lure college graduates by power points stressing on the magic of global brand presence and pick up laggards as GITs from reputed colleges
production roles (such as design, after-sales service including logistics). But in the long run, manufacturing’s share of employment will remain under pressure as a result of ongoing consumer focused products, like in food and health care products; global competition, will push advanced economies to specialise in activities requiring more skill and efficiency.
computers. With the growth and scale of manufacturing and process units in India the requirement of humanware along with hardware & software has become critical. To induct the right candidate has become a compelling need.
How some organisations hire?
What some organisations have done and are still doing is to hire candidates whom they believe have requisite education, intelligence and personal characteristics to become successful Man’s quest to improve on efficiency, earn more money revenue producing employees. Other organisations prefer to and save energy has driven technology innovation to enable start with a blank canvas, in the sense they hire college manufacturing with new instruments which has pushed him graduates with the intent of teaching everything they need to beyond barriers to an age where automation plays an integral know about the company’s offerings, adoption patterns of part in the life of a manufacturer. Today, we find automation vertical markets, etc. We have seen that compared to the lucre in homes, workplace and in manufacturing units. It is promised by IT outfits the automation industry is left wanting understanding information on measurements, sensing and in terms of salary and work life balance. As a result, some controlling speed, controlling process variables within a automation companies lure college graduates by power points production, or manufacturing area, detecting foreign objects stressing on the magic of global brand presence and pick up in beverage bottles, picking up steel bars from open hearth laggards as GITs from reputed colleges. These graduate furnaces managing inventory, detecting and preventing trainees somehow tend to get disillusioned with their machine downtime and performing many other critical companies and usually do not last more than two years. For functions on the production floor. the automation companies, the search begins once again and the net result, wastage of time and money. There are other automation companies who poach and some hire rejects which Humanware: Critical for growth have been let go from large companies. They hire without any The discipline of instrumentation and automation due diligence, as a result, unethical practices gets transferred engineering branched out of the streams of electrical and from one company to the other. electronic engineering sometime in the mid 80’s. It is a multiThe pattern of induction differ from industry to industry, disciplinary stream and covers subjects from various branches job profiles, its needs, immediacy, expectations on its RoI such as chemical, mechanical, electrical, electronics and cycles and market competitiveness. Sometimes, indoctrination
Automation and its role in modern day manufacturing
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E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y
A typical automation lab
sessions can range from a few days to few months depending on the complexity of product basket, technology and candidate’s ability to absorb quickly and convincingly. But can you afford to slowdown your manufacturing or sales with this outdated indoctrination process? The answer is a plain ‘no’. No one can wait, not at least your customers. We need a ‘ready to deliver’ model. Candidates will be required to hit the road running. Today, there are worldclass players in the country and some more savvy than the other. The enterprise must be equipped with relevant sustainable industry knowledge in order to give them that cutting edge with customers, and one that can garner productivity and efficiency in the customer’s or manufacturing organisation. Today’s learning models should begin early because both the automation vendors and manufacturers cannot wait. They must in turn respond to their customers on time and at the right place.
How do we change and respond? In an era of choices, engineering still dominates as a favoured discipline. India is now home to 3,393 engineering colleges that have 14.86 lakh seats across 36 courses approved by the All India Council of Technical Education (AICTE). Of the total number of colleges, 65% are in the south and 35% in the north. Maharashtra, Andhra Pradesh, Tamil Nadu, Karnataka and Uttar Pradesh have about 70% tech institutes. Somewhere between a fifth to a third of the million students graduating out of India’s engineering colleges run the risk of being unemployed because either their college does not offer the desired curriculum required by the manufacturing or automation vendors; hence, falling short of the desired expectation of the prospective employer to hire the right talent relevant for his industry.
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This happens to all fresh graduates who join the automation industry without any hands-on knowledge hardware, software. No end-user buyer wants to talk to a solution seller who does not have industry/application knowledge, least of all the delivery expertise. There is a need to be able to offer appropriate solution for a machine, manufacturing line or a process across the table and close the sale. Today, salesperson must be the beacon light for his customer. He needs to be ready with value propositions that can impress his customer and vendors can get him to pay any price premiums they demand. He must be able to steer his customer with the trust quotient and help customers gain in productivity improvements in his organisation. The gestation time for these engineers is long before they become application savvy. Many colleges in India have taken cognisance of the role automation in manufacturing and have in the past few years shown interest in wanting to invest in automation education. These colleges have seen how industries are able to save precious rupees by sheer management of energy. With the government adding new Indian Institutes of Technology (IIT) and National Institutes of Technology (NIT) to the existing list in tier-II cities, and with the birth of more private institutes, we will perhaps see the emergence of newer centres of engineering excellence in cities such as Indore, Jodhpur, Jaipur and Bhopal, Baroda. Aside many popular courses being offered, inclusion of appropriate automation education and knowledge of automation application will help the manufacturing units source prospective candidates who are automation aware and ready to deliver faster and able to shorten the ROI cycle time. This will help better prepare and deliver ‘the soldiers’ to face the manufacturing battle of tomorrow. South and West continue to be the hub of machine building. There are colleges coming up in states like Uttar Pradesh,
A&D India | Oct-Nov 2013
T E C H N O L O G Y | E D U C AT I O N & T R A I N I N G
Many colleges in India have taken cognisance of the role automation in manufacturing and have in the past few years shown interest in wanting to invest in automation education
Rajasthan and Madhya Pradesh. Also, since electrical is a popular choice, implementing automation education can create a differentiation and help students become competent for the automation industry.
Accreditation Board for Engineering and Technology (ABET), Inc, and there are another 710 accredited programmes in engineering technology.
Curriculum @ present Need to incorporate automation education Out of the multitudes of engineering colleges, a few have Almost all process and manufacturing industries such as started implementing Industrial Automation in their steel, oil, petrochemical, power and defence production, have curriculum in Coimbatore and the College of Engineering, a separate instrumentation department, which is manned and Pune, have established labs showcasing architecture of various managed by instrumentation engineers. Automation is the products integrated with one another. In these labs, 20-30 main driver in the process industry, and it is the core job of students can develop PLC programs on 10-15 stations. Once instrumentation engineers. Hence, the demand for the PLC program is ready, they download the program to PLC instrumentation will always be there in pharma, food, through a communication network. Multiple PLCs, HMI and petrochemical, chemical or any continuous process plant. The SCADA are connected to this network (Ethernet). A screen growth in avionics, aeronautical and space science sectors has developed in the individual stations can be downloaded to also increased the scope for automation. Skilled in automation HMI and SCADA through Ethernet. engineers can also fit in both software and hardware sectors. Nature of work of an automation/instrumentation engineer Competency development ranges from designing, developing, installing, managing and Enhancing employability and skill development should be supporting automation systems that are used to monitor and the responsibility of various manufacturing associations and control machinery and processes. In addition to the standard engineering degree, many the automation industry – the two single largest consumers of colleges today are offering 2-year or 4-year degree programmes the end product. They should provide cross-border in engineering technology. These programmes, which usually collaboration with colleges and institutes all over the country. include various hands-on laboratory classes that focus on Automation industry should keep aside a promotional budget current issues in the application of engineering principles, for university programmes and scholarship grants for prepare students for practical design and production work, encouraging students to undertake research projects and build rather than for jobs that require more theoretical and scientific careers in this industry. They should also donate or sell knowledge. Graduates of 4-year technology programmes may hardware at subsidised prices and assist in setting up labs for get jobs similar to those obtained by graduates with a Bachelor’s the benefit of students. India will indeed benefit by the private sector’s participation in transforming the skills’ landscape degree in engineering. About 1,830 programmes at colleges and universities offer of India. ☐ > MORE@CLICK ADI03329 | www.AandD24.in Bachelor’s degrees in engineering that are accredited by the
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EVENT | REPORT
Showcasing new age technologies To highlight the impact of latest technologies for solving engineering challenges in India and introduce futuristic technologies, National Instruments recently held the 10th annual NIDays 2013 in Bengaluru. A report… National Instruments, a worldwide leader in the test and measurement industry, recently hosted the 10th annual NIDays 2013 in Bengaluru. The event was attended by more than 700 engineers, researchers, scientists and witnessed participation from NI customers & alliance partners across a range of industries including healthcare, semiconductor, aerospace, automotive, life sciences, robotics and telecommunication. The keynote during the event was delivered by Dr James Truchard, President, CEO & Cofounder, NI. Addressing the conference, Dr Truchard said, “It is extremely rewarding to see our Indian customers solve some interesting challenges with NI tools. We are seeing the idea of ubiquitous computing and real-time systems becoming center stage to the next industrial revolution. We feel like we have got the technology that can really help redefine how industry works to continue solving the world’s grand challenges.” Adding further on the importance
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
of NIDays for the Indian market, he noted, “The most important thing that we do is to educate engineers on the present opportunities that they have in solving problems. That is why we work with over 7000 universities around the world and around 600 in India. Education is a very important part of our operations, and we want to make that information available, train engineers on how to use these tools, so they can be most productive. NI Days is one of the key initiatives where we stress on education, while showcasing new solutions.” Addressing the conference, Victor Mieres, Vice President, Emerging Markets, Asia/Rest of World, said, “NI leads the revolution in the instrumentation field with a software-defined approach to building systems. Being a global organisation, NI has some region specific programmes including ‘Planet NI’. The mission of ‘Planet NI’ is to empower engineers in emerging countries to achieve sustainable prosperity by providing
A&D India | Oct-Nov 2013
REPORT | EVENT
The various pavilions at NIDays 2013 showcased the latest NI technologies for the power, renewable and manufacturing sector, among others
increased access to NI technology.” According to Jayaram Pillai, Managing Director, NI (India, Russia and Arabia), “NIDays 2013 brought together LabVIEW developers from all over India to share best practices. The annual Graphical System Design Achievement Awards aimed to highlight efforts by engineers, scientists and researchers for their innovative test, measurement and embedded control applications. With the large pool of knowledge in India, NI’s open platform provides an opportunity to quickly bring ideas to reality and, through the LabVIEW Tools Network, gain market access around the world.” The conference at Bengaluru highlighted the impact of NI technology on solving engineering challenges in India. The NI Application of the Year was awarded to the team from VSSC Trivandrum (ISRO), AERO Department, for their application titled ‘Development of 1 m hypersonic wind tunnel control, networking, data acquisition system and graphical display system.’
Do engineering
National Instruments (NI) and the NICE (Nurturing Innovation and Creativity in Education) Committee also hosted the 12th Annual Educator’s Day 2013 in Chennai. The conference showcased the latest tools and best practices in engineering education. It was a compelling success with participation of over 500 researchers, professors and eminent academicians across the country. It emphasised the necessity of hands-on learning in making engineers industry ready. National Instruments also announced NI myRIO, an embedded hardware device to help students design real, complex engineering systems more quickly and affordably than ever before. Based on the same powerful technology as the popular NICompactRIO platform, NI myRIO is smaller and more student-friendly than its industrial counterpart. NI myRIO includes the latest Zynq® all programmable system on a chip (SoC) technology from Xilinx, which combines a dual-core ARM Cortex-A9 processor and an FPGA with 28,000 Highlights programmable logic cells. Using the power of the NI LabVIEW During the NIDays 2013, the company introduced the graphical programming environment, students can program latest version of LabVIEW system design software, LabVIEW the FPGA and evolve their systems in real time, giving them 2013, that utilises the most current and powerful technologies the flexibility to prototype and quickly iterate on their to make the design of complex systems more intuitive than designs. ever. It facilitates the management, documentation and “NI believes in inspiring the next generation of innovators debugging of increasingly complex systems. It adds support for to solve the world’s engineering grand challenges. By giving the Linux Real-Time OS, giving developers access to dynamic, the students of today access to hands-on learning, students community-sourced libraries. LabVIEW 2013 focuses on three have the opportunity to do engineering and gain valuable skills primary areas – integrating access to the latest technologies that prepare them for the jobs of tomorrow,” said Dr Truchard that make systems better, enhancing the environment so during the event. ☐ developers are more efficient, and providing access to an > MORE@CLICK ADI03330 | www.AandD24.in ecosystem of training and partner tools.
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T E C H N O L O G Y | TA L K
SOLUTIONS FOR AUTOMOTIVE APPLICATIONS Suggesting the right cabling solutions for crane and drag chain applications, here is a case study on the customised solutions provided by Lapp Cables for the automotive industry The automotive industry is one of the most rapidly growing industrial sectors in the country. With the cumulative FDI inflow into the market, India is becoming the magnet for car makers. The industry is highly competitive with a mix of Indian and foreign players and is also one of the most important sectors from the economic point of view. India‘s passenger car and commercial vehicle manufacturing industry is the sixth largest in the world, with an annual production of more than 3.9 million units in 2011. The production of passenger vehicles in India was recorded at 3.23 million in 2012-13 and is expected to grow at a compound annual growth rate (CAGR) of 13 per cent during 2012-2021, as per data published by Automotive Component Manufacturers Association of India (ACMA). The automotive industry has been facing the challenge of maximising efficiency due to the extreme pressure of the market demands and expectations. Automobile manufacturing involves managing several large and complex processes. Hence it is imperative to maintain the health of the machines. Thus, it is very important to install proper cabling to ensure operations do not come to a halt. Lapp India recently catered to a leading automotive manufacturing company that is popularly known for making conscious efforts in implementation of several environmentally sensitive technologies in the manufacturing process. The company
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uses some of the world’s most advanced technologies for emission check and control.
Cabling requirements Flexible and long lasting cables for crane and drag chain applications include data communication cables for transferring data from one part of the plant to another; cables for critical applications on the factory floors; automation cables for remote monitoring; flat cables for space constrained applications and power cables for supplying power to the machines.
Flexible and long lasting cables for crane and drag chain applications include data communication cables for transferring
Cabling solutions Lapp India has provided flat cables for cross travel and crane operations that need less space than round cables. These cables are resistant to abrasion and are able to withstand harsh environmental conditions. For data transfer purposes it has supplied communication cables that are ideal for locations with space constraints with an added advantage of low-loss data transmission between the control panels and the factory floor. Depending on where the cables would be used, Lapp India has provided specific type of cables. It has supplied robot cables for welding division, for powering and controlling its gun welding equipments. These cables are HFFR compliant, flame retardant and can withstand temperature load upto 1200o C. These are made up of
data from one part of the plant to another
extra-fine strands of bare copper wire and a twisted core thereby making the cables ideal for flexing and torsion load application. For body shop division, it has supplied cables which adhere to space constraint factors and are capable of withstanding mechanical stress. Because of their high durability and flexibility these cables are ideal for power and control solutions in drag chains. The company has provided cables for paint division that are chemically inert and are highly temperature resistant. They are silicon-free cables with high current carrying capacity and offer enhanced resistance to oxidation and PWIS. ☐ Courtesy: Lapp Cables > MORE@CLICK ADI03331 | www.AandD24.in
A&D India | Oct-Nov 2013
TA L K | T E C H N O L O G Y
PROTECTION FROM ARC FLASH The article deals with the arc resistant equipment that can help protect employees working on or near energised equipment An electric arc flash is the result of an arc fault that superheats the air around it, expanding and creating a pressure wave within an electrical enclosure. This arc plasma vaporises everything it comes in contact with, such as copper, insulating materials, bolts and steel enclosures. This massive heat and energy wave can inflict serious injuries, including severe burns, damaged hearing from the powerful sound waves, impalement from projectiles and impaired eyesight from the highintensity flash. Arc resistant equipment can help protect employees working on or near energised equipment. IEEE codes set standards for protective equipment and ‘limits of approach’ focused on withstanding an arc flash. These and other guidelines include technical specifications to help companies choose appropriately rated equipment with proper protection levels.
Arc resistant equipment & accessibility Arc resistant equipment is electrical equipment designed for controlling the exposure and/or release of the dynamic elements associated with an internal arc flash. The equipment is defined by the level to which these elements are extinguished or controlled, or prevented from seriously injuring personnel or from propagating. Generally, the protection applies only when all equipment doors are closed and latched; the manufacturer must test the equipment to validate the level of protection. A fundamental approach to arc flash safety must include all personnel, whether
A&D India | Oct-Nov 2013
electrically qualified or not. For equipment to meet the IEEE C37.20.7 arc resistant standard, all doors and covers must remain closed during an arc flash incident. No parts can be ejected from the equipment, and the arc does not burn any holes in the exterior of the test structure. The grounding connections must remain effective through the entire test cycle. Per IEEE C37.20.7, levels of arc resistant accessibility are defined in three types. The Type 1 includes equipment shields personnel from arc exhaust materials only when in front of the equipment. This equipment does not provide any specific level of protection outside the protected zone, and all doors must be closed and latched. The Type 2 offers equipment shields personnel from the arc dynamic components on the front, sides and rear of the equipment. Doors must also be closed and latched. A third level of protection, Type 2B, shields personnel from arc exhaust materials on the front, sides and rear of the equipment, even when the low-voltage control compartment door is open.
Rating choice and selection Equipment is determined to be arc resistant based on applied voltage, source impedance and the duration of the arc event. The duration of the arc can be specified in time or by relying on a specified upstream protective device. A duration rating is strictly based on quenching the arc in a maximum amount of time. This rating is independent of other protective devices. Device limited ratings use a tested protective device to limit the duration of an arcing fault. In
IEEE codes set standards for protective equipment and ‘limits of approach’ focused on withstanding an arc flash
device limited rating, no specific time duration is stated. In arc resistant equipment that has been duration rated, the vendor name plate will include accessibility type, the standard or guide used for validation testing, and the maximum short circuit current and duration. The vendor nameplate for equipment that has a device limited rating includes accessibility type, maximum short circuit current and a list of tested, protective devices. When buying arc resistant equipment, it is important to consider the overall system requirements to purchase exactly what the system needs. The system short circuit current at the point of the equipment’s use can help determine the correct rating for the system. Operators will also need to consider how long their system can sustain an arcing fault. The longer the time, the greater amount of energy is released and the higher degree of internal damage is sustained to equipment. ☐ Courtesy: Rockwell Automation > MORE@CLICK ADI03332 | www.AandD24.in
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S E N S O R S & E N C O D E R S | I N N O VAT I O N S
REDEFINING THE FUTURE Opening up a world of possibilities, the new age sensors have completely changed the way automation was perceived in this decade. A look at the latest innovations introduced in the Indian market by leading sensor manufacturers…
Innovation: Mini Mini Sensor – the world’s smallest inductive sensor Technical details: The enormous reduction in size was made possible by using the latest mixed-signal ASIC technology. This technique combines analog signal processing with digital computing power on a single chip, making it particularly suitable for all applications where signals are recorded in analog form, but must be digitised for transmission. Another advantage is that, by eliminating the need to use analog components, device reliability is increased. Applicability: ASIC technology in sensors which gives a high level of accuracy, repeatability, and reliability. Advantage: The sensor is in the size range of 12 mm length and diameter 3 mm having inbuilt sensing including amplifier and processing circuits. It also impresses with its high switching frequency of 8 kHz and excellent temperature stability from -25° C to +70° C. Alongside the standard version with a plastic cap.
Company: ifm
electronic
rinex Automatio
n
Innovation: efector pmd 3d – the first industrial 3D sensor that can detect objects in three dimensions at a Inn gla glance Tec Technical details: The measurement and the evaluation of the time of flight are integrated on one chip. The dimensions of the extraordinarily compact sensor housing are just 60 x 42 x 35 mm. The resolution of the sensor is 64 x 48 pixels. Each pixel of this matrix evaluates its distance to the object. This results in 30 distance values at the same time. The image of the object on the matrix and the respective distance 3072 val values correspond to a 3D image. The geometrical characteristics of the object result from these values. Ap Applicability: The award-winning PMD technology enables the evaluation of geometrical characteristics suc as volume, distance, level or surface area. Irrespective of the distance between sensor and object, the such vol volume is determined from a top view. Ad Advantage: By means of the 3D sensor, the measurement of distances to uneven surfaces is no longer a pro problem – a clever alternative to ultrasonic measurement. Levels can also be determined on the basis of a def defined background and search zone.
Innovation: SmartReflect light barrier Technical details: With the SmartReflect light barriers, the light beam – in contrast to a retro-reflective or through beam sensor – is set up between the sensor and a machine part. An object interrupts the light beam and triggers the sensor. The only condition is that there must be a background, for example, any machine part, in the sensing distance of the sensor. In this way, the separate reflector becomes superfluous and a common weak point is rectified. Special SmartReflect variants can use the same principle to detect transparent objects like bottles, trays or even foils. Applicability: It can be used for diverse industrial environments to address the need for a robust light barrier solution, which would not have the disadvantages of conventional sensors. Advantage: The product is capable of enabling a very high ROI due to savings in maintenance costs. No need to replace reflectors, downtime is reduced and productivity is improved. It not only ensures substantial reduction in operating costs, but also cost savings due to easier installation, commissioning and alignment.
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Company: Cont
Company: Baum
er
A&D India | Oct-Nov 2013
I N N O VAT I O N S | S E N S O R S & E N C O D E R S
Innovation: New Performance Level ‘c’ version pressure sensors In Te Technical details: The Melt pressure filled sensors with an extensimetric technology have been en enriched by new versions specifically designed to increase the safety level of machinery imposed by current international standards. Ap Applicability: The product is an ideal solution for increasing the safety of extruders. Ad Advantage: This version features smart electronics with auto-diagnostics that detects all possible fau fault conditions. Additional safety is ensured by an integrated relay that changes state in case of ov over-pressures or passing of the set limit in conformity to the requirements of Namur NE21 and NE NE43. The benefits are tangible and immediate – lower risks for operators, higher safety levels for the machinery and complete respect of the environment.
Company: Gefra
n Group
Innovation: High precision high speed triangulation sensor optoNCDT 2300 Technical details: The measurement principle of laser triangulation is simple: the sensor operates with a laser diode, which projects a visible light spot onto the measurement target. The reflected light is imaged by an optical receiving system onto a position sensitive element. If the light spot changes its position, this change is imaged on the receiving element and evaluated. Applicability: The sensor can be used to monitor vibrations on difficult, uneven surfaces. Advantage: This new series offers adjustable measuring rates up to 49 kHz. The sensor is offered as a set of 5 models with measuring ranges between 2 mm and 100 mm. With the entire electronics integrated, the sensor is very compact and measures 80 mm x 75 mm.
Company: Micr
Company: Pepp
erl+Fuchs(FA)
o-Epsilon
Innovation: 360° high speed rotating scanner Inn Tec Technical details: The company has successfully developed a very futuristic 360° high sp speed rotating scanner on a platform that measures the time of flight of a pulse of light an delivers a highly fast and very accurately scanned 360° view of the area around it. and Ap Applicability: The excellence of this technology is in its high scanning frequency of up to 50 Hz and the sampling rate of 250,000 measurements which allows a gapless vision of 36 360° and ensures that the scanner has a direct view on the environment at any me measuring angle. Ad Advantage: The equipment simulates an on-board beautiful, highly visible multi dir directional display through which status reports can be displayed or application-specific inf information like distance values, measuring profiles etc can be easily displayed.
Innovation: The BNS series Technical details: The sensors have high-quality stainless steel, making it resistant to corrosion and cleaning liquids; it meets ECOLAB test requirements for wash down with acid and alkaline-based cleaning agents. Applicability: The switch and matching coded actuator are IP69K rated for use in high-temperature (176°F) and high-pressure (1450 psi) wash down applications. The sensors have more tolerance to misalignment, individual coding to avoid bypassing of the switches by the operator. Advantage: Many other variants are available for installation in hazardous area in petroleum, refineries industries with ATEX approved products for compliant to Zone 1 & 2.
Company: Schm
ersal Group
> MORE@CLICK ADI03333 | www.AandD24.in
A&D India | Oct-Nov 2013
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TECHNOLOGY | NEWS
Spring loaded terminal blocks
Output circuit protection replay
Connectwell’s spring loaded feed through terminal blocks come with springs below the clamps. These terminal blocks are preferred for connections that involve safety requirements of the electric supply industry (ESI) standards, British CEGB regulations and NTPC applications. In addition to high torque screws, these blocks have a built-in spring loading feature. It is recommended to use hook type lug / ferrule for terminating wires in such connections. These terminal The terminal blocks are blocks have specially designed preferred for connections that current bar for the right location & involve safety requirements placement of wires crimped in hook type of the electric supply Industry lug / ferrule, thus preventing loosening of (ESI) standards, British the wires even when the screw clamps CEGB regulations and NTPC are not tightened. The terminal pitch applications includes CTS4USC-6 mm, CTS6USC8 mm and CTS10USC-10 mm.
Finder Relays has recently introduced the new Master Plus series that is equipped with a fuse module at the contact side, for a standard 20x5 mm glass fuse. This gives the relay interface a complete modularity along with the pluggable relay which can be mounted over a DIN Rail base/ socket. Optional fuse bypass switch allows the user to operate the relay even without a fuse module due to the internal Optional fuse bypass switch allows the user to operate the relay even without a fuse electrical link. This provides an module due to the internal electrical link advantage to use the relay and in turn the complete system without affecting the signal continuity, if required. Condition of the fuse is easily visible through a window. The features of this series include complete output protection with unique replaceable glass fuse; reliability in wiring and is equally cost and time saving. It offers advantages like pluggable electromechanical or solid state relay, plug-in jumper links (for looping) in red, blue and black colour and protection for leakage current suppression.
> MORE@CLICK ADI03334 | www.AandD24.in
> MORE@CLICK ADI03335 | www.AandD24.in
Precision regulators
Power supply units
Janatics India has recently launched its light weight, compact, diaphragm operated, relieving type (exhaust) precision regulators. These regulators are designed to provide a constant output pressure with high degree of accuracy to ensure that the output pressure is maintained precisely irrespective of fluctuations in the inlet pressure. The company has offered precision regulators in 1/4” port size, with supply pressure of maximum 10 kg/cm² and regulating pressure range of 0.1 The precision regulators are to 8 kg/cm². The sensitivity of the designed to provide a constant precision regulator is ≤ 0.02 kg/cm and output pressure with high repeatability is within ± 0.04 Kg/cm², degree of accuracy to ensure with a flow 1100 lts/min.The precision that the output pressure regulator has wide use applications like is maintained precisely metrology gauging systems, printing, irrespective of fluctuations in textile, packaging and medical the inlet pressure equipments and many more.
Phoenix Contact has recently offered power supply units for AC to DC conversion, DC to DC conversion, redundant module and design to fulfil the requirements of various different sectors. Compact power supply units from the QUINT POWER ranges maximises the availability of the system. Even standard circuit breakers can be tripped quickly with the SFB (Selective Fuse Breaking) technology. Comprehensive diagnostics are provided through constant monitoring of the output voltage and output current. The preventive function monitoring visualises critical operating state and Compact power supply units from the QUINT POWER ranges maximises indicates them to the controller the availability of the system before errors can occur. In order to trip standard circuit breakers magnetically and quickly, power supply units must be able to supply several times the nominal current for a short period. With SFB technology, which supplies up to six times the nominal current for 12 ms it ensures the reliable tripping of the circuit breakers as a result of the availability of dynamic power reserve.
> MORE@CLICK ADI03336 | www.AandD24.in
> MORE@CLICK ADI03337 | www.AandD24.in
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A&D India | Oct-Nov 2013
NEWS | TECHNOLOGY
Standardisation & automation software Eplan Platform has launched Version 2.3 that focuses on standardisation & automation and opens up new opportunities for users for standardcompliant design & handling safety values. Simple macro editing and extended search functions for system settings guarantee highly productive engineering for users. Another benefit is the central administration of phased-out devices and associated test runs to give transparency and safety to existing projects. The latest version Eplan 2.3 focuses on is characterised by standardised and largely standardisation & automation automated engineering across a consistent and opens up new opportunities database. There is a comprehensive support for users for standard-compliant for new standard-compliant designations design & handling safety values based on EN 81346 and the safety values focused VDMA 66413 exchange format. The central administration of phased-out items and a new search function for system settings are additional new features of the CAE software to allow interdisciplinary cooperation and configuration. Version 2.3 offers extensive options for handling macros/partial circuits and their variations. These macros can be edited and if required can be updated across the entire project within a clear table view. > MORE@CLICK ADI03338 | www.AandD24.in
Brushless motor
HMS Industrial Networks has launched a range of CAN repeaters under the IXXAT brand. These products enable coupling of two or more CAN network segments, provide them with galvanic isolation and eliminate the effects of EMI (Electromagnetic Interference). The CAN repeaters are offered under HMS’s recently acquired IXXAT brand and enable machine builders and system integrators to use extended CAN topologies including tree or star topologies. Furthermore, the integrated IXXAT CAN repeaters enable galvanic isolation provides a built-in protection coupling of two or more CAN against over voltage and the anti-noise circuit network segments, provide of the units eliminates the effects of EMI. them with galvanic isolation and IXXAT repeaters are especially designed for eliminate the effects of EMI use in industrial environments, meeting high demands for robustness, temperature ranges and safety. With the use of a repeater, it is possible to build independent electric segments that can be optimally terminated in terms of signals. The repeater substantially increases system reliability, partly because it increases the signal quality and it makes it possible to isolate malfunctions – keeping the remaining CAN-system fully operational. > MORE@CLICK ADI03339 | www.AandD24.in
Industrial wireless access point
Portescap has recently introduced the 22ECS brushless motor. Designed to deliver exceptional efficiency in high speed applications, the 22ECS runs up to 30 per cent cooler than similar motors, at speeds greater than 50K RPM. As a result, the brushless slotless motor stays much cooler and offers greater power density than equivalent models at a gi given operating point. The 22ECS also uses unique high performance lubrication u and a ball bearings to extend motor life The 22ECS brushless motor is and maximise performance at high designed to deliver exceptional speeds. Due to its high power, efficiency efficiency in high speed and low rotor inertia, the 22ECS can applications, the 22ECS runs up change speed and accelerate rapidly. to 30 per cent cooler than similar The superior efficiency not only enables motors, at speeds greater than cooler operation at high speeds, but also 50K RPM offers battery capacity and life advantages. The motor’s superior efficiency allows battery operated applications to run longer between charging cycles and can reduce the size of the battery. > MORE@CLICK ADI03340 | www.AandD24.in
A&D India | Oct-Nov 2013
CAN repeaters
ProSoft Technology has released the 802.11n industrial wireless access point/bridge/repeater with fast roam technology. The 802.11abgn fast industrial hotspot is an advanced, high-speed wireless Ethernet solution designed for plant-floor automation, SCADA systems, mobile worker Wi-Fi infrastructure and process control systems. The hotspot offers a broad range of industrial wireless capabilities including unique features such as fast roaming and has excellent packet-per-second The 802.11abgn fast performance and robust communications in industrial hotspot is an demanding industrial environments. These new advanced, high-speed capabilities provide seamless high-speed Ethernet wireless Ethernet solution connections for moving machines and vehicles designed for plant-floor traveling long distances in assembly plants, crane automation, SCADA systems and mining. The secure, high speed wireless systems, mobile worker network reduces project costs, while improving Wi-Fi infrastructure and productivity by eliminating mechanical festooning, process control systems rails and slip rings for economical and reliable mobile applications. The radio’s fast roaming technology uses less than 50 msec time between access points and provides full device bridging. The module provides secure 802.11i and 128-bit AES Encryption and operates securely in the 2.4 GHz or 5 GHz bands. > MORE@CLICK ADI03341 | www.AandD24.in
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TECHNOLOGY | NEWS
Flexible compact AC drives Rockwell Automation has recently designed PowerFlex 520-series of compact AC drives, including the new, economical PowerFlex 523 AC drive, with flexible features that help users be more competitive. Ideal for builders of simple, stand-alone machines, the PowerFlex 523 AC drive balances user needs for control with a design that lowers the cost, to develop and deliver machines. To make configuration easier, machine builders can use a standard USB connection for uploading and downloading drive-configuration files. They can also program the drive through its PowerFlex 520-series help built-in human interface module (HIM), which speed up configuration displays data on the drive’s LCD with by providing groups of scrolling QuickView text and detailed parameters for common explanations of parameters and other codes. applications and by allowing The HIM has multiple language options to users to save their settings to address global needs. Unique to the new parameter groups PowerFlex 520-series AC drives, app view and custom view tools help speed up configuration by providing groups of parameters for common applications and by allowing users to save their settings to new parameter groups.
Pressure transmitters Keller AG has introduced a complete range of pressure transmitters for use in hazardous areas. These intrinsically safe transmitters offer measurement ranges between 0.2 bar and 1000 bar, so they can be used for measurements of all types in areas subject to explosion hazards in Group II (Gas), and as per the relevant ATEX directive. Individual types from the product range are also approved for Group I (mining) respectively Group II (dust). Common features of all Y-line pressure transmitters include a very low temperature error, with correspondingly high measurement accuracy. Thanks to the integrated temperature sensor and an additional digital circuit, the range of The pluggable series is an envisaged operating temperatures can be excellent solution for creating divided into as many as 120 sections with wire harnesses which ease field a width of 1.5 K. During factory calibration, wire connections a mathematical model is used to calculate individual compensation values for TK zero point and TK amplification for each of these sections; the values are then stored in the transmitter.
> MORE@CLICK ADI03342 | www.AandD24.in
Online colour measurement system Micro-Epsilon Eltrotec has introduced colorCONTROL ACS 7000 with a ΔE < 0.08. The innovative colorCONTROL ACS 7000 colour measurement system is used where colour sensor measurements are not accurate enough. The measurement system provides a number of operating modes. The users can employ one of several methods to perform simple measurements between colour distance ΔE and the reference The innovative colorCONTROL ACS 7000 value: ΔE(CMC), ΔE99, ΔE94, colour measurement system is used ΔEDE2000. The measuring spot is where colour sensor measurements are 9 mm with a measurement not accurate accuracy of ΔE < 0.08. All modes support measurement speed up to 2 kHz. It can be used for both production line measurements (inline) and for laboratory or sample measurements (offline). The measurement system is suitable for automotive paint inspection, interior colour measurements, forensics, foils, injection moulding, wood, veneers, textiles, printing, medical technologies, and coating technology. > MORE@CLICK ADI03344 | www.AandD24.in
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> MORE@CLICK ADI03343 | www.AandD24.in
Frequency inverters Nord Drivesystems has introduced SK 180E which is mounted on asynchronous motors, just like its larger counterparts. Featuring proven ISD vector control, the SK 180E is more cost-effective than the currently available range of decentralised units. The new inverter focuses on the core requirements of speed control and efficiency. Featuring two analog inputs and integrated process and PI controller functions, it can autonomously manage simple drive The new inverter focuses on the core applications. It is suitable requirements of speed control and efficiency both for stand-alone variable frequency drives and for synchronised operation with several units. It can save upto 30 % energy by automatic magnetisation adjustment under partial load. Providing class C1 radio interference suppression and a discharge current below 16 mA, the SK 180E can be operated in residential and business buildings. For use in mobile pumps, shredders, or mixers, variable frequency drives are available with a conventional mains plug. > MORE@CLICK ADI03345 | www.AandD24.in
A&D India | Oct-Nov 2013
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 - Dec’13-Jan’14 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net
» Food & Beverage Industry The food & beverage industries are as diverse as the global consumer base they serve. There is a continuous demand for a greater variety of packaged products to satisfy a wide range of demographics. Faced with these challenges, producers still need to improve the bottomline and grow. The next issue will highlight the advanced automation solutions in the food & beverage industry.
» Industrial Computers An equipment optimisation of the industrial computers targeted at ‘increased system availability’ is one of the easiest possibilities of improving productivity by minimising downtimes, even though the ambient conditions in the industrial sector are much harsher than in offices. A&D India will provide the technology trends in industrial computers in the next issue.
» Machine Vision Machine vision technology is used in a variety of different industries to automate the production, increase production speed and yield, and to improve product quality. This industry is a knowledge driven industry which experiences an ever increasing complexity of components and modules of machine vision systems. The next edition of A&D India will present case studies on the use of new machine vision systems in various applications.
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COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Analog Devices India. . . . . . . . . . . . . . . . . . 16 Alstom . . . . . . . . . . . . . . . . . . . . . . . . 10, 12 AIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 ARC Advisory Group . . . . . . . . . . . . . . . . . . 26 B&R Industrial Automation . . .Cover, 8, 9, 10, 52 Beckhoff Automation . . . . . . . . . . . . . . . . . . 1 Baumer. . . . . . . . . . . . . . . . . . . . . . . . 32, 76 Connectwell Industries . . . . . . . . . . . . . 11, 76 Control Techniques . . . . . . . . . . . . . . . . . . . 12 Contrinex Automation . . . . . . . . . . . 19, 32, 76 Delta India Electronics . . . . . . . . . . . . . . . . 39 EPLAN . . . . . . . . . . . . . . . . . . . . . . . . 57, 77 Fieldbus Foundation . . . . . . . . . . . . . . . . . . 12 Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 2 Finder India . . . . . . . . . . . . . . . . . . . . . 35, 76 GE Technology . . . . . . . . . . . . . . . . . . . . . . 10 Galil Motion Control . . . . . . . .Back Inside Cover Güdel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Gefran India . . . . . . . . . . . . . . . . . 32, 47, 77 HART Communication Foundation. . . . . . . . . 12
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Hilscher India . . . . . . . . . . . . . . . . . . . . . . 13 Hummel Connector Systems . . . . . . Back Cover Hilscher India . . . . . . . . . . . . . . . . . . . . . . . 18 Honeywell Process Solutions . . . . . . . . . . . . 20 Hanning Motors . . . . . . . . . . . . . . . . . . . . . 49 HMS Industrial Networks . . . . . . . . . . . . 21, 77 IFR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Ifm electronic India . . . . . . . . . . . . . 32, 43, 76 ISA Bengaluru . . . . . . . . . . . . . . . . . . . . . . 10 Janatics . . . . . . . . . . . . . . . . . . . . . . . . 6, 76 Keller . . . . . . . . . . . . . . . . . . . . . . . . . 53, 78 Katlax Enterprises . . . . . . . . . . . . . . . . . . . . 4 Kubler Automation . . . . . . . . . . . . . . . . . . . 15 Lapp India . . . . . . . . . . . . . . . . . . . . . . . . . 72 Mitsubishi Electric. . . . . . . . . . . . . . . . . . . . . 3 Micro-Epsilon. . . . . . . . . . . . . . . . . . 7, 32, 78 Nord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 National Instruments . . . . . . . . . . . . . . . 30, 70 Omron Automation . . . . . . . . . . . . . . . . . . . . 5
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Pepperl+Fuchs . . . . . . . . . . . . . . . . . . 32, 77 Protescap . . . . . . . . . . . . . . . . . . . . . . . . . 77 Prosoft . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Red Lion Controls. . . . . . . . . . . . . . . . . . . . 14 Rockwell Automation. . . . . . . . . . . . 36, 73, 78 Renu Electronics . . . . . . . . . . . . . . . . . . . . 25 SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Stäubli . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Siemens PLM . . . . . . . . . . . . . . . . . . . . . . 60 Schunk Intec India . . . . . . . . .Front Inside Cover Schmersal India . . . . . . . . . . . . . . . 17, 32, 77 Schneider . . . . . . . . . . . . . . . . . . . . . . . . . 51 Tetra-Pak . . . . . . . . . . . . . . . . . . . . . . . . . 62 Kirpekar Engineering . . . . . . . . . . . . . . . . . 59 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 61 Phoenix Contact . . . . . . . . . . . . . . . . . 63, 76 VDMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Annual Subscription Price Rs 600 AandD.india@publish-industry.net Ph+91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.aandd24.in
A&D India | Oct-Nov 2013