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It Can Be a Sure
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CONTENTS
APRIL 2 012
FEATURES
30 Cover Story
Green Is No Gamble
It Can Be a Sure Thing to Develop Sustainable Machines and
Production Lines That Will Improve Your Bottom Line
Jim Montague, executive editor
Volume 16, No. 4
40 Measurement, Sensing and Vision
Accuracy: Know What You’re Getting
What’s Accurate for One Application Might Be Approximate for
Another. The First Step Is to Understand the Terms
Bill Mostia Jr., P.E.
30
49 Product Roundup
Mechanical Innovation in Motion
New Materials, Customization Keep Systems Running Smoothly
X X
X XX
X XX
COLUMNS
40
7 ControlDesign.com
29 Embedded Intelligence
15 Articles to Celebrate
Back to the Drawing Board
9 Editor’s Page
47 TechFlash
The Prodigal Job Returns
Machine-Mount I/O
Go Everywhere
15 Machine Builder Mojo
Virtual Machine,
Real Savings
62 OEM Insight
Cooperative Provides
Skilled Workers
17 Live Wire
Safety Dance: Safe to Dance?
HOT BUTTONS
54
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by
Putman Media, 555 West Pierce Rd., Suite 301, Itasca, Illinois 60143.
(Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at
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©Putman Media 2012. All rights reserved. The contents of this publication
may not be reproduced in whole or part without consent of the copyright
owner. POSTMASTER: Send address changes to Control Design, Post Office
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Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada
N9A 6J5. Printed in the United States.
19 OEM Spotlight
54 Real Answers
Automotive Powertrain
Pushes Automation
On the Go With HMI
58 Product Showcase
20 InDiscrete
ITIF: U.S. Manufacturing
Losses Worse Than Thought
April 2012 Control Design
5
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15 Articles to Celebrate
MULTI-TURN ENCODERS
Meet user requirements for
resolution and reliability.
THIS YEAR we celebrate our
EMBEDDED SWITCHES
Is it time for automation
component suppliers to get on
this bandwagon?
EXPLOSION PROTECTION AND
INTRINSIC SAFETY 101
Everything you need to know
about intrinsic safety.
energy-efficient motors.
iting some of our more timeless
7. Relays Yield More Program-
content.
Control Design has been in
print since 1997. Our website
launched in 2003. In 2009, we
switched to our latest analytics
reporting system.
With that in mind, here are
the 15 most-read articles since
To download PDF papers,
go to ControlDesign.com/
whitepapers.
all in one place, visit www.
Consider the process, select
the appropriate device, and
design a correct installation.
5. 2009 Readers’ Choice Awards
Winners: (September ’09):
toparticle.
The 2009 Readers’ Choice
15. The Fieldbus Jungle—Part
Awards winners soar high in
II (May ’11): The advan-
a sometimes unsettled auto-
tages and disadvantages of
the major process control
networks.
mation supplier sky.
4. The Fieldbus Jungle (Febru-
14. Ball Screws, Lead Screws
ary ’11): Fieldbus can be good.
Fieldbus can be bad. An experi-
Face Off (January ’09): Real-
enced integrator examines the
world differences on ball
benefits claimed and their rela-
13. PC-Based Controls Choice Still
tionship to industrial reality.
3. Steps Above the Rest (Sep-
Evolving (April ’09): Decade-
tember ’10): The 2010 Read-
old debate over PC vs. dedi-
ers’ Choice Awards winners
cated controller still rages.
have what it takes to climb
12. What Does NFPA 70E Allow?
(March ’10): What can somebody tell us about this?
11. Machine Safety Incorpo-
to the top.
2. Closed-Loop PID Algorithms
in Motion/Motor Control
(April ’07): Use differential
rates Relays, PLCs, Risk
feed forward for numerical
Assessment and Standards
controls, or integral feed
(May ’09): Don’t get burned.
backward for trajectory con-
Machine safety is no trip to
the beach.
10. 2010 Salary Survey Results
(November ’10): They say
trol of motion.
1. How Do We Synchronize Motor Speeds? (September ’02):
Experts help a reader solve
money can’t buy you love.
this problem.
Apparently it can’t buy you
This month, we also highlight
job satisfaction either.
9. Network Behemoth (April
“Accuracy” (p40), the first of a
two-part series we ran original-
’09): Does Ethernet trample
ly in April 1999, examining the
all competitive industrial
concepts and terminology used
networking alternatives?
to define accuracy of measure-
8. Efficiency Cuts Cost of
ments. Read the entire timeless
Electric Motor Operation
article at www.ControlDesign.
(February ’09): Total cost of
com/accuracy.
April 2012 Control Design
7
kbonfante@putman.net
controldesign.com
mitters Wisely (July ’02):
t
RECEIVE CONTROL DESIGN
ELECTRONICALLY
Subscribe to the digital
issue, and you’ll be able to
download a high-quality PDF
of the magazine exactly as it
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www.ControlDesign.com/
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encroach on PLCs.
6. Choose Pressure Trans-
managing editor, digital media
KNOW WHAT ACCURACY
YOU’RE GETTING
What’s accurate for one
application might be
approximate for another. When
assessing accuracy, the first step
is to understand the terms.
www.ControlDesign.com/
accuracy
capabilities increase, relays
ControlDesign.com/15birthday-
screws and lead screws.
STEM TO THE CORE
Share what you hear from
the industry about the latest
initiatives in STEM education
and workforce development.
www.ControlDesign.com/stem
Options (June ’09): As control
t
SPECIAL REPORT:
SMART. SAFE. SUSTAINABLE
Find the best of the many
presentations from Rockwell’s
Automation Fair 2011.
www.ControlDesign.com/
autofair11
2009. To read these articles
mable Machine Control
Katherine Bonfante
SPECIAL TO THE WEB
ownership can be less with
15th birthday, and we’re revis-
CONTROLDESIGN.COM
NEW WHITE PAPERS
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Perfection in Automation
www.br-automation.com
The Prodigal Job Returns
THERE’S BEEN A spate of good
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
EDITORIAL TEAM
EDITOR IN CHIEF
JOSEPH FEELEY
jfeeley@putman.net
EXECUTIVE EDITOR
MANAGING EDITOR
AARON HAND
ahand@putman.net
ASSOCIATE EDITOR, DIGITAL MEDIA
SARAH CECHOWSKI
scechowski@putman.net
Chinese-manufactured goods will
back to the U.S. from China.
be about 10–15% when actual labor
The idea that those lost jobs
content is factored in. When ship-
might someday be recovered often
ping and the risks and hidden costs
was dismissed as the musings of
of extended global supply chains
the daydream believers among us.
are considered, many companies
A newly released study by the
will find that products destined for
Boston Consulting Group (BCG,
the U.S. will bring only marginal
www.bcgperspectives.com) rein-
savings—and that manufacturing
forces the developing optimism.
these products in the U.S. could be
BCG says that production of up to
more economical.
30% of goods that the U.S. now im-
“Factory automation in China
ports from China in seven industry
is unlikely to significantly change
the equation,” BCG notes. “Install-
before the end of the decade. This
ing state-of-the-art automated
DAN HEBERT
dhebert@putman.net
would add $20 billion to $55 bil-
production lines would undercut
lion in output annually to the U.S.
the chief competitive advantage
domestic economy. Machinery and
of export manufacturing in Chi-
fabricated metals are two of the
na—low factory wages—because
groups. The other groups thought
it would reduce the labor content
to be at or near the tipping point
of products. Any labor-cost advan-
LORI GOLDBERG
lgoldberg@putman.net
COLUMNIST
JEREMY POLLARD
jpollard@tsuonline.com
DESIGN/PRODUCTION
SENIOR PRODUCTION MANAGER
ANETTA GAUTHIER
ART DIRECTOR
DEREK CHAMBERLAIN
SUBSCRIPTIONS
CUSTOMER SERVICE
888/644-1803
CIRCULATION
AUDITED JUNE 2011
Air & Gas Compressors
872
Engineering & Systems
Integration Services
8,472
Engines & Turbines
1,560
Food Products Machinery
1,848
Industrial Fans, Blowers
& Air Purification Equipment
719
Industrial Heating, Refrigeration
& Air Conditioning Equipment
1,377
Industrial Process Furnaces & Ovens
928
Machine Tools
5,622
Materials Handling, Conveyors
& Conveying Equipment
1,595
Metalworking Machinery
3,866
Mining Machinery & Equipment
699
Oil & Gas Field Machinery & Equipment 1,254
Packaging Machinery
929
Paper Industries Machinery
405
Printing Trades Machinery & Equipment 506
Pumps & Pumping Equipment
927
Rolling Mill Machinery & Equipment
210
Semiconductor Manufacturing
Machinery
1,211
Textile Machinery
242
Woodworking Machinery
308
Other Industries & Special Industrial
Machinery & Equipment NEC
6,470
TOTAL
40,020
are furniture, plastics and rubber
products, computers and electronics, appliances and electrical equipment, and transportation goods.
The shift, says BCG, combined
“Factory automation
in China is unlikely to
significantly change
the equation.”
with increased exports due to
improved U.S. competitiveness,
tage would then apply to a much
could create 2 million to 3 million
smaller portion of total costs.”
jobs, reduce unemployment by
The report contends that this
1.5–2 percentage points, and lower
business is unlikely to go else-
the non-oil-related merchandise
where, since low-cost nations
deficit by 25–35%.
such as Vietnam and Indonesia
BCG notes that in 2000, factory
don’t have the infrastructure,
wages in China averaged 52 cents/
skilled talent and supply networks
hr—only 3% of what average U.S.
to absorb all the displaced export
factory workers earned. “Since
manufacturing.
then, Chinese wages and benefits
Mexico is in the same boat,
have been rising by double digits
says BCG, and also raises safety
each year, averaging increases
concerns related to drug trade.
of 19% from 2005 to 2010. The
More importantly, Mexico’s current
fully loaded costs of U.S. produc-
production in some of the tipping-
tion workers rose by less than 4%
point industries is quite limited.
annually between 2005 and 2010,
and labor unions have become
more flexible in negotiating future
pay and benefits.”
April 2012 Control Design
9
jfeeley@putman.net
EDITORIAL ASSISTANT
t
groups could shift back to the U.S.
SENIOR TECHNICAL EDITOR
editor in chief
KATHERINE BONFANTE
kbonfante@putman.net
ing return of manufacturing jobs
t
MANAGING EDITOR, DIGITAL MEDIA
total labor-cost savings of many
Joe Feeley
JIM MONTAGUE
jmontague@putman.net
By 2015, BCG estimates, the
news about the return or impend-
EDITOR’S PAGE
controldesign.com
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Virtual Machine, Real Savings
trical control systems, hydraulics, pneumatics
and fluid transfer need to be seamlessly com-
regulatory requirements—but changes often are
bined,” observes Stephen Hooper, senior product
required because of design mistakes or changes
manager for Product Design Suite at Autodesk
in requirements. The later these changes are
(www.autodesk.com). “Our Product Design Suite
implemented, the greater the negative impact on
delivers a combination of AutoCAD Electrical
cost and schedule.
and Inventor Routed Systems to provide electro-
One way to identify discrepancies quickly is
mechanical workflow capabilities. This allows
to build a virtual model of the machine prior to
engineers to produce not only the mechanical
bending metal and assembly. Various tools exist
design necessary to address their customers’
to implement virtual designs, many of which are
requirements, but also the underlying control
aimed at the machine and robot builder market.
systems architecture.”
Mechatronics is a popular term for integrated
Once electrical schematics have been defined
design of a machine, and automation suppliers
in the 2D AutoCAD Electrical environment,
offer up their definition of what that means.
Hooper says, Product Design Suite provides the
ability to “export wiring and cabling information
approach that relies on the collaborative applica-
to the Inventor Routed Systems environment,
tion of motion design software and products, as
where it can be used to develop a 3D representa-
well as the efficient collaboration between me-
tion of the electrical design.”
are many complementary virtual design tools
at Rockwell Automation (www.rockwellautoma-
available from other suppliers. “Our CLIP Proj-
tion.com). “Using a mechatronic approach, engi-
ect design suite is a tool that helps the engineer
senior technical editor
For machine OEMs that use Autodesk, there
Michael Bayer, commercial engineering manager
t
chanical, electrical and controls engineers,” says
neers are able to reduce design time through virtual prototyping. For example, a common setback
at the end of the design process is finding that the
mechanical system doesn’t meet the application’s
“Finding performance limitations in
a virtual environment allows faster
resolution of issues.”
t
dynamic performance requirements. In traditionselect, lay out and mark our DIN rail-mounted
often responsible for selecting the coupling to at-
hardware,” says Bill Schalon, product market-
tach the motor to the load mechanism. But this is
ing manager for industrial cabinet connectivity
actually a mechatronic decision, as the stiffness
at Phoenix Contact (www.phoenixcontact.com).
of the coupling affects the dynamic performance
“This tool provides a graphical front end to our
of the load mechanism.”
product database, and includes a checking feature
that ensures that the correct components, such as
allows engineers to verify commanded vs. actual
covers and end clamps, have been selected. Once
velocity, and select appropriate tuning gains, Bayer
the rail has been laid out, the user can examine
says. “Many times, engineers find they need to go
the finished product in the software’s 3D environ-
back and choose a stiffer coupling. Finding perfor-
ment, then export the design and bill of materials
mance limitations in a virtual environment allows
to other programs such as AutoCAD.”
faster resolution of issues as opposed to finding
problems in the commissioning phase.”
Many machine and robot designers use soft-
Digital communications networks are a big part
of many modern machines, and automated analysis of these networks can verify designs prior to
ware tools from Autodesk, and the company
commissioning. “Our LogWin feature logs tag
provides a suite of virtual design products. “The
values and database error messages, and can act
design of skid-based systems for the process/
as a serial/Ethernet data analyzer when detailed
plant industry and automated machinery for
communication investigation is required,” notes
markets including automotive production are
Fabio Terezinho, vice president of consulting ser-
excellent examples of environments where elec-
vices at InduSoft (www.indusoft.com).
controldesign.com
April 2012 Control Design
15
dhebert@putman.net
al design approaches, a mechanical engineer is
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WE DIDN’T INVENT
CONTROL,
WE’RE
PERFECTING IT.
Safety Dance: Safe to Dance?
So it’s reassuring to see more safety solutions
that work hand in hand with productivity, which
these days has some safety component to it. And
is the case as integrated safety becomes more
that makes sense. Safety should be an integral part
prevalent. The trend seems to be moving away from
of pretty much every automation conversation.
forcing operators to shut things down to instead
front of mind for many machine operators or even
keeping machines running within safe parameters.
Safety is utterly important, and I don’t want to
between safety and productivity; safety and cost;
also class some of what’s reported within what I
safety and convenience.
consider the Stuxnet realm. Like safety, cyberse-
A machine that is stopped when it shouldn’t be
curity is important, but when all the information
stopped is the most dangerous kind of machine,
we can get about what a threat cybersecurity is
contended Derek Jones, safety business develop-
comes from network security providers, we have
ment manager for Rockwell Automation, at Rock-
to stop and think about the claims.
As I reported on arc flash last month, I worried
ago in Chicago. “You’ll find that somebody did
there, too, that the statistics so often quoted about
something completely well meaning, trying to
the direness and ubiquity of electrical accidents
get production back on track,” he said. “But the
came only from those companies trying to sell arc
guy hadn’t gone through all the proper steps.”
flash protection. I tried to make sure I had backup
Next thing you know, the machine starts up again
from other sources, but I’m sure I didn’t do as well
while somebody’s arm is still in the danger zone.
as I could have to make sure that, for example,
Some of the first products I saw demonstrated
“tens of thousands of electrical accidents occur
each year in industrial environments.”
to keep operators from slipping into a running
machine to make a quick—but dangerous—adjustment. The focus seemed to be on products
designed to force operators into responsible action.
A machine that is stopped when it
shouldn’t be stopped is the most
dangerous kind of machine.
Reporting on arc flash issues last month (www.
ControlDesign.com/arcflash), the same concerns
I still need to address an email that was sent to
were expressed there about operators or main-
me a few days ago, but I wanted to share a bit of it
tenance personnel who choose productivity over
here. It comes from Kim Ground, senior electrical
safety. In a presentation about arc flash mitiga-
engineer, controls, for the Surface Finishing Tech-
tion, Patrick Ostrenga, compliance assistance spe-
nologies division of Technic, who understands
cialist for OSHA, kept coming around to one key
the importance of protective gear and de-energiz-
piece of advice: “Just turn it off.” Arc flash safety
ing, but questions the stats.
is simple: De-energize before an employee works
“In my 40 years of experience as an industrial
on or near electrical contacts. Too many manu-
electrician, licensed electrical contractor doing
facturers, as Ostrenga put it, interpret their own
only industrial work including some MV work,
situations as exempt from the de-energize guide-
and controls engineer in the industrial machinery
line. “Most people confuse ‘continuous industrial
industry, I have witnessed one arc flash incident
process’ with convenience.”
25 years ago where an untrained non-electrician
Safety strikes me as one of those things that you
worker using a $9 multimeter tried to test for
might want to pay extra attention to even when
blown fuses on a 480 V system,” Ground writes.
you’re not sure you need it; kind of like looking out
“The results were spectacular, and he was tempo-
for the environment even if you don’t believe CO2
rarily injured but fortunately had no lasting inju-
emissions have anything to do with global warm-
ries. His eyeglasses (non-safety) probably saved
ing. But telling operators that they have to shut
his eyesight. Compliance with OSHA regulations
everything down seems to be exactly what’s going
in place 10 years or more ago would have prevent-
to make them take chances in the first place.
ed that accident, as would common sense.”
controldesign.com
April 2012 Control Design
17
ahand@putman.net
when I joined Control Design were new ways
t
well’s Safety Automation Forum a few months
managing editor
give the impression that I think otherwise. But I
t
plant managers. It’s a classic struggle, it seems,
Aaron Hand
And yet, from what we hear, safety is still not
LIVE WIRE
SAFETY’S BEEN ON my mind lately because, well,
it’s everywhere. It seems every interview we do
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Automotive Powertrain Pushes Automation
OEM SPOTLIGHT
Carmakers Demand More Vision, Robotics, Safety From Fives Cinetic
IN THE 1910S, Henry Ford
changed the face of manufacturing, and the automotive
industry has been at the forefront of automation ever since.
Today, automotive powertrain
assembly demands some of the
highest levels of manufacturing
controls and automation.
This is where Fives Cinetic
Automation has its primary
business; where customers
FIVES CINETIC
such as Ford, GM and Chrysler
typically dedicate large amounts
of money to the manufacturing equipment and integration.
“Our location works primarily
with automotive powertrain
(engine/transmission) in discrete
assembly and automation,” says
RIDING THE POWERTRAIN
Fives Cinetic’s typical automotive powertrain assembly/test cells are loaded
with automation, including vision and robots.
Corey Radley, technical software
manager at Cinetic Automation
The assembly requirements
future engine model or trans-
are strict, Radley says, and
mission model is designed, they
equipment is pretty controls-
could retool the existing lines
formed in 1965 as part of Inger-
heavy. “There’s a ton of ma-
quickly, cheaply, and without
soll-Rand, feeding off the surge
chine vision, a ton of robotics,
much effort to run new models.”
in automotive automation. The
and industrial Ethernet is
division was bought in 1999 by
pretty ubiquitous.”
in Farmington Hills, Mich.
Fives Cinetic Automation was
the Fives Group (www.fives-
Safety has become huge,
The use of machine vision has
grown tremendously, Radley
says, with more than half of
group.com), a €3 billion French
Radley notes, pointing to a shift
the processes now equipped
company active in industrial
from PLCs to safety PACs. “We
with cameras. Fixed 2D and 1D
automation and machine build.
even do quite a bit of safety
readers, and handheld scan-
Of about 300 employees, close
over industrial Ethernet, with
ners have become integral to
to two-thirds are in engineering
Profisafe or EtherNet/IP safe.”
a manufacturing industry that
As with other industries,
demands traceability down to
employees work at Fives Cinetic
there’s been increasing call
the bolt level. This is driven by
through a cooperative education
for more flexible machines, to
recalls and warranties—carmak-
program (see “Cooperative Pro-
enable tasks to be dynamically
ers want to know, in the case of a
vides Skilled Workers,” p62).
redesigned among machines.
recall, exactly who was respon-
“GM Powertrain worldwide
sible for the part.
or production control. And 25
The 100,000-mile warran-
Where operators are present,
ties that have become common
standardized on a new platform
for powertrains have forced
called eFACS (Flexible Automa-
unique logins let manufactur-
increased automation, Radley
tion Configuration System),
ers identify even which opera-
says. “The controls engineering
which allows dynamic process
tor worked on a specific part or
teams from these customers de-
mapping from a single console,”
subcomponent, Radley adds.
mand cutting-edge technology,
Radley cites as an example.
“There’s a full build history in
and we provide that,” he says.
“The goal would be when a
terms of variable process data.”
controldesign.com
April 2012 Control Design
19
INDISCRETE
ITIF: U.S. Manufacturing
Losses Worse Than Thought
THE EROSION OF American
manufacturing with high-
manufacturing in the past de-
valued-added manufacturing or
cade has been far more severe
opening new plants to replace
than commonly recognized,
closed ones. There is a differ-
with sharp declines not only in
ence between restructuring
employment, but also in output.
and decline. American manu-
That’s the finding of a report by
facturing is in decline.”
the Information Technology and
From January 2000 to January
Innovation Foundation (ITIF,
2010, the U.S. lost one-third—
www.itif.org), a non-partisan
almost 5.5 million—of its
research and educational think
manufacturing jobs. This is
tank that aims to formulate and
likely the highest rate of manu-
promote public policies to ad-
facturing job loss in American
vance technological innovation
history, exceeding even the rate
and productivity.
of loss in the Great Depression.
“Worse Than the Great
In addition, economy-wide job
Depression: What the Experts
losses in the past decade were
Are Missing About Ameri-
far more concentrated in manu-
can Manufacturing Decline”
facturing than during the Great
debunks widely held myths
Depression. But unlike the pe-
about productivity gains, re-
riod after the Depression or in
structuring and a manufactur-
the recoveries from recessions
ing renaissance, and reveals
after World War II, the recent
the stark reality of a historic
rebound in manufacturing has
decline in U.S. competitiveness
been far weaker than portrayed
and unprecedented deindustri-
by recent news reports, and
alization. The report explains
comes off the steepest decline
that what the U.S. is experi-
of any post-war recession.
encing is not merely another
In the face of these unprec-
boom-and-bust cycle, but a
edented losses, expert opinion
structural decline more akin
has attributed the massive
to what the U.K. experienced
job loss to manufacturing’s
in the 1960s and 1970s when it
superior productivity perfor-
lost its industrial leadership.
mance. That view is based al-
“What we discovered flies
most entirely on one number:
in the face of nearly all the
change in real manufacturing
reporting and commentary on
value added as a share of GDP.
manufacturing and reveals a
But the ITIF report finds that
disturbing truth,” said Robert
U.S. government data signifi-
Atkinson, ITIF president and
cantly overstates this macro
the report’s chief author. “U.S.
number, in part by vastly
manufacturing jobs have been
overstating value-added
lost not simply because the sec-
growth in the computer and
tor is more productive. It is pro-
electronic products sector and
ducing less. And unlike some
by miscalculating the price
high-wage nations, America is
of imports of intermediate
not replacing low-value-added
manufacturing inputs.
20
Control Design April 2012
FLASHBACK
1997-2012
April 5, 1998:
The Akashi
Kaikyo Bridge in
Japan opened,
becoming
the largest
suspension bridge in the world.
A pril 21, 1998: Astronomers
announced in Washington
that they had discovered
possible signs of a new family
of planets orbiting a star 220
light-years away.
April 14, 1999: Pakistan test-fired
a ballistic missile capable of
carrying a nuclear warhead and
reaching its rival neighbor India.
April 3, 2000: A U.S. federal
judge ruled that Microsoft had
violated U.S. antitrust laws by
keeping “an oppressive thumb”
on its competitors.
April 28, 2001:
A Russian rocket
launched from
Central Asia
with the first
space tourist
aboard. The crew consisted of
California businessman Dennis
Tito and two cosmonauts,
destined for the international
space station.
April 27, 2005:
The A380,
the world’s
largest jetliner,
completed its
maiden flight with a passenger
capability of 840.
April 21, 2009: UNESCO launched
the World Digital Library (WDL),
operated by UNESCO and the
U.S. Library of Congress.
April 3, 2010:
The Apple iPad
went on sale.
controldesign.com
©2012 Siemens Industry, Inc.
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An Electrocomponents Company.
According to the U.S. Bureau
The report shows these losses
of Economic Analysis, growth
have not been caused by declining
of output in the computer and
demand for manufactured goods,
electronics sector accounted for
but a decline in U.S. production of
more than all the output growth
those goods as the manufacturing
in U.S. manufacturing. In other
trade deficit has soared.
words, collectively the other 18
Despite the sobering findings,
U.S. manufacturing sectors pro-
the report also emphasizes that
duce less today than they did in
manufacturing is still critical to
2000. When measured accurately,
America’s economic future. Manu-
ITIF said, real manufacturing
facturing still adds $1.6 trillion to
output declined by 11% in the past
GDP, employs 12 million people
decade, at a time when the overall
and is a traded sector, which
economy grew by more than 11%.
means when we lose a manu-
That compares 35% or more manu-
facturing job because of foreign
facturing growth in prior decades.
competition it is not automatically
The report also refutes the view
that other industrialized high-skill
replaced by the market.
ITIF emphasizes that policy
nations are also falling behind
changes like a more competitive
in manufacturing. While nations
corporate tax code, increases
such as Austria, Germany, Korea,
in funding for manufacturing-
the Netherlands and Sweden have
focused R&D and programs to
seen increased or stable manufac-
train manufacturing workers, and
turing output growth, only the U.S.
increased efforts to fight unfair
and a handful of other nations (e.g.
or illegal trade practices can stem
Canada, Spain, Italy and the U.K.)
the tide and help restore the U.S.
have seen outright losses.
manufacturing base.
MERGERS, ACQUISITIONS & ALLIANCES
Rockwell Automation (www.rockwellautomation.com) purchased the
assets of SoftSwitching Technologies (www.softswitch.com), which
provides industrial power quality detection and protection systems.
Stop wiring.
Start connecting.
FFD (www.sequencesoftware.com), which makes software solutions to
help manufacturers author and deploy visual work instructions, formed
a partnership with Auburn University’s (www.auburn.edu) Industrial
Engineering Manufacturing Laboratory to support the facility’s new
manufacturing curriculum.
SmartWire-DT from Eaton
eliminates point-to-point
wiring in control cabinets
and replaces it with this
simple eight wire connector.
B&B Electronics (www.bb-elec.com), which develops wired and wireless
connectivity technology, deepened its wireless solution portfolio with the
acquisition of Conel (www.conel.cz), which makes wireless communications
routers, gateways and devices that connect cellular networks to Ethernet,
serial and other data networks. This follows soon after B&B’s acquisition of
Quatech (www.quatech.com), whose products enable machine-to-machine
communications in industrial environments.
Imagine the time and labor
savings. Learn more today.
The Assn. for Manufacturing Technology (AMT, www.amtonline.org) and
the American Machine Tool Distributors’ Assn. (AMTDA, www.amtda.org)
merged, and will use the name and existing headquarters of AMT.
controldesign.com
April 2012 Control Design
23
For more information, visit us at
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GROWTH IN BRAZIL’S market
list of Brazil’s export countries,
market is slowing. Since June
for medium-voltage drives will
and the Brazilian market is
2011, the Chinese government
outpace the market in China by
increasingly dependent on
has tightened monetary poli-
2% over the next three years,
China’s demand for iron con-
cies on bank loans, which has
with revenue growth forecast
centrate and crude petroleum.
held up many large projects,
at 18.5% annually in Brazil from
China has also increased its
such as high-speed railways,
2011 to 2014, according to two
foreign direct investment in
city metros, highways, and fac-
new studies by IMS Research
Brazil, with totals reaching
tory renovation projects. Both
(www.imsresearch.com).
almost $10 billion in 2010 and
end users and machine build-
However, China’s market is still
2011, focused largely on the oil
ers are facing financial strain
considerably larger, account-
and gas, and mining sectors.
from these policies because
ing for 28% of the world’s drive
“With China’s need for raw
investments in many indus-
consumption, compared with
materials fueling sales of medi-
just 3% for Brazil.
um-voltage drives in Brazil, high
tries slowed quickly.
Still, growth in the Chinese
The recent high growth in
forecasted growth for this mar-
market will remain strong
Brazil is driven predominately
ket will depend in part on Chi-
because of policies implement-
by oil and gas, and mining
na’s future economic health,”
ed for motor efficiency and
expansion, as well as projects
said Michelle Figgs, analyst for
continued government support
for infrastructure improve-
IMS Research. The International
of energy-saving renovations
ment. Brazil’s state-run energy
Monetary Fund predicts that
in various industries, including
company’s plan to achieve daily
China’s GDP growth will remain
mining, metals, and oil and gas.
production of 500,000 barrels of
higher than any other country
Also, resumed investments are
oil from the Tupi field discov-
during the next few years, with
expected by the end of 2012 for
ered off the coast of Brazil by
economic expansion forecast at
large-scale projects.
2020 is one of the many proj-
9.4% in 2011 and 8.9% in 2012,
ects propelling growth.
Figgs added.
The two countries are intertwined, with China topping the
Unlike Brazil, growth in the
Chinese medium-voltage drive
Average annual revenue
growth in the Chinese market for
medium-voltage drives is forecast at 16.6% from 2010 to 2015.
What
are the
crucial
considerations to
determine the correct
level detection sensor?
©2012 TURCK
askTURCK.com
INDISCRETE
Brazil Speeds Past China in
Medium-Voltage Drives
International Trade
to Accelerate Sooner
Than Expected
PREVIOUSLY FORECAST to pick up in 2015, international trade growth is now expected to begin accelerating in 2014 as the global economy enters a new period
of trade growth, according to HSBC’s Global Connec-
TEP series:
DC/DC-Converters
from 75 to 240 W for operation
without forced air cooling
tions trade forecast (www.hsbc.com/tradeconnections).
Headquartered in London, HSBC is one of the largest
banking and financial services organizations in the
world, with a network of about 7,200 offices in over 80
countries and territories. The Trade Connections report
uses that network to explore current and future opportunities for businesses operating internationally.
Because of two key trends—trade fueling more
trade, and international business looking for new
trade corridors—international businesses are expected to recover more quickly than previously expected.
The forecast predicts U.S. trade volumes to grow by
69%, somewhat less than world trade volumes, which
are forecasted at 86% growth by 2026.
“The U.S. economy is expected to grow moderately
in 2012, but our latest trade forecast shows that to
accelerate growth and keep pace with the rest of
the world, particularly the emerging world, over the
long term, U.S. businesses will want to begin better connecting themselves to international markets
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now,” said Stephen Bottomley, senior executive vice
president, head of commercial banking, HSBC–North
America. “Across industries, and across regions of the
world, the trade forecast reveals there is plenty of opportunity for many years to come for forward-looking
internationally minded companies that plan ahead.”
Overall global trade is projected to grow by $1 trillion year-on-year to 2016. U.S. trade growth rate will
increase substantially from 1.95% annually to 5.7%
between 2017 and 2021, though still below the forecasted annual world rate of around 6.2% during the
same period. However, the annual growth rate of U.S.
exports to China is expected to outpace U.S. imports
from China during the next five years.
Emerging trade corridors suggest that North
America will reduce reliance on China, while Vietnam, Indonesia, Turkey and Poland will emerge as key
trade partners, HSBC explained. Trade growth in Latin
America is predicted to grow at a third faster rate
than predicted for the rest of the world, which reflects
strong infrastructure development in the region.
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Back to the Drawing Board
secondary server had the same issues. In other
words, there was a new server that was running
My customer is a water municipality with 15
in a totally different environment that saw the
remote sites running local PLC-based control for
communication problems and the timing issues
some operations along with some local control for
of the PLC protocol. It can’t be server-based be-
chlorine and treated water. We communicate with
cause of this, I figured.
the mother ship using public network 802.11a.
In 2005, we used a lower-cost PLC with only
serial communications. The server used custom
We brought the rest of the sites online despite
the problems. We used IntraVue, Wireshark, and
normal ICMP stuff. Nothing seemed amiss.
software I’d written that used virtual serial port
We completed all our work in the field, and
drivers to communicate with hardware remotely
then went back to the server office. We still had
over the broadband wireless network.
severe network issues and were unable to connect
Ethernet device servers connected to the remote
serial ports on the PLCs at each location. Simple.
Well, yes, except that wireless latency was a
to the remote sites reliably for any given time.
Has to be the network, right? Has to be connectivity issues. Can’t be my application software. And, most importantly, it can’t be local, but
resulting application software.
maybe it’s the wireless network?
I enlisted the help of Lynn Linse, who is the
I used a piece of software from Sysinternals
called TCPView. I wondered why there were con-
wireless. He said this sort of latency required
nections to ports and IP addresses that didn’t ex-
some very special code to take just about every-
ist. In the conversion, we changed the IP address-
thing into account. My code was good, but not
es and the VLAN domains to different entities.
good enough. We had various routines to telnet
I wondered why there were a bunch of packets
into the devices to reset, and to monitor com-
destined to the old IP addresses.
t
guru of communication software for all things
The system had resident drivers installed that
connected between the devices and the application code. We found that, regardless of the reliability of the wireless network, we had all kinds
The new code was running, and
should have been well with the world.
But something happened. It all blew
up on us a day later.
of issues with gathering data.
So, as I said, we moved from a virtual serial port
In checking with the device manager in
device endpoint to a true Ethernet solution. This
Windows, the drivers for the serial port virtual
meant changing the application code to use the new
drivers were still there. Wow. So I removed them
environment. The serial port drivers and all code
again and, what do you know, the years of spo-
were uninstalled. The new code was running, and
radic network communications disappeared.
should have been well with the world. Then it all
blew up on us a day later.
We had many red herrings, including that a
secondary machine had comm issues from a
I had no ideas or options to solve this problem.
different environment at the same time as the
Back to the drawing board. I made a change to a re-
original server. But the resident drivers from a
mote PLC, and noticed a very important piece of the
previous installation were the root cause.
puzzle: The network communications went to hell
I felt really incompetent. I got over it. Who
in a hand basket. No idea why that would happen.
knew a local issue could cause a global network
I rebooted the server and all came back as nor-
meltdown? I do now.
mal. So what I thought was a network issue became a network problem and/or a server problem.
JEREMY POLLARD has been writing about technology and
The kicker is that when the server had an issue
software issues for many years. Publisher of The Software
talking with the PLCs out in the field over the
User Online, he has been involved in control system
radio network and with all the remote sites, the
programming and training for more than 25 years.
controldesign.com
April 2012 Control Design
29
jpollard@tsuonline.com
munications to reboot the server if necessary
because of repeated issues.
Jeremy Pollard, CET
really big issue for the virtual serial ports, and the
EMBEDDED INTELLIGENCE
I LIED. The network nightmare I wrote about in
January really wasn’t fixed after all.
ction Lines
It Can Be a Sure Thing to Develop Sustainable Machines and Produ
That Will Improve Your Bottom Line
orried about blowing your dough on building
stream bottling and packaging operations. These
greener machines and more-sustainable pro-
lightweight bottles are far less tolerant of the line
duction lines? Don’t be. You can’t lose.
pressure created when the conveyors on tray packers
Of course, it’s still vital to be careful and prag-
and loaders, case packers, shrink wrappers and bottle
matic in your approach to designing, building and
packers decrease speed to collect and organize them
implementing machines that use less power, pro-
for packaging, and so they can be distorted or dam-
cess more-sustainable raw materials, and produce
aged and cause processing problems.” It was clear
greener products. In the context of this article,
that Standard-Knapp had to reduce and balance the
green and sustainability mean any device, mate-
line pressures on its lighter bottles.
rial or product that requires less energy, consumes
fewer resources, and enables operators and end
Stand Out With Sustainability
users to do the same. Then, if you can add sustain-
Similarly, the commercial development team at Paper
ability to the usual goals of speed, efficiency, sim-
Converting Machine Co. (www.pcmc.com) in Green
plicity, safety and security, it becomes just another
Bay, Wis., saw going green as a way to differentiate its
required design element and specified operating
machines from their competition. A division of Barry-
parameter—and one that can generate substantial
Wehmiller, PCMC makes wide and narrow printers for
savings for users and added revenue for builders.
rewind lines for flexible packaging, tissue and wet wipes
“The message from our customers is, ‘We want to
packaging, and other equipment. So the team sought to
use less material and less energy,’” says Mike Weaver,
increase sustainability along with the efficiency of its
president and co-CEO at Standard-Knapp (www.
flagship Fusion flexographic, wide-width printing ma-
standard-knapp.com) in Portland, Conn. “All the
chine, which is the latest generation of the central im-
water bottles that our machinery works with started
pression (CI) presses it has built for 20–30 years. Because
out at 18 g of plastic, but now they’re down to about
a machine can be built greener as well as run greener,
12 g. This has a positive impact on sustainability, but
PCMC redesigned its CI press, so its 18-month-old Fusion
they’re less substantial, and this ‘lightweighting’ of
would have 46% fewer parts by combining castings and
typical PET bottles creates a ripple effect on down-
using frameless servo motors (Figure 1).
In addition, instead of using a traditional forced-air, inkdrying section, the team implemented PCMC’s FleXtreme
compressed-air drying method. Compressed-air drying is
more efficient than forced air because its speed and turbulence break the boundary layer on individual ink droplets,
drying them faster by overcoming the “skin effect” associated with forced-air systems.
Choosing compressed air might seem counterintuitive because it usually requires more energy, and so it’s viewed as a
less-sustainable approach. However, FleXtreme and its earlier,
patented eXtreme method use only 20 psi compressed air, not the
more costly 60–80 psi air used in most tools and factories.
As a result, FleXtreme’s exhaust volume is only 4,000 cfm, so
it uses far less energy than the 7,500 cfm exhaust from a typical
CI press’s forced-air system. In addition, while eXtreme runs its
compressed air over a heating element and onto its web, FleXtreme also uses heat from the compression process itself to heat
the dryer’s air, which saves both air heating costs and compressor
cooling expenses.
“We OEMs usually take the most recent machine we’ve sold, use
it as the closest reference, and then add whatever new brackets or
components are needed for the new specified concept,” says Rodney
Pennings, PCMC’s product line engineering leader for printing. “However, we often don’t take enough time to really clean up our designs.
So, to avoid risk, we just add bigger motors, and this can waste a lot
of energy. However, with Fusion, we took the time to evaluate each
part. For each one, we asked, ‘Does it add value?’ If it did, we kept it. If
not, we got rid of it. And if it didn’t add value but was still necessary,
then we tried to keep it to a minimum.” This was a time-consuming
process, but more than worthwhile in the long run.
Improving the Odds
Perhaps the best way to make sure a machine sustainability project
will be a sure winner is for its builders to open their minds to what
going green really means and what it can accomplish. It certainly
starts with increasing efficiency and saving energy on individual
machines, but that’s only the beginning. Next, green thinking
spreads quickly to designing machines that can process more sustainable raw materials and produce greener end products, which
in turn involves larger sections of production lines and
whole facilities, supply chains and communities.
controldesign.com
April 2012 Control Design
31
This is similar to quality guru W. Edwards Deming’s
principles that go beyond trying to stop defects from
reaching customers by inspection and sorting them
out, instead finding their root causes and eliminating
SOU RCE: PCMC
them. “Likewise, while it’s important to comply with
environmental rules for treating waste and limiting
pollution, it’s better to come up with a solution that
prevents waste from becoming pollution in the first
place,” says Professor John Sutherland, head of the
Environmental and Ecological Engineering Dept. at
Purdue University (www.purdue.edu). In the early
1990s, 15–18% of machining production costs were for
cutting fluids because people thought they had to use
them. However, the development of minimum-quan-
DRIER, FASTER WITH LESS POWER
Figure 1: PCMC’s Fusion flexographic printing machine was
the result of a redesign project that enables it to be built from
47% fewer parts, and implement a compressed-air system
that dries ink faster, vents half as much exhaust air, and uses
its own compression process to aid air heating and save on
cooling the compressor.
tity lubrication (MQL) methods in the past 20 years
means far less is used now.”
Christopher Zei, vice president of the global OEM industry group at Rockwell Automation (www.rockwellautomation.com), adds, “Green is not a fad or a cost.
chain in its heat-train tunnels with a plastic conveyor
belt to conserve heat and reduce energy costs.
“To some extent, these technological breakthroughs
Green is a best practice and a discipline. Green means
sell themselves,” Weaver says. “They not only help com-
savings for machine builders and their users by finally
panies become greener, but they generate cost reduc-
getting the right-sized motor on their machine and
tions in materials, labor and energy without sacrificing
saving on power. For example, one of our customers
quality. Being sustainable is a worthwhile pursuit by
had 15–18 motors on his machine, and they were all
itself, but if it costs a company an arm and a leg to get
oversized. So adopting a sustainable procedure helped
there, it makes the effort far less attractive and less
him wring a lot of capital costs out of his machine.”
achievable. Our goal is to help customers attain sustainability while justifying payback on their investment.”
Tender, Loving Packaging and Handling
Similarly, beck packautomaten (www.beck-packau-
Not surprisingly, many pioneers of the sustainable
tomaten.de) near Stuttgart in Frickenhausen, Germa-
machine building movement serve packaging and
ny, reports it’s making thrifty use of power and film in
related users, who always want to improve energy
its SXJ mobil packaging machine (Figure 2). Its “beck-
efficiency, but also strive to use less material in their
ecofficiency” program seeks to process thin films into
containers to reduce the environmental impact and
tightly enclosed, reduced-consumption packaging, as
save on material costs.
well as reducing parts that wear out, compressed air
To solve its line-pressure problem, StandardKnapp’s engineers developed Zero-Gap II Infeed for
use, setup times and required maintenance.
To help it use less compressed air, beck worked with
continuous, low-pressure conveying. This method
Lenze (www.lenze.com) to migrate the hoist drive of
ensures balanced lines and resists jams by using
SXJ’s seal bar from pneumatics to a synchronous servo
electronic population sensors to monitor bottles ac-
motor, which is directly mounted on a shaft-mounted,
cumulating in low-pressure areas, and then signal the
helical gearbox. Because its machine uses two rolls of
conveyor to increase speed, maintain balance, and let
film, beck’s packages can be sealed more precisely on
the bottles enter their lanes with little pressure and
four sides, which is especially useful for handling stacks
no gaps. Likewise, to cushion the blow of lightweight
of printed material or clothing with minimal film.
bottles dropping to cases and to avoid leaks, Stan-
To enable closed-loop control, beck built the vertical
dard-Knapp devised its Soft Catch method, which also
welding bar drive with a Lenze servo inverter, and its
handles bottles more gently and reduces shock energy
L-force platform makes sure the machine runs horizon-
by 80% compared with regular drop packers. In addi-
tally in sync with SXJ’s overall production speed. Be-
tion, Standard-Knapp is using a U-board to reduce its
cause the welding bar constantly resynchronizes itself
corrugated material and glue, and replaced the metal
with the speed of the packaging material, the edges are
32
Control Design April 2012
controldesign.com
continually joined together within the machine’s material flow. SXJ’s control system was created using L-force
Engineer software. To coordinate its axes, the frequency
and servo inverters use CAN bus, and communication
with higher-level controls occurs via Profibus.
“We’re achieving 120 cycles per minute, and we’ve
integrated the entire feed coordinating system into SXJ
without add-on modules by implementing its available
space more efficiently, and also by integrating the control
cabinet into the machine frame,” explains Julia Deharde,
beck’s control and marketing manager. “By making the
packaging process more efficient for our customers, we
boost their competitiveness, and simultaneously reduce
the consumption of energy and raw materials.”
Factory-Wide Sustainability
Once you begin to get a handle on making individual
machines and lines more sustainable, this leads to
looking at whole facilities to see if similar gains are
possible across all equipment and systems.
To improve sustainability at several plants in Europe, Volkswagen Group and its Audi division (www.
volkswagenag.com) in Wolfsburg, Germany, cooperate
BECK AND LENZE
with several partners to optimize compressed-air use
in pneumatic systems on various machines and production lines. This effort is part of VW’s membership
in the Green Car Body Technologies (GCBT) alliance
with Festo (www.festo.com), Boge (www.boge.com) and
the Fraunhofer Institute for Machine Tools and Forming Technology (IWU, www.iwu.fraunhofer.de). GCBT’s
collective goal is to save up to 50% of the energy used
during the automotive production process.
PRECISE FILM WITH SERVOS
Figure 2: Beck packautomaten’s SXJ mobil migrated from
pneumatics to servo motors and drives, and can achieve 120
cycles per minute, using two rolls of film to seal its packages
more precisely on four sides.
Thousands of enclosures
Hundreds of sizes
Next-day shipping
ENCLOSURES
POWER DISTRIBUTION
CLIMATE CONTROL
So far, the partners have surveyed and measured
and maintenance costs, and enable us to make compre-
many of VW’s body-assembly production systems,
hensive assessments for automation solutions according
and identified parameters for increasing energy effi-
to total cost of ownership (TCO) criteria during produc-
ciency via better leak prevention, reduction in volume
tion,” explains VW staffer Thomas Rommel. “We need to
due to shorter hoses, lower pressure levels and opti-
know how to realize efficiency pragmatically.”
mal drive configurations. Presently, compressed air is
As a result, Festo is implementing a planning-
used in more than 350 pneumatic actuators in VW’s
support tool at VW for simple energy-consumption
loading and unloading stations, robots with
estimates at system level and dynamic simulation at
component level. This tool enables primary energy
“Being sustainable is a worthwhile pursuit
by itself, but if it costs a company an arm
and a leg to get there, it makes the effort
far less attractive and less achievable.
Our goal is to help customers attain
sustainability while justifying payback on
their investment.”
consumers at the factories to be identified at the push
of a button, so users can immediately and moreefficiently derive requirements for compressed-air
generation and distribution. Consequently, operators will be able to compare which robots, clamping
devices and welding tongs are more energy-efficient
for various tasks over different time periods, and then
decide which is more economical to use and has better TCO in the long run.
handling and processing functions, and encapsulated
“Sometimes, real sustainability means going back
laser welding stations. Festo’s condition-monitoring
to the philosophy of how a machine or production line
systems permanently check consumption and devia-
was built, and exploring what changes are more ap-
tions to identify and record leaks or other problems.
propriate and efficient,” says Frank Latino, Festo USA’s
In addition, VW’s automated controls manage con-
product manager for valve terminals and electronics.
ventional or servo-pneumatic welding tongs, grippers,
“We’re seeing a lot more acceptance and willingness
toggle-lever clamps and pin-pulling cylinders. The
to do this lately.”
survey revealed that more of VW’s body-assembly
equipment, especially welding tongs, are moving to
Deep Green Production
servo-pneumatics because they’re easier to control and
Once the individual machine, its extended produc-
allow rapid electrode positioning, which reduces cycle
tion line, raw materials and end products, and facility
time and helps the robots work around obstacles.
have been made more sustainable, where else can this
“We were lacking transparent consumption data that
also can be applied in relation to acquisition, operating
IT INFRASTRUCTURE
concept spread? The next logical step is to turn around,
and make green its own end product and industry.
SOFTWARE & SERVICES
SURVIVAL OF THE FITTEST
In this case, MBA Polymers (www.mbapolymers.
com) in Richmond, Calif., combined three types
of plastic recycling into one 25- to 30-step plant,
which turns shredder residue, previously too hard to
recycle, into practically new plastic pellets (Figure 3).
This residue is mostly the byproducts of simpler
recycling efforts, and so it contains the shredded
remains of everything from refrigerators to PCs to
cars, including their plastic, metal, cloth, glass, rubber, foam, wood, paper and other substances.
The fi rst plant section grinds the residue down
to about 6 mm pieces, and uses several methods
that sometimes are repeated to separate as much
of the different materials as possible, including
Endurance To Withstand
The Environment
Pepperl+Fuchs is the clear choice for industrialgrade flat panel monitors and workstations. Our
visualization systems range from general-purpose
and Div. 2 monitors to fully integrated Class I,
Div. 1 systems. Manufactured with industrial-rated
equipment, a full family
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visualization
solutions include
10 to 22 inch
displays,
scanners,
keyboards,
and other
peripherals.
size and air classification techniques used in food
processing. Although it builds many of its own
machines to do these jobs, MBA Polymers also
buys some commercial machines, and adapts
them to meet its requirements.
The second plant section washes the plastics,
and further separates them by type, grade and color.
“This step is where we had to get creative, and use some
mineral mining and processing methods,” says Mike
Biddle, MBA Polymers’ president and founder. “We’ve
learned to exploit small physical, molecular manifestation differences in the plastic grades—the reasons why
they don’t like to be combined—and use these differences as a way to separate them.”
Finally, the third section takes single type, grade and
color, compounds them into made-to-order grades such
as ABS, HIPS, polypropylene, fi lled and unfi lled polyethylene and others, and then melts and extrudes them
into strands that are cut into pellets.
To make its own processes more sustainable, MBA
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Polymers implemented a variety of multivariable drives
and motors in its machines and lines, optimized temperatures applied during grinding and compounding, and even
researched the materials used in its blades to find a happy
medium between hardness and durability, Biddle says.
Both its proprietary and adapted-COTS machines are monitored by about 200 I/O points that check temperatures, amperage and voltage levels, conveyor motors, auger speeds
and other operating parameters, and they and the rest of
the plant are managed by PLCs from Rockwell Automation.
“We have I/O points and controls for each unit carrying out
the 25–30 steps in our recycling process,” Biddle says.
Pepperl+Fuchs, Inc.
Twinsburg, Ohio
330.486.0002
As a result, its initial, longstanding plant in Richmond
serves as a pilot and research facility, and MBA Polymers
has three other full-size plants running in Austria, China
controldesign.com
MBA POLYMERS
(9(5<3/$171(('6
$3$571(572.((3
7+,1*6%8==,1*
SUPERFINE SORTING
Figure 3: MBA Polymers’ three-stage plant carries out 25–30
processes to grind, sort and wash shredder residue plastic into
different grades, types and colors, and then compounds, melts,
extrudes and cuts it into made-to-order pellets. To improve its
own sustainability, the plant’s engineers have implemented
multivariable drives, but they’ve also researched and optimized
its sorting methods, heat treating temperatures, and even
the material properties of its grinding blades to improve the
efficiency and sustainability of their applications.
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and the U.K. The first two can process 94 million pounds of
shredder residue per year, and the U.K. plant is designed to
handle twice as much. Of the total shredder residue input,
50–60% is recycled into usable plastic product, but MBA
Polymers also produces a significant amount of metals and
other secondary products that it can sell, as well as some
mixed plastics than can’t be separated but can still be used
in plastic lumber and other low-end products. The remaining wood, rubber and foam are disposed of as solid waste.
“Our processes were manual when we started development 15 years ago, but we mixed in PLCs over time, so
when our plants in Austria and China opened in 2006,
they were fully PLC-controlled,” Biddle adds. “In the
future, we’ll likely monitor these facilities remotely from
California. We’ll probably add more PLCs to manage our
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separation process more closely by taking in more measurements via more I/O points.”
Instead of turning out pellets, Polyflow (www.polyflow.co) in Akron, Ohio, has developed a practical and
cost-effective pyrolysis process, which basically heats
controldesign.com
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®
Computing/HMI
Serial
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PCIe digital I/O boards offering Reed relay outputs and optically
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match your mechanical
configuration.
SOME SUSTAINABILITY
RESOURCES
Many industries, regions and manufacturing
suppliers appear to have their own green
programs, but there are some common
resources that might be useful to machine
builders and discrete manufacturers as they
seek sustainability success.
t64&OWJSPONFOUBM1SPUFDUJPO
"HFODZ&1"
www.epa.gov/sustainability
t&1"T&OFSHZ4UBSQSPHSBN
www.energystar.gov
PCIe Serial I/O
Š NN N$N&3)"4798
t/BUJPOBM*OTUJUVUFPG4UBOEBSET
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www.nist.gov/green-manufacturingportal.cfm
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RS-485 Interfaces
Š $J'>9*8
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www.nist.gov/mep/sustainability.cfm
PCIe Digital I/O
Š **)*1&>:95:98
Š 59.(&11>841&9*)35:98
t'FEFSBM5SBEF$PNNJTTJPOT(SFFO
(VJEFTGPSUIF6TFPG&OWJSPONFOUBM
.BSLFUJOH$MBJNT
www.ftc.gov/bcp/grnrule/guides980427.htm
Software for standard
PCI boards works directly
with PCI Express boards,
simplifying your transition to
next generation computing.
t$BSCPO%JTDMPTVSF1SPKFDU
BOE-FBEFSTIJQ*OEFY
www.cdproject.net
Compatible with any
PCI Express slot
t1(
www.pg.com, www.futurefriendly.com
t4VTUBJOBCMF1MBOU
www.sustainableplant.com
sealevel.com > sales@sealevel.com > 864. 843. 4343
PCIe Serial I/O
Learn more at sealevel.com/pcd/pcie-s about PCI Express
serial I/O boards or scan this QR code with your smart phone.
t$POUSPMT4VTUBJOBCMF1SPDFTT"VUPNBUJPO
,OPXMFEHF$FOUFS
www.controlglobal.com/knowledge_centers/
sustainability.html
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FOWJSPONFOUCMPH
green.blogs.nytimes.com
t/FX:PSL5JNFT%PU&BSUICMPH
dotearth.blogs.nytimes.com
PCIe Digital I/O
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© 1986-2011, Sealevel Systems, Inc. All rights reserved.
controldesign.com
dirty waste plastic in a reaction
precise drive controls, which have
vessel until it breaks down into a
improved its ink mileage by 10–15%.
fluid similar to crude oil that can be
It employs Indramat servo motors
refined into fuels. Though pyrolysis
and drives from Bosch Rexroth
has been possible for decades, Poly-
(www.boschrexroth.com), and Ki-
flow says it’s only been a few years
netix drives, Point I/O components
since it’s been possible to tweak it
and ControlLogix software from
well enough to handle multi-stream
Rockwell. Because of Fusion’s sim-
plastic sources. As a result, Polyflow
pler design and fewer parts, it re-
is working with integrator South
duced I/O points from 750 to about
Shore Controls (www.southsho-
500, networked on EtherNet/IP.
recontrols.com) in Perry, Ohio, to
Also, the team further improved
scale up to an 8½x60 ft reactor
Fusion’s ink efficiency by adding
cylinder that will continuously pro-
a force-loaded doctor chamber
cess 2.5 tons per hour. The plastic
for removing excess ink from its
waste input will result in 70% liquid
rollers. Unlike traditional, manual
product, 13% char and 17% non-
doctor chambers with blades that
condensable gas, which can help
are often set too tight and wear
run the cylinder. Also, Polyflow’s
out too quickly, Fusion’s chamber
process will need 1.7 million BTUs
automatically adjusts and often
to operate, but the liquid produced
uses lower pressure to keep the
reportedly will be able to produce
chamber and blade on its roller,
about 27 million BTUs.
and so extends blade life and reduces downtime.
Quality Time to Grow Green
Finally, because Fusion’s FleX-
Whether you’re just beginning to
treme and PCMC’s eXtreme
add more efficient motors or you’ve
compressed-air dryers both use
gone green throughout your facility
electricity, they can make better
and supply chain, becoming a more
use of renewable energy sources
sustainable organization takes time.
than forced-air drying that relies
It took PCMC’s team six to eight
mostly on natural gas, Pennings
months to evaluate Fusion’s five
says. “However, to come up with
main sections, for example, and Pen-
improvements like this, you have
nings reports they found that chunks
to take some time to sit and think
of its machine were over-designed
about them,” he adds. “You have
compared with required perfor-
to look at every part, and see if
mance. “To better update what had
it’s necessary or not. Everyone
been tacked-on before, we visited
can think of ways to make their
users to examine existing machines
machines and applications more
to check actual torque readings and
energy-efficient and sustainable,
loads on motors, and more accurately
but it won’t happen overnight.”
update our designs,” he explains. “It’s
Consequently, while there are
unusual to be able to take the time
many ways to go green—from
and go to the level that we did before
increasing machine efficiency to
even making a sale.”
designing new equipment and
Consequently, Pennings adds, Fu-
products—all can produce positive
sion also has better tension control
results and revenue if they’re given
of its web thanks to low-friction
time to grow and thrive. The only
bearings in its rollers and more
way to lose is to not play.
controldesign.com
April 2012 Control Design
39
TRANSMITTERS
TRANSDUCERS
PROX
SENSORS
ENCODERS
K N O W
PHOTOCELLS
W H A T
LOADCELLS
Y O U ’ R E
We first published this article in April 1999.
It’s a pretty timeless article that’s well-suited
for our anniversary look back at the content
we’ve produced during Control Design’s
15 years. This is a large excerpt from Part I of the two-part
article. Part I examines the concepts and terminology used
to define accuracy of measurements. Part II explains how to
combine errors within an instrument or system to provide an
estimate of total error. You can read it in its entirety at www.
ControlDesign.com/accuracy.
The importance of accurate measurement is critical to control system designers and engineers. Both of them
have a direct incentive to make sure
their machines are providing the most
accurate outputs possible.
The thickness of their paychecks is
ultimately determined by how well customers benefit from the accuracy and precision in the equipment they build. That
customer will judge the OEM by how
well the machine produces his product
and by what it took to produce it.
In other end user machine environments, accuracy might be less important.
There could be less concern if readings
aren’t exact, as long as there’s enough
usable product to keep the boss off their
back. Only if they’re lucky is that likely.
These days, increased competition
40
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G E T T I N G
and government regulations have boosted the demands for
improved operating efficiency, business unit accountability,
cost leadership, and quality certifications. The accuracy of
measurement and control systems is of greater concern. Extensive applications of computers, data collection facilities,
and databases are relying on accurate measurements.
When an OEM provides a system to accurately measure all
the control variables, from web thickness to milled dimensions to chamber temperature, it helps the end user eliminate
waste, improve efficiencies, and reduce costs. Businesses are
putting stricter accountabilities at lower levels in business
units, and that requires accurate
internal accountability for the
unit as well as for intercompany
or intracompany transfer.
X X
So accuracy is important. But
X XX
what
is accuracy? The language
X XX
of accuracy is not universal, and
any discussion depends on a common understanding of terminology. For definitions of commonly
used terms, see the sidebar.
Absolute Accuracy
or Repeatability?
FIGURE 1: BIAS VS. PRECISION
The shift of the bullet holes from
the bull’s-eye center is the bias error, and the tightness of the bullet
pattern is the precision.
By definition, all accuracy is
relative: how accurate a measurement is compared to a standard.
When discussing the error of an
instrument or system, we need to
determine what form of accuracy
AN ACCURATE GLOSSARY
we need for a particular function. Absolute accuracy refers
to how close a measurement is in relation to a traceable standard (see the traceability pyramid in Figure 2).
“Repeatability,” on the other hand, refers to how accurately a measurement can be duplicated or repeated. The
term “repeatability” in this context is the common field
usage and not the ISA definition of the term. The common field usage is essentially the same as the ISA term
“reproducibility”; that is, the combination of linearity, repeatability, hysteresis and drift.
If it is important that you make a measurement in reference to an absolute value, we are talking about absolute
accuracy. When most people talk about accuracy, they talk
about absolute accuracy. In order to have absolute accuracy for your measurement, you must have traceability from
your measuring device to the National Institute of Standards and Technology (NIST)/National Bureau of Standards (NBS) reference standards (the “golden rulers”). The
accuracy of your measurements is directly dependent on
the accuracy of your calibrators, which is directly related
to the care and feeding of your calibrators, the calibrators’
calibration cycle, and the traceability of your calibrators.
In a plant where ambient and process conditions can vary
substantially from a reference condition, the OEM needs to
understand how the end user will attempt to maintain accuracy, and this can be a daunting task to simulate. Calibration
cycle and methods, instrument location, instrument selection, maintenance, recordkeeping and training all become
important issues in maintaining instrument accuracy. A
formal calibration program is the only way to ensure accuracy of instrumentation. This is essential for achieving and
maintaining an ISO 9000 certification.
In days past, and probably today in some plants, it was
not uncommon for an operator to control a flow to so many
“roots” or some other variable to so many divisions. Here
the concern is how repeatable the measurement is—if we
are controlling to seven roots today, we want seven roots
tomorrow to be the same thing. We want the instrument to
provide the same value each time for the same process and
operating conditions.
Many controllers that have relatively crude setpoints,
such as pneumatic controllers and HVAC thermostats, specify “repeatability.” The object is to maintain an acceptable
setpoint, with little concern about the absolute value.
More critical applications such as laboratories and research facilities often use calibration curves. The accuracy of measurement or control is related to a particular
Accuracy: The degree of conformity of an indicated value to
a recognized accepted standard value.
Accuracy for instruments is normally stated in terms of
error (±0.05% of upper range value [URV], ±1% of span,
±0.5% of reading, ±¾ degree, etc.).
Accuracy can also be stated in terms of bias and precision
errors. Looking at Figure 1, the shift of the bullet holes from
the bull’s eye is the bias, and the tightness of the bullet pattern is the precision error.
Bias could be known or unknown. An example of a
known bias is the deviation of a calibration standard from
a National Institute of Standards and Technology (NIST)/
National Bureau of Standards (NBS) reference. Large known
biases are normally calibrated out. Small known biases are
normally compensated out.
Examples of unknown biases include human error, installation effects, environmental disturbances, etc.
Precision errors are considered statistically random. They
can be stated as the product of the measurement’s standard
deviation and Student T distribution, which will provide an
error specification to the 95% confidence level.
Also random are errors specified for transmitters, calculation devices, constant uncertainty, recorders, input/output
devices, etc. Bias and precision errors can be individually
combined using the root sum square (RSS) method, then the
bias and precision errors can be combined:
where:
E = total probable error; B = total probable bias errors;
b = bias errors; P = total probable precision error; and
p = precision errors.
Absolute accuracy: How close a measurement is to the NIST/
NBS standard (the “golden ruler”). The accuracy traceability
pyramid is shown in Figure 2.
Conformity: The maximum deviation of a calibration
curve (average of upscale and downscale readings)
from a specified characteristic curve. Conformity can
be independent (best fit), zero or terminal-based. This
spec is commonly used as a measure of how close an
instrument converts a non-linear input signal to a linear
output signal.
41
TRANSMITTERS
TRANSDUCERS
PROX
SENSORS
ENCODERS
PHOTOCELLS
LOADCELLS
reading, which is then translated to an absolute accuracy
value using a calibration curve. For this type of measurement, we again are talking about repeatability. For devices
in which influence errors are minimized and the drift error is controlled by the calibration cycle, this method can
reach a higher level of accuracy.
Error Specifications
Manufacturers specify error limits for an instrument.
These are not the actual errors that a particular instrument will have, but rather the limits of the error that
the instrument could have. On an individual basis,
a given instrument might be able to be calibrated
to a higher accuracy than its specification, and a
group of the same instruments will fall within
the error specification.
FIGURE 2: TRACEABILITY PYRAMID
Absolute accuracy refers to how
close a measurement is to a traceable standard, such as NIST/NBS.
Deadband: The range through which
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If a manufacturer states an error specification, it is
generally true to within the vendor’s testing methodology. The user should question any manufacturer that
does not give an error specification. You could find that
there is a good reason the specification was left off. But
manufacturers do not typically give just one error
specification. Instead, they give multiple specifications and sometimes in different ways.
This is because the error will typically
vary when ambient and process conditions vary from the reference conditions where the instrument is
calibrated, and the different
error specifications allow the user to determine the probable error
at other conditions. So
in reality, these error
specifications define
an error envelope. An
example of the error for
a generic transmitter is
given in Figure 3.
get to a safe state in a timely manner.
an input signal may be varied upon re-
pensate for variations in operating
conditions. Influence errors are often
versal of direction without initiating an
EMI/RFI errors: Errors caused by
significant contributors to the overall
observable change in the output signal.
electromagnetic or radio frequency
error of an instrument.
interference.
Drift or stability error: The undesired
Inherent errors: Errors inherent in an
change in output over a specified period
Filter error: Error caused by the im-
instrument at reference conditions.
of constant input under specified refer-
proper application of a filter on the
These are caused by the inherent
ence operating conditions.
signal. This error can also be caused by
mechanical and electrical design and
improper settings in exception report-
manufacturing of the instrument.
Dynamic error: The error resulting
ing and compression algorithms.
from the difference between the
Linearity: The deviation of the calibra-
reading of an instrument and the
Hysteresis: The dependence of the
tion curve from a straight line. Linear-
actual value during a change in the
output, for a given excursion of
ity is normally specified in relation to
actual value. Instrument damping con-
the input, upon the history of prior
the location of the straight line in rela-
tributes to this error as does measure-
excursions and the direction of the
tion to the calibration points: indepen-
ment and transport deadtime, and the
current traverse.
dent (best straight line fit), zero-based
significance depends on the process
42
(straight line between the zero calibra-
time constant. Dynamic error must be
Influence errors: Errors caused by
tion point and the 100% point) or
considered when designing safety sys-
operating conditions deviating
terminal-based (straight line between
tems—if your instrumentation system
from base or reference conditions.
the zero and the 100% calibration
cannot measure a developing hazard-
Typically specified as effects on the
points). Devices are normally calibrated
ous condition in time for the safety
zero and span, these errors reflect
at zero and at their upper range value
system to react, the process might not
the instrument’s capacity to com-
(URV)—the terminal points.
Not All Errors Are Created Equal
Errors are specified in a number of
different ways. In order to compare
and combine error specifications,
they must all be of the same type.
Some of the typical error specifications are as follows:
±0.2% of calibrated span including
the combined effects of linearity, hysteresis and repeatability;
±0.2% of the upper range limit
(URL) at six months from calibration;
±0.1% of calibrated span or upper
range value (URV), whichever is
greater;
±0.5% of span per 100 °F change;
±0.75% of reading; ±1 °F;
±½ count; and
±1 least significant digit (LSD).
Transmitter reference accuracy
is typically rated in percent of span
or URV, and primary measuring
FIGURE 3: ERROR VS. AMBIENT TEMPERATURE
The error due to ambient temperature for a generic transmitter is a combination of the reference accuracy and temperature error. Because of cancellation, the total probable error is less than the worstcase error.
Overrange influence error: Error
measurements. In digital systems, this
the output for the same value of input
resulting from the overranging of the
is related to the number of bits of
made under the same operating condi-
instrument after installation. This is
resolution of an analog signal (e.g.,
tions over a period of time, approach-
normally a zero shift error.
the analog span divided by the count
ing from both directions. Reproducibil-
resolution).
ity includes the effects of hysteresis,
Power supply effect: The effect on
deadband, drift and repeatability.
accuracy caused by a shift in power
Repeatability: The degree of agree-
supply voltage. This error could also
ment of a number of consecutive mea-
Sampling error: The error caused
apply to the air supply pressure for a
surements of the output for the same
by sampling a signal with too low a
pneumatic instrument.
value of input under the same operat-
sampling frequency. In general, the
ing conditions, approaching from
sampling frequency should be at least
Reference accuracy: Accuracy, typi-
the same direction. Note that this
twice the highest frequency in the
cally in percent of calibrated span,
specification is approaching from one
signal being sampled.
specified by the vendor at a reference
direction and does not include any
temperature, barometric pressure,
effects of hysteresis or deadband. The
Temperature effect error: The percent
static pressure, etc. This accuracy spec
repeatability error specification is the
change in zero and span for an ambient
may include the combined effects of
largest error determined from both
temperature change from reference
linearity, hysteresis and repeatabil-
upward and downward traverses. The
conditions. This can be a significant
ity. Reference accuracy also may be
field or common usage of this term is
contributor to the total error.
stated in terms of mode of operation:
closer to the term “reproducibility”
analog, digital or hybrid.
than to the ISA definition.
Vibration influence error: The error
caused by exposing the instrument to
Resolution: The smallest interval that
Reproducibility: The degree of agree-
vibrations, normally specified per g of
can be distinguished between two
ment of repeated measurements of
acceleration and up to some frequency.
43
TRANSMITTERS
TRANSDUCERS
PROX
SENSORS
ENCODERS
PHOTOCELLS
LOADCELLS
elements such as turbine meters and thermocouples
are rated in percent of reading or actual measurement
error. For a transducer that is connected to a thermocouple, the error specifications are not the same—the
former is typically in percent of span or URV, and the
latter is in percent of reading. To combine these errors,
they must be the same type.
Digital device errors are usually resolution errors that
are related to conversion errors, roundoff errors and numerical precision. For example, a 12-bit resolution input
device resolves the signal into 0–4,095 counts. It cannot
resolve to less than a ½ count out of 4,095 counts.
Roundoff error occurs when a digital device rounds off
a partial bit value: ¼ bit, ½ bit, etc. These errors can also
be specified in terms of the least significant bit (LSB). For
digital displays, errors are typically stated in terms of least
significant digit or in percent of reading.
Precision errors involve the kind of math that is being
done: single precision vs. double precision, integer vs. floating point math, etc.
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Actual Errors
The error stated in the error specifications represents the limits of the error, not necessarily the error that the device will
exhibit in the field. Actual error can be determined by testing
the instrument in use and under process ambient conditions.
Testing a single instrument does not provide sufficient
data to characterize a group of the instruments, but there are
statistical methods that can be used when a small group of
instruments are tested to estimate the accuracy of the instrument in general. This can be particularly useful in comparing manufacturers.
The actual errors determined during calibration can be
compared to prior calibrations for the same instrument to measure the need to service or replace the instrument or to change
the calibration cycle. This is becoming much more practical
with the advent of calibration management systems that can
easily retain the calibration history of an instrument.
William (Bill) L. Mostia Jr., P.E., is a process control and engineering
consultant. He can be reached at wlmostia@msn.com.
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Machine-Mount I/O Go Everywhere
Wadowick says. “To serve in more diverse appli-
your cabinet or other comfy shelter, you can travel
cations, more machine-mount I/Os are sealed and
anywhere to provide assistance—if you bring the
IP67-rated against dust, oil and water, and extend
right tools and protection. This is just as true for
their range to -13 to 140 °F for normal operations.
machine-mounted I/O devices.
We keep a close eye on our customers’ applica-
“Builders want to get the costs out of their
tions, and adapt to help fill any gaps that appear,
such as installing safety I/O components to detect
same people, and so they’re learning they can
a safe-stop condition about 200 ft up in windmills
assemble controls faster with machine-mount
that are, by turns, colder, hotter, windier and
I/O,” says Will Healy, marketing manager for
harder to reach than other settings.”
networking products at Balluff (www.balluff.com).
Charlie Norz, I/O product manager at Wago
tory reforms allow many popular I/O compo-
have been investigating out-of-cabinet I/O in the
nents governed by IP20 to take on their own IP67
past two years, especially machine builders and
protection, so they can do many of the same jobs
process industry applications seeking to reduce
outside their former enclosures.
terminations and wiring. “IP67 allows just one I/O
block on the machine, so there’s only one wire
t
“Customers are demanding higher IP ratings
from it to the solenoid or RTD and only two termi-
manager of the Intelligent Systems Group at
nations,” he says. “Using a cabinet requires four
Pepperl+Fuchs (www.pepperl-fuchs.us). “Where
terminations or more.”
Machine-mount I/O blocks also are becoming
customers won’t settle for IP65 any longer, and
more sophisticated and diverse, and so digital
really want IP68/69K.”
I/O points are being joined by data on electrical
To achieve this machine-mount I/O simplicity,
single- and two-piece designs are best, Hornis explains. “Fifteen years ago we designed I/O housings with bases that contained moving parts,” he
notes. “Now this same functionality is available
“When you go IP67, it means using
pre-built I/O blocks and standard
cable lengths, which also simplifies
installation.”
in designs that are simpler, more rugged, and offer higher IP protection at lower cost. Installation
current, encoders, RTD modules and serial com-
time probably is reduced by a factor of five to 10.”
munications, Norz says. “This allows users to do
Pepperl+Fuchs offers Connect & Done I/O
a lot more tasks on the IP67 platform. In fact, our
modules, which are so small that most users don’t
Speedway IP67 PLC can even do high-speed data
even need to mount them in the usual way, Hor-
processing at this device level, instead of the tra-
nis adds. “Once connected to the network cable,
ditional approach of sending it back to a higher-
they’re simply dropped into the cable tray.”
level controller and waiting for a response.”
Free of its cabinet-based straightjacket,
To help machine-mount I/O protected by IP67
machine-mount I/O devices have diversified,
journey further onto equipment in the field, many
too. Adoption of I/O modules with sealed con-
users employ IO-Link (www.io-link.com), a field-
nectors has picked up speed for five or six years,
level, intelligent networking method for sensors,
and suppliers also provide more interface types
actuators and other components on machines and
and capabilities, such as functional safety, mo-
other equipment. “IO-Link is point-to-point, but
tion control and position feedback, reports Kurt
it requires fewer conductors, and so it simplifies
Wadowick, I/O specialist at Beckhoff Automation
cabling,” explains Frank Latino, product manager
(www.beckhoffautomation.com).
for valve terminals and electronics at Festo (www.
“I/O density has increased from eight in a single
festo.us). “This means the same four-wire, two-
width to 16 in a double width, and there are more
signal cable used for a proximity switch also can
types of I/O, such as those for encoder inputs,
be used to control a manifold of 24 valves instead
motor drives and I/O-Link for communications,”
of the complex and costly cables it used to need.”
controldesign.com
April 2012 Control Design
47
jmontague@putman.net
and simpler installation,” says Helge Hornis,
IP65 used to be good and IP67 was great, many
executive editor
(www.wago.us), agrees that more potential users
t
Consequently, technical advances and regula-
Jim Montague
machines and produce them faster with the
TECHFLASH
ONCE YOU’RE WILLING and able to get out of
Festo’s CPX machine-mount I/O
pick rugged I/O blocks for RFID,
and CPI networking system will
analog, discrete, temperature or
soon be joined in the U.S. by CTEU,
specialty tasks. These products can
a simple, low-cost, distributed I/O
withstand extreme temperatures,
that’s IP65- and IP67-rated.
shock, vibration and environmen-
Many users want machinemount I/O that can perform
tal protection up to IP69K.
Balluff’s Healy agrees that using
distributed motion, safety and
Ethernet to access web functions
specialized interface jobs, accord-
is getting easier for distributed I/O
ing to Corey Morton, solutions ar-
devices. “Previously, we needed a
chitect at B&R Automation (www.
node or IP address for each device
br-automation.com). “The way our
added to a machine’s network, but
X67 and X20 I/O modules are con-
distributed modular I/O means we
nected, their form factor doesn’t
can hook them all up via one IP
matter,” Morton explains. “We can
address,” he explains. “Basically,
interconnect each randomly, and
we can collect information from
they all can sit behind a user’s
digital I/O points, analog channels,
chosen fieldbus interface. What’s
controllers and smart devices, and
new is that digital I/O enables us
put it through one IP67-enabled,
to handle mixed analog signals,
Ethernet component.” Besides its
temperature modules, fieldbus
distributed, modular I/O devices,
interfaces, automatic configuration
Balluff provides an IP67 machine-
and web servers.”
mount power supply, so users don’t
Similar to its XV valve control module that connects onto a
manifold, B&R has a new motion
have to add a junction box every
time they need 24 Vdc power.
Likewise, Phoenix Contact
module, AcoposMulti65m, which
(www.phoenixcontact.com)
mounts directly onto a motor
launched its Factory Line (FL)
frame, and has a built-in Ethernet
1605 Ethernet switch to join its
Powerlink hub. “It’s all about giving
Field Line Modular (FLM) IP67 I/O
users more options, whether it’s
components. “Machine-mount I/O
safety, fieldbus, less programming
and Ethernet switches with M12
or web servers,” Morton adds.
connections mean we can daisy
Turck (www.turck.us) has also
chain IP67-based I/O, and bring
invested in machine-mount, IP67-
multiple functions closer to their
shielded I/O, especially for multiple
sensors and production flows,”
Ethernet-based protocols. “This
says Jason Haldeman, Phoenix
approach makes moving between
Contact’s I/O products marketing
protocols, or simply implementing
specialist. “Also, when you go IP67,
a fieldbus for the first time, plug-
it means using pre-built I/O blocks
in simple,” says Randy Durdick,
and standard cable lengths, which
director of Turck’s network and
also simplifies installation.”
interface division. “These multi-
Of course, once IP67-rated,
protocol products are self-configur-
machine-mount I/O uses Ethernet
ing, recognizing the protocol of the
to reach the web, then wireless
master automatically, which offers
capabilities are sure to follow. In
seamless transition to whatever
fact, Phoenix Contact already has
type of Ethernet they need.”
wireless I/O modules, while its
For especially harsh conditions,
FLM Bluetooth adapter secures
Turck developed configurable
its machine-mount I/O signals
block I/O, which allows users to
within 10 m.
48
Control Design April 2012
controldesign.com
New Materials, Customization Keep Systems Running Smoothly
THE REALM OF MECHANICAL motion com-
Thomson incorporates polymers into its bear-
ponents is one inhabited by rail guides, slides,
ings that create a spacer in between each ball in
gearboxes, actuators and more. Many of the con-
a circuit. It’s part of a movement toward “lube for
figurations are similar, and the fundamental me-
life,” Castelli explains, in which customers need
chanical aspects really haven’t changed that much
not worry about keeping bearings lubricated.
over the years, but don’t be fooled into thinking
that there isn’t innovation taking place there.
Mechanics of any kind are likely to limit speed
TRUST THE THRUST
Linear thrusters push,
pull or carry a payload
some type of mechanical coupling to the motor
for distances less than
or fi nal motion element, so manufacturers are
1 m. They are suited to replace
taking steps to better couple those parts, and to
internally designed belt or linkage
improve any elements that affect wear and tear.
systems that convert rotary into linear
End users are increasingly asking for more
motion. They provide velocity to 5 m/s and accel-
configurable tools, where existing systems
eration to 12 Gs. A washdown version is available.
don’t quite fit their applications. “Customiza-
Rockwell Automation; 414/382-2000; www.ab.com
tion of these units is bubbling to the top,” says
Pete Castelli, engineering manager for Thomson Systems (www.thomsonlinear.com), which
TOOL SECURITY
uses mechanical components such as linear
Power drawbar holds cutting tool in the spindle
guides and ball screws from sister companies
taper with gripper fi ngers that are pulled into
to build pre-engineered systems for customers.
the taper with the spring pack. Loss or reduction
Those customers are making more requests,
in hydraulic pressure will not release the tool.
he says, for their specific stroke, rail lengths,
geometries and more.
Key to performance is being able to match
motors more closely with the mechanical components, argues Nuzha Yakoob, Festo (www.
festo.us) product manager, positioning. “Some
The power-off design requires pressure applied
companies only sell the mechanical actuator,”
to the hydraulic piston and transmitted through
she explains. “Other companies only sell rotary
the rod to push the clamping sleeve down.
motors or servo motors. By being able to do both,
Ott-Jakob/Advanced Machine & Eng’g;
we can integrate the two very easily.”
800/225-4263; www.ame.com
Beyond that, innovations are taking place
with bearings, trying to reduce the wear and
tear that can slow a system down or even cre-
SLIDE SMALL
ate catastrophic failure. “Performance really
Microslide
comes from the speeds and accelerations that
linear actuator
you can attain from the linear motion technolo-
has 15 μm/step
gies,” notes Scott Carlberg, product marketing
resolution and
manager, motion products, for Yaskawa (www.
maximum load of
yaskawa.com). “So you try and pick bearings
13 N with a 64 mm
that will allow you to maximize that.”
maximum stroke length. The slide load carriage
Primarily that means having the least
is made from self-lubricating polyacetal and
amount of friction as possible in the system.
features a built-in clearance take-up mecha-
Yaskawa is even looking at air bearings for
nism for load rigidity during motion.
some custom applications, Carlberg says.
Haydon Kerk; 203/756-7441; www.haydonkerk.com
controldesign.com
April 2012 Control Design
49
cdroundup@putman.net
capabilities, but most motion systems require
PRODUCT ROUNDUP
Mechanical Innovation in Motion
PRODUCT ROUNDUP
IT’S AN ORIGINAL
THE ANGLE IS RIGHT
All stainless steel Original
W37/W47 Spiroplan
Line cylinders in-
right-angle gear units
clude 12 bore sizes
with aluminum hous-
5 16
/ -3 in. bore
ings are lubricated
with stainless
for life, and can be
steel end caps,
mounted in any ori-
standard urethane wip-
entation (except M4) with the same amount of oil.
ers, PTFE-based rod and pivot
First-stage helical gearing and second-stage hyp-
bushings, and food-grade synthetic grease.
oid gearing combination provide high mechanical
Bimba; 800/44-bimba; www.bimba.com
efficiency and low energy consumption compared
with worm gear units.
SEW Eurodrive; 864/661-1122; www.seweurodrive.com
FAST TRAC
Sigma Trac SGT linear actuators have automatic
motor recognition, and speeds to 5 m/s and
STRONG PROFILE
acceleration to 5 Gs. A Large integrated cable
400 Series Profile
carrier allows space for peripheral cables
Rail Linear Guides
and hoses, and covers and additional
are available in 4 m
accessories are available.
lengths with rail sizes
Yaskawa; 800/927-5292;
5–45 mm in 5 mm
www.yaskawa.com
increments. They
include double-faced
ball track bearing arrangements with standard or
LINEAR AND PARALLEL
ball cage carriages that use the same rail design.
EGSL electric slides operate with linearity
Guides are rated to handle loads 9800–129,500 N.
and parallelism to an accuracy of ±0.0006 in.
Thomson; 540/633-3549; www.thomsonlinear.com
for strokes to 11.8 in. The ball screw is
enclosed, and slides are available in
four slide-width sizes of 1.4,
FAST RIGHT TURN
1.8, 2.2 and 3 in.
Zero-Max Crown right-
Festo;
angle gear drives with
631/404-3173;
AGMA Class 10 spiral
www.festo.us
bevel gears and nonmagnetic stainless
steel shafts have precision
LINEAR ACTUATOR
hardened and ground ball bearings
ETH Series rod-style electric actua-
for speeds to 2,000 rpm. The internal gears are
tor cylinder has three profile sizes
permanently mounted to the shafts with locking
with either in-line or parallel
pins. Standard two- and three-way models have
motor mounting configurations.
1:1 and 2:1 speed ratios in shaft diameter combi-
Design elements include Class
nations of 3/8, ½, 5/8 and ¾ in.
7 ball screw with ground nut,
Zero-Max; 800/533-1731; www.zero-max.com
angular contact thrust
bearings, ground and
polished stainless
ACTUATOR ALTERNATIVE
steel thrust tube, and
ACT linear motor ac-
parallel timing-belt
tuator alternative to ball
tensioning station.
screws and belt drives has
Parker Electromechanical; 724/861-3221;
travel ranges 100 mm to 1.5 m,
www.parkermotion.com
acceleration capability to 5 g,
50
Control Design April 2012
controldesign.com
version has a matte silver, hard-chrome-plated
output to 270.7 N with a maintenance-free,
steel body. The line sizes range 25–55 in accuracy
direct-drive, zero-cogging motor and noncon-
classes P and SP.
tact optical linear encoder.
Bosch Rexroth; 800/322-6724;
Aerotech; 412/963-7470; www.aerotech.com
www.boschrexroth-us.com
AIR POWER
CAM-DRIVEN
Nitra pneumatic line of
Camco RSD zero-back-
stainless steel, round
lash, cam-actuated
body, non-repairable
drive can be used with
cylinders feature type
both rotary and linear
304 stainless steel bod-
systems. It is compat-
ies with double rolled-in
ible with a variety of
construction with high-
industry-standard
strength aluminum al-
servo motors, and offers ratios of 4:1 to 18:1 in
loy porting ends. Single- and double-acting models
a single stage. Output options are large fl ange
are available with nose, pivot and double-end
with through hole, 32 mm diameter shaft,
mounting options. Some models are available with
external shrink disk for 30 or 40 mm shaft, and
magnetic pistons for position indication. Bore sizes
internal shrink disk for 30 mm shaft.
range 7/16 –2 in. Depending on bore size, available
De-Sta-Co; 248/836-6750; www.destaco.com
stroke lengths range ½–18 in.
AutomationDirect; 770/889-2858;
www.automationdirect.com
TO MEASUREMENT AND BEYOND
Infinity 1 roller screw actuator has an
IP rating of IP64+ and possible IP68
GEARED TO GO
(motor-dependent) via a
Precision planetary
hermetically sealed case.
gears for synchronous
The enclosed integrated
and stepper motors
position transducer
are single-stage for
offers absolute posi-
gear ratios i=3, 4, 5,
tion measurement in analog and SSI output. The
8 and 10, and have
integrated load and torque sensor offers absolute
≤8-15 arcmin backlash. The gears are also of-
load measurement in analog mV output with no
fered in two-stage or three-stage designs. The
translating wires.
premium series provides backlash ≤1 arcmin as
Nook Industries; 800/321-7800;
an option paired with high-output torques. The
www.nookindustries.com
planetary gears are delivered fully mounted on
8LSA, 8LVA, 8JSA and 80MP series motors.
B&R Industrial Automation; 770/772-0400;
SMOOTH SLIDING
www.br-automation.com
Series FGXS twin bore,
precision table slides
have a rail bearing sys-
SLIMMER, STRONGER
tem for smooth opera-
Slimline-normal
tion. Magnetic pistons and
and slimline-long
sensor mounting slots are standard. Optional sen-
runner blocks re-
sors feature surge protection, polarity protection,
place ball rail with
LED indicator, and fast switching speeds. Options
roller rail systems
include adjustable stroke and shock absorbers,
to increase the load
bores 8–25 mm, and strokes to 150 mm.
capacity of the axis. Corrosion-resistant Resist CR
Fabco-Air; 352/373-3578; www.fabco-air.com
controldesign.com
April 2012 Control Design
51
PRODUCT ROUNDUP
velocity to 5 m/s, maximum continuous force
PRODUCT ROUNDUP
PROTECT YOUR LOWER BACKLASH
tions include 304 stainless steel tubes for low
RLSS rod locks,
breakaway, anodized heads for extra corrosion
Generation 2,
protection, sintered bronze bushings, U-cup
with optional
piston seals, and accessories.
embedded engage-
Clippard Instrument Laboratory; 513/521-4261;
ment sensor de-
www.clippard.com/cylinders
liver holding forces
to 5,000 lb with low
backlash. A clamping collar
CONTROL THE TURNS
applies a 360° holding force around the cylinder
SLM and SLG
rod. Models are CE-marked and RoHS-compliant.
rotary actuators
Nexen Group; 651/484-5900; www.nexengroup.com
with Class I, Div.
2 certification are
suited for operat-
CYLINDER LINE
ing quarter-turn or
Line of pneumatic
multi-turn valves
Minimatic cylinders in
or shaft drive dampers. Directly coupled shaft-
stainless steel, brass,
to-shaft, these actuators eliminate cumber-
metric, corrosion-
some mechanisms needed by pneumatics. To
resistant and compact
meet application requirements, the Class I,
series are offered in
Div. 2 rotary actuators are also available with
12 bore sizes with
resolver feedback and handwheel options.
strokes to 40 in. Op-
Exlar; 952/368-3434; www.exlar.com
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INDUSTRY PARTNER:
PRODUCED BY:
OFFICIAL PUBLICATION:
WE INTEGRATE MULTIPLE machines into a
complete manufacturing process line. The operator has to physically attend to all of the machines.
Rather than have an HMI at each machine, we’re
thinking about handheld HMI, maybe wireless,
that the operators would carry with them. We’d
like to hear about experiences with this approach.
—From February ’12 Control Design
ANSWERS
Single-Operator Capabilities
INTERSTATES CONTROL SYSTEMS
controldesign@putman.net
REAL ANSWERS
On the Go With HMI
The ease and cost of deploying your handheld
HMI solution will depend on a couple of criteria:
the level of functionality you desire from the
handheld, and your current infrastructure.
A remote access capability that allows operators and plant managers to view the system from
anywhere can be quite simple. Being able to see
the entire operation in real time can be extremely
MOBILE FLEXIBILITY
helpful when a plant manager or maintenance
Mobile HMIs can enable a facility to run with only a single
operator on staff at any given time.
personnel get a call from an operator in the middle of the night, allowing them to log in remotely
to either dismiss the alarm or help the onsite
We selected Intermec model CN4-C PDAs as the
team troubleshoot over the phone. If you are
mobile HMI hardware for this facility primarily
looking for the full functionality of your current
because of the intrinsic safety rating. The plant
stationary HMI in a mobile platform, a system
had an existing control system that used Facto-
integrator or your distributor can help you deter-
ryTalk View Site Edition HMI software from Rock-
mine the best design and components to use.
well Automation for visualization. We created an
We recently installed a mobile HMI that offered
app for FactoryTalk View SE that allows the PDAs
full manual control of all machines and devices
access to the system via remote desktop session.
at a flour mill. The mobile HMIs also have barcode
The screens from the stationary control system
scanners, so operators can scan a machine or
HMI were optimized for the mobile platform.
component and the HMI automatically will bring
up the manual control screen for that device.
Prior to getting the handhelds, in the case of
A centralized security service adds the ability to
configure user and group permissions within the
system so only verified users are able to log in via
an alarm, a plant operator would have to travel
the stationary system or the mobile HMIs. If you
as many as six stories to the control room to
require additional levels of security, certain ven-
acknowledge the alarm and identify the issue be-
dors offer secure overlays for handheld devices.
fore heading out to the device to enact necessary
If you are working from your existing control
changes, only to then return to the control room
system and have a visualization application
to reset the alarm. Mobile HMIs allow operators
already running that you can tap into remotely,
to see an alarm from any area of the plant and
you will save the cost of purchasing that server,
immediately log in to the manual control screen
as well as a new software licensing fee. A wireless
to reset the alarm (if all is well), or make the nec-
infrastructure would be required, and you would
essary changes to fix the problem and restart—all
want to confirm you do not have problematic
from their mobile location. This also allows the
weak signal points in your facility. Additionally,
facility to run with only a single operator on staff
you will need to determine what devices would
at any given time.
work best in your plant environment. Many of our
54
Control Design April 2012
controldesign.com
floor at all times. The ability to have such valuable
the latest consumer devices, only to determine
information at their fingertips in real time en-
they need a device that can hold up in an indus-
ables professionals to manage their activities and
trial setting. This could involve anything from the
responsibilities efficiently anywhere, anytime.”
temperature rating of the hardware to requiring
It is also true that some points should be
the ability to clip on to the body for use on a man-
taken into consideration when adopting a mo-
lift or other plant equipment, for example.
bile HMI solution:
A mobile HMI solution can save a lot of time
Availability: To take full advantage of the solu-
and money, but the investment in creating the
tion, the operator’s handheld device should com-
solution could vary greatly depending on what
municate with the controllers (e.g. PLCs) through
functionality you desire from the mobile plat-
a wireless network such as Wi-Fi. Industrial wire-
form, your current wireless infrastructure, and
less hubs and switches available in the market
what control system you already have in place.
provide a high level of availability and decent
REID VANDER VEEN, business development,
Interstates Control Systems, www.interstates.com
ranges. However, it is important to plan where the
access point(s) will be located to make sure that
the user will have enough signal strength within
Manufacturing Awareness
the area of interest. Moreover, mobile devices
Mobile HMIs have been used for years to monitor
require batteries, and the users must follow a
machines and industrial processes. The advent
schedule to recharge the devices so they have
of new technologies and the recent populariza-
enough energy to operate when required.
tion of mobile devices such as tablets, PDAs and
Security: It is easier to restrict access to a wired
cellphones on a larger scale have accelerated the
network than to a wireless network. When using
adoption of mobile HMIs in many industries.
mobile HMIs in a manufacturing process, it is
imperative to follow guidelines to prevent unau-
Typically, the number of handheld
HMIs required to monitor a set of
machines is considerably lower than
the number of fixed HMIs required for
each machine.
It is easy to perceive the convenience and cost
savings associated with the use of mobile HMIs
rather than installing one fixed HMI panel on each
machine. Typically, the number of handheld HMIs
required to monitor a set of machines is considerably lower than the number of fixed HMIs required
for each machine. Moreover, as technology evolves
and the hardware platforms need to be replaced,
it is more affordable to upgrade a small number of
mobile devices than a large number of HMI panels.
Using built-in tools from HMI packages, operators could receive remote notification for alarm
conditions immediately and have the information
they need to diagnose the problem immediately.
This advantage is pointed out by Dan McCarthy,
ASME central engineering manager for Chrysler:
thorized access to the system, such as configuring a strong, encrypted key for the access point(s),
making sure that only authorized personnel have
access to such keys, changing the password regularly, and other security measures.
JUNE’S PROBLEM
WE WORK ON older, hydraulically powered,
multi-axis systems, so we have a big interest in them
not all converting entirely to electrically powered
alternatives. By sharing a pump across many axes of
motion, we believe we can keep our per-axis cost in
line with any solution. We’d like to hear what tips
readers have for ensuring a well-tuned hydraulic
system with emphasis on the controls and the
embedded sensors.
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include it in
the June ’12 issue, and post it on ControlDesign.com.
Send visuals if you’d like—a sketch is fine. Email us
at controldesign@putman.net. Please include your
company, location and title in the response.
“Mobile HMIs create the tool for manufacturing
awareness,” he says. “Today’s production requirements drive management and engineering to be
HAVE A PROBLEM YOU’D LIKE TO POSE to the
readers? Send it along, too.
fully aware of the activity on the manufacturing
controldesign.com
April 2012 Control Design
55
REAL ANSWERS
customers are excited about the capabilities of
cols that do not require authentication, connecting the controllers directly to the wireless
network increases the risk of attacks. In this case,
it is recommended to use an HMI (or SCADA) node
as the gateway between the handheld devices
(wireless network) and the PLCs (wired network).
This way, even if someone accesses the wireless
B&R INDUSTRIAL AUTOMATION
REAL ANSWERS
Furthermore, since most controllers currently
deployed in automation systems support proto-
network, there is another layer of protection—the
HMI/SCADA software—shielding the control network (PLCs) from the remote user.
In our experience, the most successful use
of mobile HMIs on the plant floor is when they
are used as an additional tool to augment the
traditional fixed HMIs. In other words, instead of
replacing the fixed panels with handheld devices,
both interfaces are deployed concurrently in the
plant. Fixed HMI panels provide high availability
to critical operational tasks, while mobile HMIs
provide remote notification and diagnostics to
CONNECTED OPTION
Industrialized handheld HMIs typically incorporate some
type of display, more traditional operator devices such as
pushbuttons or dials, and a hardwired cable connection
to the machine (either permanent or with quickdisconnect connectors).
reduce the time to identify and resolve problems,
reducing the cost associated with downtime and
increasing the productivity.
Mobile HMIs are particularly useful for tasks
Handheld HMI devices can come in a variety of
shapes and forms, from industrialized handheld
units to consumer products such as an iPad or
that are not suitable for fixed panels, such as cali-
iPhone. The industrialized units typically incor-
bration of large machines. Instead of having one
porate some type of display (perhaps touch), more
operator calibrating the machine and another one
traditional operator devices (e.g. pushbuttons,
in front of the HMI checking the result of the cali-
switches, dials), and a hardwired cable connec-
bration, a single operator with a handheld device
tion to the machine. The hardwired connection
can monitor in real time the result of the calibra-
can be permanent in some cases, limiting the
tion wherever this operation has to be executed.
benefits of the device to a single machine. As an
Mobile HMIs are commonly used not only as an
alternative, some hardwired solutions could in-
operational tool, but also as an analysis tool by
corporate cables equipped with quick-disconnect
plant supervisors and managers to monitor online
connectors, allowing operators to easily move it
data and history data in dashboards that provide
from machine to machine. This extends the ben-
key performance indicators (KPIs), such as overall
efits of operating a machine from a mobile device
equipment effectiveness (OEE) at their fingertips.
across multiple machines.
FABIO TEREZINHO, vice president of consulting services,
InduSoft, www.indusoft.com
However, with the benefits of portability come
some important application considerations.
These considerations could be as simple as de-
Flexible Solution
termining the correct cable length or connector
Handheld HMIs have been a common requirement
location on the machine, to more complex issues
for certain applications, such as overhead cranes,
related to the safe operation of the machines.
for a number of years in both wired and wireless
The cable length and connector location, for
formats. This is becoming more common in other
example, must allow the operator to use the
application areas typically served by machine-
handheld HMI at several locations on a given
based HMI devices for a variety of reasons, includ-
machine. Could the cable come into contact with
ing technological advances that have made wireless
moving parts of the machine, or against sharp
devices and networks ubiquitous, and user demand
edges, when moved to various locations around
for greater operating efficiency and freedom.
the machine? These considerations could be
56
Control Design April 2012
controldesign.com
possible wherever the controller communication
implementation of the handheld device more
interface can be converted to a wireless medium.
complicated. If the handheld HMI contains safety
All you need then is HMI software running in a
devices such as an E-stop pushbutton, care must
handheld PDA with capability to access the PLCs,
be taken that the overall machine safety is not
where the I/O from the various machines are
compromised if the handheld device is discon-
brought in for monitoring and control under the
nected from the machine.
programmed logic in the PLC.
Wireless solutions can offer a greater degree
The PLC should be wireless-enabled, which is
of freedom when using handheld HMIs across
easy to accomplish using a wireless adapter (ac-
several machines, and the range of available
cess point) if the PLC has an Ethernet port. If only
devices is greater because both industrial and
a serial port is available, then use of a serial/Eth-
consumer devices could be used. As before, how-
ernet adapter takes care of the conversion.
ever, several application considerations must be
Wireless HMI can enable an operator to move
accounted for in the machine design, ranging
from machine to machine as he monitors and
from how to keep the devices from disappearing,
controls systems in a variety of fields. In one ex-
to determining how to ensure that the operator
ample, we helped a packager of peat moss prod-
knows which machine he is controlling. A wire-
ucts simplify operation on its form, fill and seal
less solution comes with some degree of latency
baggers; automatic palletizer; robotic palletizer;
that could also impact machine operation.
and stretch wrapper machines. The customer
Machine builders have to ask whether this limits
previously had to walk to the top of the machine
what can be done from the handheld HMI.
to start or stop it, or to determine any problem.
Now the customer can see the issue with the
As with other operating functions, you
should consider the latency associated
with the wireless connection.
machine directly on the wireless PDA, and can
start and stop the machine remotely, minimizing
valuable down time.
HMI software in conjunction with a wireless
link to relevant information lends a helping hand
Safety and security also are factors to con-
to the human decision maker to zero in on the
sider when determining if a wireless handheld
critical subsystem that needs his attention and
HMI is the correct solution. The overall security
take appropriate timely action. You should be able
of the wireless interface should prevent unau-
to accomplish the multi-machine mobile monitor-
thorized access to machine operation. Open-
ing and control task using a PDA-based HMI in a
standard, digital safety networks now exist that
simple, natural and straightforward manner.
enable the handling of safety-certified functions
over a wireless connection, across multiple ma-
RAMAL MURALI, president,
Software Horizons, www.instanthmi.com
chines. As with other operating functions, you
should consider the latency associated with the
Wireless Fears
wireless connection.
Most HMIs connect with some device such as
When correctly implemented, handheld HMIs
a barcode scanner, PLC or controller by using
can be extremely flexible and robust solutions
some type of communication port like a serial
for machine builders in a number of different
or Ethernet port. So some people have concerns
applications.
about the safety of handheld wireless, and might
COREY MORTON, solutions architect,
choose to not use it.
DANIEL GHIZONI, senior solutions engineer,
There are three key elements when doing HMI:
B&R Industrial Automation, www.br-automation.com
alarm, control and monitor. If the HMI is used for
information monitoring and/or alarm to collect
For Peat’s Sake
data, then a handheld HMI solution would be a good
Portability and mobility are essential in the pres-
fit. If, however, the HMI is doing control, it might not
ent scenario. Since most PDAs readily support
be the best way to use a wireless solution.
wireless RF (Wi-Fi and Bluetooth) capability, untethered communication links to the controllers is
controldesign.com
JONNEY CHANG, HMI product manager,
Advantech, www.advantech.com
April 2012 Control Design
57
REAL ANSWERS
different from machine to machine, making the
PRODUCT SHOWCASE
controldesign@putman.net
RESIST THE SURGE
TEMPERATURE VIA THE WEB
SPD Series DIN-rail-
OM-Web-TC thermocouple
mountable surge protec-
input module with built-in
tors have local and re-
web server provides view-
mote self-monitoring for
ing access to thermocouple
low-voltage distribution
data and configuration set-
and protection. Design
tings using a standard web
is based on high-energy
browser. It has eight thermocouple input chan-
varistors (MOVs) equipped with thermal discon-
nels; supports thermocouple types J, K, T, E, N, R,
nects and integral failure indicators. Varistors are
S and B; and has built-in cold-junction compensa-
housed in pluggable modules with connections
tion and open thermocouple detection, and 24-bit
that are mechanically keyed to the base to pre-
measurement system.
vent incorrect arrestor module replacement.
Omega Engineering; 203/359-1660; www.omega.com
Weidmüller; 804/677-2745; www.weidmuller.com
WE HAVE LIFT OFF
IT’S NOT HARD, IT’S...
VC4X and VH4X 304 or 316L stainless steel
EZ-Screen LP low-profile Type 4 safety light
enclosures have a one-piece silicone gasket that
curtain with integral muting has a sensing
provides IP66 ingress rating. They include stan-
range that spans 100 mm to 7 m. It has seven,
dard lift-off door hinges, ¼-turn door latches and
predefined muting configuration options in-
a double bit insert. Customizations such as holes
cluding Bypass, Mute-De-
and cutouts, breather/
pendent Override, Mute
drains, terminal block
Enable and Mute-Cycle
population, various
Time Extensions for L-
¼-turn inserts, gland
style cell exit application
plates and operators
are available. Other
requirements. Diagnostic
indicators and displays
versions that include a clamped cover and screw
communicate the number of beams blocked and
cover are also available.
provide detailed diagnostics.
Adalet; 216/267-9000; www.adalet.com
Banner Engineering; 888/373-6767;
www.bannerengineering.com
DRIVEN SENSORLESS
SK 200E decentral-
PLUGGABLE SPD
ized drive with a
UL 1449 3rd-Edition-certified OVR DIN-rail surge
size 4 inverter and
protective devices (SPDs) are approved as UL
rated power output
Type 4 recognized components and are usable in
11–22 kW has sensor-
Type 2 applications intended for permanent in-
less current vector control, an integrated brake
stallation on the
chopper, a control module for an electromag-
load side of the
netic brake, and Safe Torque Off. Programming
service equip-
and operation is via a choice of control boxes or
ment overcur-
free Nordcon software.
rent device. The
Nord Drive Systems; 888/314-6673; www.nord.com
SPDs have pluggable cartridges, so the circuit
need not be isolated, nor does the entire device
need to be removed when replacements are
WIRED AND UNWIRED
needed. Wiring an integrated 3-point 1 A volt-
DataMan 8000 series handheld industrial ID
free contact enables the operational state of the
scanner has extended-range, cord-free code-
SPD to be monitored remotely.
reading and communication via EtherNet/IP, Pro-
ABB; 888/385-1221; www.abb.us/lowvoltage
finet, MC Protocol and traditional support for USB
58
Control Design April 2012
controldesign.com
hardware gamma. Compared with standard 8-bit,
reader provides a work-
the 12-bit color depth offers 16X the level of detail.
ing range to 100 m with
IDS; 781/787-0048; www.ids-imaging.com/usb3
a large memory capacity
for reading codes when
offline or out of range. It
HOT READS
offers liquid lens variable-focus technology to
Snap-AIRTD-1K two-channel,
read small 2-D direct part marks (DPMs) as well
isolated analog input module for
as long, linear 1-D barcodes with a single reader.
1,000 Ω platinum resistance tem-
Cognex; 877/cognex1; www.cognex.com/8000
perature detectors provides two
channels of analog temperature
input, with a nominal input tem-
RECORD VIRTUALLY
perature range of -328 to 1,562 °F
iTHX-SD transmitter lets users
and an input range of 0–4,000 Ω. The module has
view virtual charts and record
an average resolution of 0.042 °C (0.16 Ω). Used
temperature, relative humidity
primarily with RTD probes to provide tempera-
and dew point over an Ethernet
ture inputs, the module also can be used for mak-
network or the Internet with no
ing high-resolution resistance measurements.
special software—just a web browser. It
Opto 22; 800/321-6786; www.opto22.com
has a removable 2 GB SD flash memory
card that can store up to seven years of
readings taken at 10 sec intervals as a sim-
COMPACT SAFETY
ple text file for spreadsheets and other programs. It
Sinamics G120C compact
can be read directly on a PC or Mac with a USB card
inverter has a rated pow-
reader. You also can download the data remotely
er range of 0.75–25 hp.
over an Ethernet network or the Internet.
Quick-connecting, plug-
Newport Electronics; 714/540-4914;
in terminals allow faster
www.newportus.com
installation; an optional
operator panel can be mounted for commissioning; and a port for inserting a memory card is also
HOT AND COLD
available. It features safety integrated as standard
CBD terminal blocks have a UL94V-0 polyamide
with dual safe inputs to control the Safe Torque
insulating body with an operating temperature
Off (STO) function without external devices.
range of -40 to 80 °C. The metal
Siemens Industry; 800/879-8079;
bodies are a nickel-plated copper
www.usa.siemens.com/drives
alloy for corrosion protection.
Max. current acceptance ranges
up to 250 A.
FAST IN ANY LANGUAGE
ASI; 877/650-5160; www.asi-ez.com
Vitesse FA-M3 PLC
has an onboard
Ethernet port and
DEPTH OF COLOR
USB port, and com-
Compact USB 3.0 uEye in-
munications include
dustrial camera with ad-
Modbus TCP/IP de-
vanced color processing
vices via Ethernet as well as programming and
offers trigger, flash and
remote operation, maintenance and engineer-
pulsewidth modulation,
ing (OME). With the SD memory card slot, it is
as well as two general-purpose I/O that can be
possible to automatically log data in a trace set-
changed to an RS-232 serial interface, so peripher-
ting file that can be later used to troubleshoot
als can be triggered or controlled. The camera has
problems and debug programs.
brightness correction via a 12-bit lookup table and
Yokogawa; 800/888-6400; www.yokogawa.com/us
controldesign.com
April 2012 Control Design
59
PRODUCT SHOWCASE
and RS-232. The wireless
PRODUCT SHOWCASE
FAULT FINDING
GHz bands. It has three programmable function
FTR-Birdie self-con-
keys and a USB port with IP65 rating. Installation
tained electrical test
uses T-track rails and fittings that comply with
and fault-finding logger
VESA 75 and 100 standards.
records and displays all
Noax; 704/992-1606; www.noax.com
on/off voltage changes
at its 16 inputs. Applications include monitoring, logging and fault finding
ONE FOR ALL
for control systems, HVAC systems and production
AM8000 servomotor
machinery. The solid-state, isolated input chan-
series has single-cable
nels are fused, and the input on/off status of each
technology with the
line is displayed on an LCD. Input voltages of 12 V
power and feedback
to 240 Vac/dc can be monitored without needing to
system combined in
program, select or configure inputs.
one standard motor cable. The encoder data,
Saelig; 888-7saelig; www.saelig.com
rotor position, multi-turn information and the
status of the thermal conditions in the motor
are transmitted reliably and free from interfer-
REALIZE YOUR POTENTIAL
ence via a digital interface.
SW44832 potentiometer switch assembly has
Beckhoff Automation; 952/890-0000;
rotary and push-on functionality, and enables
www.beckhoffautomation.com/am8000
the user to specify a value,
so that at the push of a button, the circuit or channel
SOFTWARE
automatically opens at the
SOFT CONTROL
preset level. It features a
SPiiPlusSC EtherCat motion control platform
10 kΩ resistance poten-
enables standard PCs to run
tiometer module, and is
a 64-axis real-time motion
rated at 0.10 A resistive at 30 Vdc.
controller and high-speed
Electro-Mech Components; 626/442-7180;
PLC entirely in software.
www.electromechcomp.com
It automatically installs
the RTOS and converts a
standard Ethernet port into the EtherCat master
SOME LIKE IT HOT
communication channel to manage machine
Festoon cables are
drives and I/O.
designed for continuous
ACS Motion Control; 763/559-7669;
flexing and extreme-
www.acsmotioncontrol.com
temperature applications (-65 to 260 °C). The
flat construction allows
FIRMWARE UPDATE
for stacking multiple cables where space is at a
Firmware update v.1.5
premium. Standard cables (4–28 AWG) and custom
for PACMotion motion
designs incorporate shielded wires or signal pairs,
controller is designed
tubing for air or fluid transfer, and fastening strip.
to control up to 40 axes
Cicoil; 856/346-0801; www.cicoil.com
of synchronized motion
all at a 1 ms update rate
independent of the number of
IPC HAS PCI
motion axes. Version 1.5 features two-axis
Noax C12 Industrial PC has
analog servo control for control of one or two
two PCI/PCIe slots, and sup-
third-party amplifiers using a 10 Vdc analog
ports the Wi-Fi standards
speed or torque command. A PACMotion mod-
802.11a/b/g/n in 2.4 and 5.8
ule controls four axes, and each module can use
60
Control Design April 2012
controldesign.com
two of those axes for third-party servos
is the only magazine exclusively
dedicated to the original equipment
manufacturing (OEM) market for
instrumentation and controls—the
largest market for industrial controls.
RESOURCES
through this upgrade.
GE Intelligent Platforms; 508/698-7456;
UPDATED CATALOG
www.ge-ip.com/pacmotion
2012 catalog
of low-voltage
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
brushless dc
SEE IT ALL
and intelligent
SEE Electrical Expert V4 E-
servo motors has
CAD offers new commu-
specifications on
PUBLISHING TEAM
nication interfaces with
custom-configu-
GROUP PUBLISHER & VP, CONTENT
PLM/Mechanical CAD,
rable motors, controls, gearheads, brakes,
KEITH LARSON klarson@putman.net
PDM and other professional software pack-
encoders, interface options and acces-
DIRECTOR OF CIRCULATION
ages (labeling, PLC programming, archiving,
sories for the company’s five frame sizes
JACK JONES jjones@putman.net
etc); 3D Panel, a new module for panel design
of high-power-density, low-voltage BLDC
based on SolidWorks; and an international
motors, ranging 32–75 mm with continu-
SALES TEAM
version 100% “Unicode.”
ous output power ratings to 530 W.
NORTHEASTERN AND MID-ATLANTIC REGIONAL MANAGER
IGE+XAO; +33(0)5 62 74 36 36;
Dunkermotor; 224/293-1300;
DAVE FISHER dfisher@putman.net
www.ige-xao.com
www.dunkermotor.com
508/543-5172 Fax: 508/543-3061
24 Cannon Forge Dr.
Foxboro, Massachusetts 02035
TUNING TOOLS
DON’T BLOW IT
GalilSuite software package for configur-
Catalog 25 164-pg technical guide offers
MIDWESTERN AND SOUTHERN REGIONAL MANAGER
ing, analyzing and tuning company motion
solutions to com-
control systems has five tools: Terminal
mon industrial
GREG ZAMIN gzamin@putman.net
630/551-2500 Fax: 630/467-1124
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
to send and receive
cooling, drying,
controller commands;
conveying, blow-
LAURA MARTINEZ lmartinez@putman.net
Editor to write, save
off, cleaning,
310/607-0125 Fax: 310/607-0168
and execute applica-
coating and static
218 Virginia, Suite 4, El Segundo,
tion programs; Tuner
electricity prob-
California 90245
to select controller PID
lems. A detailed
DIGITAL SALES SPECIALIST
parameters for system
technical explana-
JEANNE FREEDLAND
tion, performance
jfreedland@putman.net
response; Scope to plot controller data such
as motor position and velocity; and Watch to
data, application photos and dimensional
display controller and I/O status.
drawings are provided for each product.
Galil Motion Control; 800/377-6329;
Exair; 800/903-9247;
www.galilmc.com
www.exair.com/cat25.htm
WESTERN REGIONAL MANAGER
805/773-4299 Fax: 805/773-0451
INSIDE SALES SPECIALIST
POLLY DICKSON pdickson@putman.net
630/467-1300 Fax: 630/467-1124
EXECUTIVE STAFF
AD INDEX
PRESIDENT & CEO
Advantech .................................................................28
Omega Engineering ................................................3, 46
Allied Electronics .......................................................22
Opto 22 .....................................................................33
ASCO Numatics .........................................................45
AutomationDirect ............................................ 11-14, 64
AVG Automation ...........................................................2
B&R Industrial Automation ...........................................8
VP, CIRCULATION
Pepperl+Fuchs .....................................................36, 37
Traco Power ...............................................................26
Questex Media Group .................................................53
Beckhoff Automation ....................................................6
Rittal................................................................... 34-35
Maple Systems...........................................................48
JULIE CAPPELLETTI-LANGE
Patlite .......................................................................44
Baldor Electric ...........................................................18
Eaton ........................................................................23
VICE PRESIDENT
Panduit .....................................................................24
Balluff .......................................................................39
c3controls ................................................................. 16
JOHN M. CAPPELLETTI
JERRY CLARK
VP, CREATIVE SERVICES
STEVE HERNER
Sealevel Systems .......................................................38
REPRINTS
Siemens Industry ....................................................... 21
Turck .........................................................................25
FOSTER REPRINTS www.fosterprinting.com
Molex ........................................................................ 10
UBM Canon Communications ......................................52
JILL KALETHA
National Instruments ....................................................4
Yaskawa Electric ........................................................63
Mersen ......................................................................27
jillk@fosterprinting.com
866-879-9144 ext. 168
controldesign.com
April 2012 Control Design
61
$PSFZ3BEMFZtDPSFZSBEMFZ!mWFTHSPVQDPN
OEM INSIGHT
Cooperative Provides Skilled Workers
OVER THE PAST several years, much has been
the students, in turn, consider the experience the
written about the threat of a retiring workforce,
most rewarding of their university careers.
the effects of knowledge loss on their companies,
Through this program, they not only learn con-
and the inherent problems that these companies
cepts in school, but also apply them to real-world
face in hiring and training replacement engineers.
situations. Most notably, the program introduces
Through STEM initiatives, the U.S. FIRST program
them to the field of automation; a field that is un-
and promoting higher education, the country
fortunately unrepresented in the curricula at most
has endeavored to maintain the supply of quality
nationwide universities. The glamour of employ-
engineers to the technical sector. But individual
ment at Apple, Google, Microsoft and companies
company action still is required to ensure that we
of the like lure many of the best engineers away.
each have a solution to replace and develop our
But by engaging these top students early in their
engineering staffs.
academic life and providing them a comprehensive
For the past 15 years at Fives Cinetic, we have
and rewarding cooperative experience, we get the
found our solution to the problem of recruiting
opportunity to show them the field of automa-
quality engineers by establishing a comprehen-
tion. Many then choose to make automation their
sive cooperative education program. We work
career choice, and often stay with Fives Cinetic.
closely with local and regional universities to
The benefits of such a program are clear. It
identify and interview students enrolled in
gives us the ability to create our own, homegrown
four-year bachelor’s programs in fields including
and vetted pool of engineers for employment. The
mechanical, electrical, computer and industrial
refreshing points of view that they bring to the
engineering, as well as computer science. Se-
table give us a definite competitive advantage,
lected students from the University of Michigan,
especially once they become full-time employees.
Co-ops are introduced to automation,
a field that is unfortunately
unrepresented in the curricula at most
nationwide universities.
Hiring people who simply can step into a position
is usually not a reasonable expectation. They require training, on-boarding and, many times, bring
with them a possibly negative corporate culture
from jobs past. Through this type of a program,
we can promote our positive corporate culture
the University of Detroit Mercy and Michigan
early on in their careers while also training them
State University participate in a program that
across a broad set of automation skills. After com-
alternates full-time employment with full-time
ing onboard full time, the newly minted engineers
academics, typically for two to four rotations.
retain their seniority and are given opportunities
For the controls engineering co-ops, each term
for accelerated career growth. All who stay with us
they are rotated through the various departments
will go on to mentor co-op students of their own.
of Proposal, Hardware, Software, Robotics, Vision,
Some of our senior management team started their
Service and others. They are assigned mentors
careers as cooperative education students.
who serve as their technical advisors and coach-
Where others have struggled, we have been
es. Many of these students are offered full-time
able to grow our technical advantage in an indus-
employment following graduation and completion
try where the constant rapid evolution of controls
of the program. Our program now has 25 students
technology has posed the largest problem. Invest-
each term across the various disciplines.
ing time in a co-op who later chooses to pursue
Students are required to perform real, valueadded engineering work. In the first rotation, they
different opportunities after graduation is a risk,
but it is well worth the potential reward.
are mainly engaged in learning design methods
and principles, machinery, and the business
COREY RADLEY is technical software manager at Fives
processes of the company. By the second or third
Cinetic (www.fivesgroup.com) in Farmington Hills, Mich.
rotation, the students are fully engaged in the
He began at Fives Cinetic as a co-op student in 2005,
design and commissioning phases of engineer-
graduating with a degree in electrical engineering from
ing and become a real asset to the team. Many of
the University of Michigan-Dearborn in 2007.
62
Control Design April 2012
controldesign.com
TWENTY-FIVE
One red cup sits on a small bleacher area for each of the associates on the line in our Buffalo Grove, Illinois
manufacturing and distribution center. In those cups, we put any screws damaged during our processes.
Know how many screws we collect on average each month? Twenty-five. That’s
right. Only 25 damaged screws for every 40,000 processed. Pretty impressive,
huh?
At Yaskawa, our people are committed to quality because to them it’s not just a
job – it’s personal.
Never compromise on quality. Call Yaskawa today.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A
YA S K A W A . C O M
Follow us:
For more info:
http://Ez.com/yai307
©2012 Yaskawa America Inc.
Mighty as a stand-alone unit, or
expand to 142 total I/O
= /(9(167$1'$/21(5$,/02817$%/(32:(5('
CPU combinations including:
- 8 DC In / 6 DC Out (sinking) -Basic and Standard
- 8 DC In / 6 DC Out (sourcing) - Basic and Standard
- 8 DC In / 6 Relay Out -Basic and Standard
- 8 AC In / 6 Relay Out -Basic and Standard
- 4 DC In / 4 DC Out (sinking), 2 analog in, 2 analog out
(current / voltage selectable)
- 4 DC In / 4 DC Out (sourcing), 2 analog in, 2 analog out
(current / voltage selectable)
- 4 DC In / 4 Relay Out, 2 analog in, 2 analog out
(current / voltage selectable)
= 8,/7,1&20081,&$7,2132576
(two in Basic CPUs, three in Standard and Analog CPUs)
= $77(5<%$&.('0(025<$1'5($/7,0(&/2&.
(in Standard and Analog CPUs)
= (029$%/(7(50,1$/%/2&.6)25($6<:,5,1*
= /(9(167$&.$%/(',6&5(7(237,2102'8/(6
= 52*5$0'2&80(17$7,216725(',1!
= 833257('%<+,*+)($785(352*5$00,1*62)7:$5(
With CLICK PLCs, you get a lot of application
control in a small package. The new Standard
CPUs feature the discrete I/O configurations of
the Basic CPUs, plus battery-backed memory,
real-time clock and a third communication port.
Download the free programming software now and
see how easy automation can be.
CHECK OUT JUST A FEW PRICES ON CLICK
AutomationDirect
Product Description
CLICK
Price/Part Number
PLC CPU with 8 DC inputs / 6 DC outputs (sinking),
two communication ports
$
69.00
C0-00DD1-D
PLC CPU with 4 DC inputs / 4 DC outputs (sinking),
2 analog inputs / 2 analog outputs, three
communication ports, real-time clock
$
Auxiliary power supply (0.5A), 100-240 VAC input,
24 VDC 0.5A output
$
AC input module, eight 100-120 VAC points
129.00
C0-02DD1-D
29.00
C0-00AC
$
40.00
C0-08NA
AutomationDirect prices are U.S. published prices as of April 2012. Prices subject to change without notice.
www.automationdirect.com
http://www.automationdirect.com/click-plc or
www.clickplcs.com
Go online or call to get complete information,
request your free catalog, or place an order.
1-800-633-0405