Some of the Web-Based Methods Available to Do

controldesign.com a little change ARC FLASH: WHOSE FAULT IS IT? FLASHBACK 1999: PERFECT HARMONY GREENING THE MACHINING Some of the Web-Based Methods Available to MARCH 2012 Do Automation Product Research Hold Little Currency for Many Machine Builders Process Measurement & Control ⁄8, 1⁄16, 1⁄32 DIN Temperature, Process and Strain Meters and PID Controllers 1 CNi Series Starts at $ 205 • Now with Embedded Internet (EI Option CNi16D Series) • First Full Series of Instruments with Programmable Color Displays • User Friendly, Simple to Configure Visit omega.com/cni_series Pre-Cut Front Panels for DIN Meters and Controllers Ultra Precise Immersion RTD Sensors Visit omega.com/cni-cb120sb OM-HFPU Series Starts at $ 69 P-Ultra RTD Series Starts at $ 53 MADE IN Visit omega.com/om-hfpu Temperature/Process Controller Panel USA Visit omega.com/p-utra_rtd ® CNI-CB120SB Starts at $ 600 omega.com ® © COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED Name Peter Simonsen Job Title Design Engineer, Embedded Software Area of Expertise Renewable Energy LabVIEW Helped Me Perform real-world simulations with total control of the application Latest Project Develop a test architecture for verification of wind turbine control systems NI LabVIEW LabVIEW makes me better because I can real-world systems >> Find out how LabVIEW can make you better at ni.com/labview/better ©2010 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 2811 800 453 6202 CONTENTS MARCH 2012 FEATURES 22 Cover Story A Little Change Some of the Web-Based Methods Available to Do Automation Product Research Still Hold Little Currency for Many Machine Builders Joe Feeley, editor in chief Volume 16, No. 3 33 Input/Output Systems Arc Flash: Not My Fault End Users Are Responsible for Keeping Workers Safe From Electrical Hazards, but More of the Onus is Now on Machine 22 Builders Aaron Hand, managing editor 39 Product Roundup A Sense of the Market Machine Builders Remain Consistent With Sensor Choices COLUMNS 33 7 ControlDesign.com 21 Embedded Intelligence Hazardous Zone Safety Flashback to 1999: I’d Like to Teach the World... 9 Editor’s Page ‘Oops’ Just Isn’t Enough 38 TechFlash Is PLC a Dirty Word Now? 11 Live Wire Manufacturing in the U.S. 50 OEM Insight Why Not Lubricate Less? HOT BUTTONS 44 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 Itasca, IL, and at additional mailing offices. Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©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 Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To apply for a free subscription, fill in the form at www.ControlDesign.com/subscribemag. To non-qualified subscribers in the Unites States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) 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Printed in the United States. 13 OEM Spotlight 44 Real Answers Plasma Tools Carve Out Place in High Tech How to Push Motor Efficiency 14 InDiscrete STEM Students Scared by ‘Hard’ Factor 47 Product Showcase CONTROL DESIGN EXCLUSIVE 46 Eaton’s OI Consolidates PLC, I/O, Wiring March 2012 Control Design 5 | EC11-09USA | Reduce Cabinet Size with the Rugged and Powerful CX5000 Controller. ® ™ The flexible CX5000 Embedded PC with Intel Atom thrives in temps from -25 to 60 °C www.beckhoff.com/CX5000 The Beckhoff CX5000 Embedded PC series with convenient DIN rail mounting: for flexible application as a compact Industrial PC or as a PC-based controller for all-in-one PLC, Motion Control and visualization: Intel® Atom™ Z530 CPU, 1.1 GHz (CX5010) or 1.6 GHz (CX5020) Durable and compact magnesium housing High operating temperature range between -25 and 60 °C (-13 and 140 °F) Fanless, without rotating components (Compact Flash as storage medium) Direct I/O interface for EtherCAT Terminals and Bus Terminals for all major fieldbuses Optional space for serial or fieldbus interface Integrated 1-second UPS CX1020/CX1030 Embedded PC with Intel® Pentium® M CPU, 1.8 GHz or Intel® Celeron® M ULV CPU, 1 GHz IPC I/O Motion Automation CX1010 Embedded PC with Pentium® MMX-compatible CPU, 500 MHz CX9000/CX9010 Ethernet controller with Intel® IXP420 XScale® technology, 266 MHz or 533 MHz CX8000 Fieldbus controller with ARM9 CPU, 400 MHz, e.g. for PROFIBUS, PROFINET, EtherCAT and Ethernet NEW WHITE PAPERS EXPLOSION PROTECTION AND INTRINSIC SAFETY 101 Everything you need to know about intrinsic safety technology, hazardous locations, surge protection, HART interface solutions and signal conditioning. Targets Intrinsic Safety.” He sell equipment to custom- asks what might happen if live ers that operate in hazardous working never created an arc in areas, there are important the first place. Read this article electrical and electronic signal at www.ControlDesign.com/ factors for both parties to DART to learn how IS require- consider. Designing systems for ments have changed over the installation in hazardous areas years. See Rezabek’s report on requires an understanding of how energy-limiting require- division and zone classifica- ments of IS previously led to tions, and whether off-the-shelf serious limitations for process components are appropriate. buses such as Profibus-PA and In the article “Operator Foundation fieldbus, and how Interface in Hazardous Areas,” FISCO and FNICO practices al- Senior Technical Editor Dan low high enough power budgets Hebert covers some of the re- to increase the number of quirements for building indus- devices permitted and simplify trial equipment for hazardous IS calculations. areas. Hebert’s article explains Safety in hazardous areas can be costly. However, intrinsic hazardous areas differently— safety makes protecting field by zones, classes, divisions. He devices easier and cheaper. How also makes suggestions how so? To get the answer to this machine and robot builder question, read the article “Less OEMs can provide safety in Bang for the Buck,” written by SPECIAL TO THE WEB these risky environments. Read Walt Boyes, editor in chief for this column at www.ControlDe- sister publication Control. HAZARDOUS LOCATION GUIDE Download this e-book to better understand hazardous locations and protection methods. Learn about intrinsic safety from industry leaders. www.ControlDesign.com/ hazguide sign.com/danger to learn how DID YOU KNOW YOU CAN RECEIVE CONTROL DESIGN ELECTRONICALLY? Subscribe to the digital issue of Control Design and you’ll be able to download a highquality PDF of the magazine exactly as it appears in print. Not only that, we’ll send you an e-mail each month when it’s ready for you! www.ControlDesign.com/ digital.html safely around high-power en- it isn’t, summarizes hazard- ergy sources, industry workers ous area classifications, and must make sure that power sup- touches on IS for analog, HART plies are specifically designed and fieldbus devices. Read this and certified for what they need. article at www.ControlDesign. It usually means that power com/bang. t how NEC standards classify Katherine Bonfante INSTALLING AUTOMATION IN HAZARDOUS AREAS Learn how to protect automation system components when used in hazardous locations. WHEN MACHINE BUILDERS CONTROLDESIGN.COM HAZARDOUS LOCATIONS SAFETY HANDBOOK This handbook educates users on the proper selection of electronic weighing systems used in hazardous locations. Hazardous Zone Safety of explosion safety systems: an environment where hazards explosion-proof, purge and are likely to exist under normal pressurization, and explo- operating conditions differs sion prevention. The article from designing systems for use looks at the basics of explosion in standard environments. prevention and examines what supplies must follow fieldbus in- intrinsic safety is and what If you are looking for more trinsically safe concept (FISCO) information on machine safety or fieldbus non-incendive con- and intrinsic safety, stop by cept (FNICO) standards. our site and check out other ar- Contributing Editor John ticles, news, white papers and Rezabek discusses energy-lim- products covering this subject. iting requirements for intrinsic Visit www.ControlDesign.com/ safety (IS) in his article “DART machinesafety today. March 2012 Control Design 7 kbonfante@putman.net When it comes to working t controldesign.com Boyes recaps the three kinds designing systems for use in managing editor, digital media To download PDF papers, go to ControlDesign.com/ whitepapers. Technology by 7+(,1129$7256 (IÀFLHQW $XWRPDWLRQ ` Increased precision and quality through synchronization and real-time capabilities ` Reduced costs through scalability and design freedom – PC-based or embedded ` Investment security through openness and full compatibility ` Increased productivity throughout the entire life cycle through intelligent service and diagnostic functions ` Space-savings through compact systems and decentralized topologies Perfection in Automation www.br-automation.com ‘Oops’ Just Isn’t Enough WILL WE NEVER learn that, cli- using the Internet, particularly 555 W. Pierce Rd., Suite 301 Itasca, Illinois 60143 630/467-1300 Fax: 630/467-1124 ché or not, it’s important to sweat global search engines. It’s like the small stuff? the yin and yang of that relation- EDITORIAL TEAM past summer about subatomic and Costello; it’s Illinois politics EDITOR IN CHIEF particles (neutrinos) that showed and corruption. You don’t get one up about 60 ns faster than light, without the other. JOSEPH FEELEY jfeeley@putman.net Remember the story this ship. It’s Cain and Abel; it’s Abbott We found that 88% of respon- when the CERN labs shot them JIM MONTAGUE jmontague@putman.net from Geneva to Italy? Faster than dents agreed or strongly agreed light? Time travel? Vacation home with the statement, “I’ve gotten on Kepler-22b? better at search strategies and MANAGING EDITOR AARON HAND ahand@putman.net ASSOCIATE EDITOR, DIGITAL MEDIA SARAH CECHOWSKI scechowski@putman.net transporter startup company techniques, and that has helped get better results.” Sounds positive. Life is good. owned by those three guys named But then we learn that 77% of respondents agreed or strongly Science reported in February that agreed with the statement, “It’s DAN HEBERT dhebert@putman.net the CERN particle physics labora- a pain to sift through the results, tory in Geneva admitted that a but at this point there’s no better loose fiberoptic cable connection web-based research tool for me.” COLUMNIST JEREMY POLLARD jpollard@tsuonline.com DESIGN/PRODUCTION SENIOR PRODUCTION MANAGER ANETTA GAUTHIER ART DIRECTOR between a GPS unit and a com- proved our abilities to obtain better surements that showed neutrinos search engine results, we’re still out-sprinting the speed of light. “There is a screw and you have to turn it, but we’re not sure if it DEREK CHAMBERLAIN was well-calibrated,” said Arnaud SUBSCRIPTIONS Marsollier, a spokesman for CERN. 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 So, while many of us have im- puter might have caused the mea- Will we never learn that, cliché or not, it’s important to sweat the small stuff? “It would be embarrassing if a nasty cable is the reason.” Let that sink in for a moment. This isn’t an unfortunate loose not at all happy that there’s nothing better out there. This helps explain the disdain screw-terminal connection in that many readers still have for the control panel that delays a Internet-based research. They machine commissioning for a adamantly stick with their local few hours. This is gazillion dollar distributor when they need product physics aimed at finding answers information. I’ve heard more than to the nature of the universe. once how they firmly believe it’s Imagine how you explain that one to the boss. Trying to maintain a level of quiet dignity, the lab announced faster and more reliable, even while conceding that this can limit the brand scope of possible solutions. As we learned from this study that the experiment probably will last year, respondent age doesn’t be repeated in May. seem to make a big difference Item 2: Some of the findings in about this, either. our annual Product Research and Buying Habits Study (p22) nicely define the complicated love/hate relationship most of us have with March 2012 Control Design 9 jfeeley@putman.net LORI GOLDBERG lgoldberg@putman.net t Jim, Scotty and Spock. The journal SENIOR TECHNICAL EDITOR EDITORIAL ASSISTANT editor in chief KATHERINE BONFANTE kbonfante@putman.net investment you made in that t MANAGING EDITOR, DIGITAL MEDIA Well, you’d better unload the Joe Feeley EXECUTIVE EDITOR EDITOR’S PAGE controldesign.com WHAT COULD YOU DO WITH MORE CONTROL? Find ways to resolve application challenges with amazing speed, impress every customer, crush the competition, and along the way be recognized as an intergalactic engineering wizard. 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LIFETIME WARRANTY GUARANTEED SAME-DAY SHIPPING FACTORY DIRECT PRICING Check out our amazing motor control offer. 800.560.8560 www.c3controls.com/MC WE DIDN’T INVENT CONTROL, WE’RE PERFECTING IT. Manufacturing in the U.S. increase wages in order to hold onto their people. Nonetheless, there is cause for hope in the U.S. the U.S. economy that is built on manufactur- manufacturing sector, hinging not only on falling ing. Within his pledge to improve incentives for unemployment rates. “North American factory manufacturers to stay in the country, he said, activity has increased for the 30th consecutive “American manufacturers are hiring again, creat- month and 65% are investing in new technology, ing jobs for the first time since the late 1990s.” both very positive signs for expanding growth in Indeed, manufacturing is looking up and unem- the manufacturing sector,” says Mitch Free, CEO of Mfg.com, an online marketplace for industry. Bureau of Labor Statistics, the U.S. added 330,000 According to Manufacturers Alliance for Pro- manufacturing-based jobs in 2011. With compa- ductivity and Innovation (MAPI, www.mapi.net), nies adding 243,000 jobs throughout the economy machinery is expected to rise 7% this year, with in January alone, 50,000 of those jobs were in man- the motor vehicle market growing 11%. overseas—a movement called “reshoring.” As we cracked up to be? Here are some figures to keep reported in December (www.ControlDesign.com/ in mind: For 35 years (1965-2000), manufacturing comeback), machinery is among seven sectors that employment in the U.S. stayed between 16 million are set to return to the U.S. for manufacturing. and 19.5 million jobs, notes Josh Bivens, acting re- This isn’t because of any renewed patriotism, search and policy director at the Economic Policy Free explains. “The U.S. dollar has gotten quite Institute (EPI, www.epi.org). Then the sector lost weak. Therefore, it’s eroded some of the cost ad- 3 million jobs in the 2000 recession, and today vantages of producing overseas,” he says. Add to employs fewer than 12 million workers. So, although the latest advances on unemployment are worthy of some optimism, we might never see the kind of employment numbers that we used to. Looking at the job market overall, we’ve Although the latest advances are worthy of some optimism, we might never see the kind of employment numbers that we used to. had zero growth over the past 11 years, though the population grew steadily. Even at January’s pace of that the cost of making trips to China, rising ship- acceleration, it would take us until 2019 to return ping prices as oil prices go up, brokerage costs, a to full employment levels, according to EPI. longer work in progress, etc., and “some compa- Another red flag that EPI’s Heidi Shierholz pointed out recently is the continued low number nies are deeming it just not worth the hassle.” The decision to bring manufacturing back to of voluntary quits, which dropped by more than the States will depend in part on how many of 40% between 2007 and 2009, and are still 34% each item a company wants to manufacture, Free below 2007 levels. “When job opportunities are notes. The bigger the order, the more worthwhile plentiful, employed workers have the chance it will be to make it overseas. “But companies are to change jobs that are a better match for their still nervous about consumer demand, business skills, experience and interests, and where demand in America,” he says. “So they would they are more productive and command higher rather produce in smaller lot sizes.” wages,” she writes in a recent blog post. “During With a 3% uptick bringing reshoring back to downturns, not only does hiring go down, so does North America to 22%, it remains to be seen if it the number of voluntary quits, as outside job op- can surpass the 38% peak Mfg.com has seen since portunities become scarce.” it began tracking. “American manufacturing has This in turn greatly affects the wages that never gotten the full throttle White House sup- workers can earn because not only do they lose a port that was addressed in the recent State of the key avenue for wage growth (changing jobs), but Union that called to return manufacturing to the employers do not see the need to substantially United States.” controldesign.com March 2012 Control Design 11 ahand@putman.net It all sounds pretty good. But is it really all it’s There’s also been news that machinery manufacturing could be coming back to the U.S. from t turing sector have grown in the past year. managing editor ufacturing. That’s the fastest jobs in the manufac- t ployment rates continue to fall. According to the Aaron Hand address in January, he laid out a blueprint for LIVE WIRE IN PRESIDENT OBAMA’S State of the Union The New Gearmotor Gold Standard The new BaldorDodge® Quantis® Gold gearmotor combines the BaldorReliance® premium efficient Super-E® motor with the superior Quantis gearbox, making the Quantis Gold the most energy efficient, coolest running gearmotor in the world. Energy Efficient Unmatched Quality Available as in-line helical or right angle helical bevel c-face units, 1/2 to 10 Hp, the Quantis Gold raises gearmotor energy efficiency, quality and reliability to a new gold standard. Superior Reliability dodge-pt.com Quickest Delivery Available baldor.com ©2011 Baldor Electric Company 479-646-4711 Plasma Tools Carve Out Place in High Tech OEM SPOTLIGHT Plasma-Therm Keeps It Simple Despite the Complexities in Diverse Industries Like MEMS and LED Manufacturing ALTHOUGH PLASMA-THERM (www.plasmatherm.com) was organized in St. Petersburg, Fla., just three years ago, its original founding actually dates back to 1975 in New Jersey. After decades of developments in plasma etch technology, it was PLASMA-THERM acquired in 2000 by Unaxis and later rebranded as Oerlikon before being reestablished in 2009 through a management buyout. Working with a wide range of high-tech industries, the machine builder finds that automation needs differ considerably TEACHING POSITION Transfer positions are programmed and checked on a Plasma-Therm MEV mask etcher using a control display module (CDM) ‘teach’ pendant. from market to market. “In some markets, the cost of the end product as it passes through our with these markets often have Therm’s engineers have system is so high that loss due to unique needs, such as the learned that it’s usually best operator error or handling-sys- plasma-enhanced chemical va- to avoid proprietary systems. tem error is significant enough por deposition (PECVD) systems “We once used a proprietary to justify higher-end automa- that require automated clean- embedded computer run- tion,” says Joe Barraco, software ing of the process chambers. ning VxWorks and outsourced engineer at Plasma-Therm. MEMS production uses deep development of the board “Conversely, some markets that silicon etch (DSE) reactors to support package (BSP),” Bar- are primarily R&D do not neces- etch deep yet narrow features raco recalls. “This proved to be sarily have the capital to justify with very smooth sidewalls. very expensive, and when the large-scale automation, so lower- “Very fine control of the pro- supplier learned that it would cost systems with less automat- cess is absolutely necessary to be very costly for us to change ed controls are justified.” achieve these requirements,” hardware platforms, they Barraco says. “Our control raised their prices dramatically. some customers start so small systems dynamically manage On top of that, the custom- that they have only enough capi- all of the parameters within build kernel turned out to be tal to get manually loaded wafer the reactor, including pressure, buggy. At the time, Windows systems, Barraco says. “Our reactor temperatures, gas mix- PCs didn’t have the horsepower Versaline product allows these tures, RF energy, electrode po- to meet our controls timing customers to grow their systems sitioning, and process timing. needs, but thanks to Moore’s along with their businesses,” In the MEMS market, timing is Law, it wasn’t long before that he says. “These systems can be especially critical.” changed. PCs now run unbe- In the LED and MEMS markets, initially configured as a single- Despite the seemingly lievably fast processors with wafer tool, and later converted to complex technologies it works large amounts of memory. Our a full cassette-to-cassette multi- with, Plasma-Therm’s software timing concerns had been ad- chamber system as the customer development philosophy is to dressed, so we made the switch moves from initial development keep it simple. “If it sounds too and now control most of our into full production.” complex, it is,” Barraco says. equipment with industrial PCs The processes associated controldesign.com Along these lines, Plasma- running Windows.” March 2012 Control Design 13 INDISCRETE STEM Students Scared by ‘Hard’ Factor ONE KEY REASON kids in good enough, and that the cost grades 6-12 don’t pursue STEM and time involved in getting a careers is that their math and STEM degree is too high. science grades aren’t good Split them out by gender, and enough; although they feel cer- the situation gets even direr for tain STEM careers offer the most the girls. Almost a third of the job opportunities, they’re afraid girls strongly agree that math is they won’t measure up. This is their most challenging subject, according to a survey from ASQ compared with 19% of the boys. (www.asq.org), conducted in an- And girls interested in pursuing ticipation of National Engineers a STEM career are four times Week last month. more likely than boys to believe ASQ and its membership of more than 14,000 engineers are concerned about ensuring a that their teachers are not preparing them well enough. In a later survey, ASQ also skilled workforce with educat- asked engineers for their per- ed engineers, so they wanted to spective. They conceded that, find out what might keep that yes, study was a challenge. workforce from developing. Almost half of them said the They discovered that, of those amount of work and study need- students interested in pursu- ed to succeed was the primary ing a career in STEM, 67% are challenge, and another 14% concerned about the obstacles said maintaining high grades in they would face. related subjects like math and Students see three main science was their key challenge. obstacles to pursuing a STEM Other challenges included lack career: of mentorship, poor-quality r5IFDPTUBOEUJNFUPHFUB teachers, selection of engineer- degree in STEM is too high ing degrees available at local compared with other subjects. universities, and a lack of prep r5IFJSHSBEFTJO45&.TVCKFDUT of math and science aren’t good enough. courses in high school. However, only 3% of the engidissatisfied with their career too much work and studying choice. Their advice? “Study compared with other careers. hard and don’t give up.” ASQ also surveyed parents of “While pursuing an engi- children aged 10–17 to get their neering degree has its chal- perspective. More than half lenges, it’s a worthwhile cause (53%) of the parents who had and one that can lead to a life- kids interested in STEM careers time of satisfaction,” said Jim also expressed concerns, with Rooney, ASQ chair and quality about a quarter of them saying engineer with ABS Consulting. that their children are not being “Students considering pursuing prepared enough by teachers a degree in a STEM-related field in STEM subjects. In addition, should be passionate about it 18% worry that their children’s and be prepared to work hard grades in STEM subjects aren’t to be successful.” Control Design March 2012 March 6, 1997: Britain’s Queen Elizabeth II launched the first official royal website. March 4, 1998: Microsoft repaired software that apparently allowed hackers to shut down computers in government and university offices nationwide. March 12, 1998: Astronomers cancelled a warning that a mile-wide asteroid might collide with Earth, saying that calculations had been off by 600,000 miles. March 25, 1998: The U.S. Federal Communications Commission (FCC) netted almost $580 million at auction for licenses for new wireless technology. March 8, 1999: The White House directed the firing of nuclear scientist Wen Ho Lee from his job at the Los Alamos National Laboratory because of alleged security violations. March 10, 2000: The dot-com bubble burst. neers surveyed said they were r45&.EFHSFFDBSFFSTJOWPMWF 14 FLASHBACK 1997-2012 March 24, 2001: Apple Computer’s operating system MAC OS X went on sale. March 7, 2003: Scientists at the Stanford Linear Accelerator Center announced that they had transferred 6.7 GB of uncompressed data in 58 seconds over 6,800 miles. March 20, 2003: Cisco Systems announced it was buying The Linksys Group for $500 million in stock. controldesign.com ©2012 Siemens Industry, Inc. SIMATIC Controller SIMATIC S7-1200 ,WſVWKHLQWHUSOD\WKDWPDNHVWKHGLIIHUHQFH The modular, compact SIMATIC S7-1200 controller is perfectly suited for an entire range of applications, offering an impressive array of communication options and integration with the Totally Integrated Automation (TIA) Portal. The SIMATIC S7-1200 PLC and SIMATIC HMI Basic Panels feature SIMATIC STEP 7 Basic engineering software for simple and efficient programming, networking and commissioning, saving you time and money. This innovative micro-PLC is fully compatible with a wide range of I/O and communication modules, providing flexible extension options to meet your needs. The system also offers a PROFINET interface for easy networking, I/O control, and communication between the engineering system, controllers, and HMI, increasing the range of possibilities in the field of compact automation with SIMATIC S7-1200. www.usa.siemens.com/controllers 2011 Robot Sales Exceed Expectations SALES OF INDUSTRIAL robots tion of Robotics (IFR, www.ifr. reached a new peak level of org). This is an increase of about try was the main driver of the about 150,000 units last year, 30% over 2010, which already strong growth. Last year, how- according to recent estimates had seen considerable recovery ever, robot suppliers reported from the International Federa- following 2009’s downturn. a significant demand increase In 2010, the automotive indus- from other industrial sectors. “Thanks to the demand of emerging countries, including China, the sales of factory automation apparatus are increasing,” said Shinsuke Sakakibara, IFR’s president. “However, the growth of sales of machine tools seems to be slowing down under the influence of Europe’s currency crisis and/or a Chinese tight-money policy. But this does not apply to robots.” Although robot manufacturers expected continued improvement in 2011, the 30% growth exceeded expectations, according to Arturo Baroncelli, IFR’s vice president, and robotics proposal manager at Comau. Robot suppliers throughout industry noted the same trends in their own businesses, each pointing to record sales in 2011, particularly in their Asian markets. “Growth in the automotive sector continued unabated and was strongly supported by an increased uptake in growth segments such as electronics, solar, and food and beverage,” said Per Vegard Nerseth, head of ABB Robotics. “We fully expect this growth to continue through 2012 with the increased demand throughout the Asia region continuing to be an important factor.” Your Sensor and Switch HQ Allied stocks the sensor and switch products you need, when you need them. ative products ov n in , rt a e th of • State s nd switch solution a or s n e s + 0 0 ,0 • 11 -class brands ld or w le b lia re , n e • Prov Get all your sensor and switch products in one place. Shop total solution. for your THINK ALLIED SM 1.800.433.5700 © Allied Electronics, Inc 2012. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company. Solar Equipment Opportunity Abounds ALTHOUGH REVENUE DECLINES that requires upgrade in 2012, and of more than 65% are predicted this figure will steadily ramp up this year for the photovoltaic (PV) over the coming few years,” said manufacturing equipment sector, Tim Dawson, senior research di- according to IMS Research’s (www. rector at IMS. “Companies wishing imsresearch.com) latest quarterly to remain competitive and take report, the analysts contend that the opportunity to gain market there is a 20 GW, $25 billion op- share will be forced to invest in portunity over the next four years new equipment.” as manufacturers replace aging Market shake-out will spur fur- equipment, either via upgrades or ther equipment demand, Dawson complete replacements. added. “Manufacturing equipment Because of overcapacity in 2011, companies that stand to benefit manufacturers of solar ingots, wa- most are those that have a clear fers, cells and modules are putting equipment upgrade strategy avail- less emphasis on ramping produc- able to their customers,” he said. tion capacities, IMS said. The “Furthermore, companies that will majority of equipment revenues resist the shake-out best will be this year will come from the need those who can go through these to replace existing tools. equipment upgrades with the least “IMS Research has estimated disruption, readying themselves that there is between 2.5 and 4 GW for the time when end demand of existing manufacturing capacity does ultimately pick up.” NOTEWORTHY The Mechatrolink Members Assn. (MMA, www.mechatrolink.org) is running a membership drive that lets end users, machine and robot builders, system integrators and motion control suppliers join the association as a Regular Member for free. The offer is good through the end of March. Stop wiring. Start connecting. Ashcroft (www.ashcroftinc.com), which produces a range of electronic and mechanical pressure and temperature measurement instruments, celebrates its 160th anniversary this year. SmartWire-DT from Eaton eliminates point-to-point wiring in control cabinets and replaces it with this simple eight wire connector. MERGERS, ACQUISITIONS & ALLIANCES Automation system provider PaR Systems (www.par.com) acquired the friction stir welding (FSW) product line from MTS Systems (www.mts. com), expanding PaR’s manufacturing process technology. PaR Systems will continue to support all current customers of MTS’s FSW products, and will pursue further development of the technology. Imagine the time and labor savings. Learn more today. Fanuc Factory Automation America (www.fanucfa.com) and Wynright (www.wynright.com) collaborated to automate and optimize Fanuc’s CNC system inventory management. Wynright designed the Goods to Person (GTP) system to automate the motion control system. 18 For more information, visit us at Eaton.com/smartwire-dt Control Design March 2012 controldesign.com Hazardous Locations Product Testing and Certification Start it Up! Choose the testing and certification organization that delivers the support you require. Today the CSA C/US mark is found on millions of electrical products used in hazardous locations and on other electrical devices that must provide spark-free performance. The CSA C/US mark signifies these products meet U.S. and Canadian standards for safety or performance. CSA International can help you streamline product evaluation and reduce time to market. And when supply chain or market opportunities expand your focus, we also deliver local service in Asia and Europe. Electrical products used in hazardous locations must inspire total confidence. For total confidence in your testing laboratory, choose CSA International. www.csa-international.org 1-866-797-4272 Building Confidence in Products Worldwide. (+(##& "/*!+.0+.&"/0(*07%.(+00"7%& $+7("2"(*!7 ((/7+/*$"("/ /%2&(("7!)+*0+*7+*0."(7+.+*0+7* +12".7.*%")0%""0%".(*!/7*$(+."*!& 1)&*!&7+*$+*$%&*71*$6%+1%&*7%*$%&%&*7"+1(",1(& +# +."7+'5+,* Brad Bundled Automation Solutions ® WE PUT IT ALL TOGETHER SO YOU CAN TOO As the industry’s most trusted brand for innovation and quality, Brad automation products have everything you need for your automation solutions. We offer one of the most extensive selections of products for connectivity, communications, control and www.molex.com/brad/cd power—all bundled together to meet your exact requirements. With our global reputation for leadership, innovation and reliability—especially in harsh environments—we put it all together for you. As part of our anniversary look back at the content we’ve created over our 15-year history, we present the first column that Jeremy Pollard wrote in February 1999, as an OEM Insight guest columnist. In April 1999, he became the first Embedded Intelligence columnist, and he’s been here ever since. Can vendors, machine OEMs, and the OEM’s customers sing in perfect harmony, as the song goes? In my view, absolutely not. Their agendas are totally different. As an OEM making machines or full systems, you have an obligation and desire to provide your customers with the best possible product at a profitable price. You need to provide service for that product, as well as a migration path for your future products and services. Vendors are constantly pounding the OEM marketplace, since that market represents the largest potential return for sales investment. That’s return for the vendor, not the OEM and not for your customers. How can you protect yourself against the sales-oriented vendor, and keep focused on your specific, and often unique, primary targets? Customers look for solutions that make their end product more profitable with lower lifecycle costs, as well as all the normal needs like maintainability and low cost of ownership. Most of the time they don’t care too much about the actual details of the control system if the process is up their alley. Maybe this makes the product or service the most important, and not the control system. Take an example where your process technology is established and proven, as is your control system. Now, suppose a vendor of PC-based control presented its case for the benefits of the technology. This applies to all new stuff like bus networks, etc. Your customer base, however, is entirely PLC-knowledgeable. Now you may be torn between accessing perceived benefits of this new technology, and risking the lack of acceptance from your customers. Easy choice, I think—the customer wins. But now, take a second example. What about those customers who the vendor has been to see, and, as a result, the customer suggests that you change your control system? Has the vendor presented his case honestly? Remember that you will be the one to implement the solution. How will you know what the influences were on your customer? The obligation you as an OEM have to your own organization is not necessarily that of the vendors or of your customers. Your needs are very different than the other two groups. So how can you keep from getting led down the garden path? When General Motors forced the use of flowcharting in an engine plant project, the OEMs had it shoved down their throats. No choices there, but some swore never to use it again. They lost tons of dough because they were not familiar with the issues since they listened to the vendor and customer, and got “hosed.” Windows CE may be the next one down the line. There is no effective difference with Windows CE as compared to QNX or WindRivers’ Tornado as an operating system. But the perceived benefits—and there will be some genuine development benefits—will most likely be presented in the best possible view for the group presenting it. If they make it sound as though it’s good for you, be very suspicious. Prove to yourself that the worth and benefits of the technology will serve you best, and not the vendors, or customer for that matter. This makes the issues surrounding the OEM and new technology varied and very different from the technology issues that affect the general-user public. The technology horizon is a changing landscape. It is estimated that technology half-life is now two years for control and computer software. Software has already been recognized as the future of control technology. To make sure that you don’t get snowed, it may be worthwhile to investigate the technology that you think you’ll one day need before you actually need to use it. Investigate the products as well as the history of the supplier or suppliers involved. Remembering that you have to support any product you sell, it is important to weigh the longevity of the technology as well as the supplier. Who in your company will be responsible for monitoring and evaluating technology? Someone has to! Don’t get snowed. Investigate the technology that you think you’ll one day need before you actually need to use it. Jeremy Pollard, CET, has been writing about technology and software issues for many years. Publisher of The Software User Online, he has been involved in control system programming and training for more than 25 years. Email him at jpollard@tsuonline.com. 21 by Joe Feeley, editor in chief Some of the Web-Based Methods Available to Do Automation Product Research Still Hold Little Currency for Many Machine Builders hether it’s money, time or resources, it this audience—occasional level of use has grown past usually isn’t wise to invest heavily in a 40%, compared with about 14% in 2008. new approach until you have a better “Videos about products or vendors help me evaluate sense of the potential value it can bring. Sometimes their capability and competence,” says Gary Cash, vice there’s not much change at all in the beginning. president of design services at Wynright Intralogistics Month-to-month change might be unperceivable. (www.wynright.com/intralogistics) in Elk Grove Village, Even year-over-year data might not reveal true pat- Ill. “You should collect links to videos in one place. I terns. It can take longer to find the emerging trends. view them as I see them. It would be nice for Control That’s what we learn each year we conduct our Design to sponsor/list a series of videos showing prod- audience study to summarize their product research ucts in a similar way so they can be compared (similar preferences and buying habits, including adoption to CNET Reviews). If this exists, I haven’t found it.” of methods such as social media and Internet-based Podcasts remain largely ignored by nearly nine of 10 video and audio options. There is no mistaking it’s a respondents, although occasional or better frequency rather leisurely amble toward greater levels of change of use doubled since 2008. among this group. Here in the early stages of our second decade of the The trend for blogs can be termed “encouraging.” Although our respondents still make no regular use new millennium, more user-friendly websites and of them for their jobs, the segment that says it reads greater bandwidth give web-based product-research blogs occasionally has inched up to 23%, from 19% in options legitimacy alongside traditional product 2008. The “never” group remains at 11%, but that’s a catalog and distributor-centric methods for machine- significant change from a 29% bloc in 2008. automation specifiers. We first started to ask the Control Design audience about its preferences in 2006, and have added questions as research options grew in subsequent years. Digital Tool Destinations The slowly accelerating affinity for use of webcasts as a source of research looks to have temporarily idled (Table I). In 2008, 16% of respondents said they used webcasts occasionally. This year it’s a clearly better 29%—but that’s identical with the 2011 finding, with the biggest support (54%) coming from the 30–39-year-old study participants. Although there’s been little change in those who claim more frequent use than monthly, those of you who say you’ve never used webcasts for your job dropped to 4% compared with 26% in 2008. Product videos and machine automation videos are one category that shows an increased acceptance by 22 Control Design March 2012 controldesign.com YOUR USE OF WEB-BASED METHODS OF INFORMATION DELIVERY Table I Never use for job, but use socially Use often (weekly) for job Use occasionally (monthly) for job Use rarely (monthly) for job ‘12 ‘11 ‘08 ‘12 ‘11 ‘08 ‘12 ‘11 ‘08 ‘12 ‘11 ‘08 ‘12 ‘11 ‘08 Webcasts 7% 5% 5% 29% 29% 16% 48% 45% 38% 4% 5% 26% 13% 17% 15% MP3s/podcasts (interview vendors) 2% 0% 2% 19% 12% 5% 43% 47% 25% 7% 4% 46% 29% 37% 22% MP3s/podcasts (interview machine builders) 4% 2% 2% 9% 8% 4% 45% 46% 21% 5% 5% 51% 38% 39% 22% Videos from/about vendors/products 5% 2% 3% 49% 36% 20% 33% 49% 49% 1% 5% 19% 11% 10% 10% Video interview of machine builders discussing automation on machine 6% 1% 3% 33% 35% 8% 41% 46% 34% 4% 5% 42% 16% 13% 13% Forums/bulletin boards 15% 15% 14% 34% 32% 41% 30% 32% 29% 6% 6% 11% 15% 15% 4% Blogs 8% 4% 7% 23% 18% 19% 30% 38% 30% 11% 11% 29% 29% 29% 15% Twitter 1% 1% 4% 2% N/A 11% 6% N/A 13% 11% N/A 70% 79% N/A Facebook 3% 1% 6% 2% N/A 7% 5% N/A 29% 30% N/A 56% 62% N/A LinkedIn 6% 4% 18% 14% N/A 23% 18% N/A 14% 17% N/A 39% 47% N/A Virtual trade shows 2% 0 10% 11% N/A 34% 40% N/A 5% 3% N/A 49% 46% N/A Bulletin board/forum use consistently pulls a 15% weekly use and 34% occasional use; that number has Nope, not even socially are just a plug for a specific company.” This sums up a number of typical responses: been unchanged in the four years of the study. It car- “None [of these tools] are bad; they just don’t fit ries most support—about 44% occasional or better— my needs. I can’t take time out of my day for a live among the 20–39 age groups. webcast, social networks (Facebook, LinkedIn) are “Forums/bulletin boards are best for me,” says an blocked at the office, and most of the videos/pod- engineering manager for a manufacturing company casts that are downloadable are nothing more than in India. “Companies are not yet using the forum/ sales pitches.” bulletin board medium fully. Personally, I would prefer if all my suppliers maintained forums with open access, because when you have a problem/query, chances are someone has already encountered it and someone else has already answered it.” A technical project leader at a packaging goods manufacturer in Massachusetts agrees. “Forums generally help particularly as it affects webcasts. Many say they can’t make the time for a live webinar presentation. This might be a message to the supplier community that you’re not making the archive option clear enough in your promotions. “Of these choices, I use some supplier tech support forums when I am doing a project with their stuff from time to time,” says a study respondent who works for me the most as they are an electroplating company. “But my first choice is just a good source for strange to call the manufacturer’s tech support line where problems,” he says. “Pod- that is available or encouraged. A very few vendors casts are usually too long offer webcasts that are actually useful in helping me and boring, and don’t relate to my projects, and in general controldesign.com A surprising number of respondents are either unaware of or don’t fi nd enough “on demand” content, use all of the capabilities of the product. The only time I use webcasts is if a vendor has a webcast available March 2012 Control Design 23 INFLUENTIAL AUTOMATION SUPPLIER FACTORS for on-demand viewing after the initial Extremely important presentation. The rest of this stuff is just Important ‘12 ‘11 ‘06 ‘12 ‘11 ‘06 Easy to use, install and maintain 54% 56% 75% 43% 42% 24% Dependable after-sales service and support 55% 54% 60% 42% 42% 39% Offers highest product quality 44% 51% 57% 55% 48% 42% Connects easily with existing systems 36% 48% 64% 57% 48% 33% Well-organized website for research 42% 40% 33% 49% 52% 57% last year, and one in 20 report occasional Offers leading technologies 30% 32% 31% 55% 51% 60% or more frequent use. Financially stable company 22% 23% 32% 58% 63% 63% Currently installed in your facility 17% 15% 20% 49% 43% 48% never gone to a supplier Facebook page. Lowest price 9% 12% 11% 49% 55% 65% Of those that commented about it, Strong brand name 8% 11% 15% 55% 56% 60% 10% 11% N/A 61% 55% N/A shows similar results, with 9% saying Read/view/hear about favorable outcome by a user via independent source (magazine, website, video) they have some occasional job-related Can buy product from website 11% 8% 9% 30% 31% 28% useless blather and a waste of bandwidth, as far as I am concerned. I do not use Facebook, Skype or Twitter.” We asked about more-recently emerging social media as product information delivery tools. About 70% of the respondents don’t use Twitter for any purpose, although that’s an improvement from 79% A rather unambiguous 97% of this year’s study respondents say they’ve almost all of them didn’t realize that suppliers had them. Other Facebook use activity with it. Tough application, ingenious solution Exactly Mastering challenges together — Rexroth makes it easy to implement automation. Our many years’ experience in a wide range of industries has given us extensive application knowledge. We offer this comprehensive understanding to the tasks you bring us, leading to ingenious solutions. Regardless of the drive technology used, we thought ahead and integrated intelligence throughout. This consistency makes you more efficient — from planning to start-up and daily operation. Your benefits are real: Increased productivity, improved energy efficiency and maximum machine safety. You can count on Rexroth to have the appropriate drive and control solution to meet your needs exactly. Bosch Rexroth Corporation www.boschrexroth-us.com Happier Relationships? products showed the most churn, In the seven years we’ve conduct- while safety components and me- ed this study, we’ve asked about chanical components had the least the stability of the participants’ supplier turnover. supplier relationships. We learned For the first time, price is no again this time that more than longer the most-mentioned reason half of the responders changed a to change suppliers. It remained at supplier for one or more primary 29%, but quality/performance was automation component in the past noted by 33% of the respondents, 12 months (Table II). up from last year’s 24%. This time, 57% said they’ve made a change or changes in the Your Favorites past year, up slightly from the We always ask study participants 55% we found last year, and the about their primary method for remarkable 62% result in the midst doing product research (Table III). of economic instability in 2009. The use of vendor websites sig- Controllers, sensors and OI/HMI nificantly again outpolled the use CHANGE STILL THE NAME OF THE GAME 2012 57% YES 2011 2009 55% YES 62% YES Yes? Which ones? ‘11 ‘09 40% Controllers 43% 47% Machine safety components 21% 45% 32% Motors/drives 28% 45% 44% Sensors/measurement 44% 42% 43% Operator interface/HMI 42% 40% 17% I/O 37% 39% 35% Mechanical components 32% 31% 16% ‘12 ‘11 ‘09 Price 29% 29% 38% Quality/performance 33% 24% 29% Discontinued product line 10% 12% 9% Poor after-sales support 11% 12% 9% Wanted open-standards architecture 4% 14% 9% Old supplier merged/was bought by another company 4% 5% 4% Why? 26 ‘12 Control Design March 2012 Table II Did you change your primary supplier for these types of control and automation components in the past year? controldesign.com With So Many EPIC® Connector Possibilities... We’ll sniff out the right solution for you. NEW ! Check out our NEW! 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'0+/*"0!./+*,0$&0/.0%---! ) #00 #0 # '0(&,0$&0/.0)( '0(&,0$&0/.0( '0+/*"0!./+*,0$&0/.0--( '0(&,0$&0/.0))( '0+/*"0(&,0$&0/.0%--( Lapp, the manufacturer of EPIC® Connectors, ÖLFLEX® Cable, and SKINTOP® Cable Glands, understands exactly how our connectors can best satisfy your specific needs. 800-774-3539 www.lappusa.com/epicultra of local distributors as the single VARIATIONS IN RESEARCH METHODOLOGY directly with the manufacturers’ What is your primary method to do product research? product experts ranks third. ‘12 ‘11 ‘06 Meet/speak with local distributors 27% 26% 31% Meet/speak directly with automation suppliers’ technical engineers/product managers 23% 25% 15% Visit suppliers at trade shows 4% 1% 1% Attend supplier(s) user group conference/event 1% 2% N/A Search independent, non-vendor websites (automation communities, magazine websites) 6% 9% 20% Search the suppliers’ websites 34% 33% 30% Read trade magazines 5% 4% 2% “I am fortunate that when I need something, I make a call to my local distributor engineer and somewhere between 20 minutes and 24 hours they are here to see Table III most-preferred method. Meeting what I need and we get the order placed before they even leave the building,” says Ray Bergeron, an engineer with many duties at Geiger (www.geiger.com), Lewiston, Maine, the company that’s been printing the Farmers’ Almanac since 1878. “If I do get stuck on my own and have to do my own research, I need a website that shows the product, shows some application examples, and at least If you can dream it, you can build it. Han® 3 A Hybrid Han-Modular® Han-Eco® Han-Yellock® Connect to Innovation Nation Connectivity needs vary, and HARTING’s Han-Modular® series is designed to meet the unique requirements of any customer’s demand. Modular inserts have been developed to allow the integration of electrical, optical, pneumatic, communication, signal, and power into a single connector assembly. Select the internal components and then choose the hoods and housings — from stainless steel to plastic — choose internal or external locking mechanisms and every aspect of the assembly. 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Over the past several years, study respondents seem to have grown a little happier with global search methods than they have been before (Table IV). Again this year, nearly 90% of the respon- DEMOGRAPHICS Respondent industries Together, we can eliminate downtime, reduce development time and get you to your tee time. Try Parker’s Xpress and experience the benefits of the first truly integrated family of machine control solutions: • SCADA • Motion Control • Machine HMI • Ethernet-based Servos • Machine Control • Smart Motors So go ahead — focus on your ROI and time to market, and we’ll take care of making sure it all works together seamlessly. Assembly 7% Electronics pick and place 2% Machining centers 5% Material handling/ transport systems 6% Metalworking 12% One-off, custom 14% Packaging 11% Paper industry 4% Plastics/thermoforming 3% Printing and converting 4% Rolling mills 2% Semiconductor tools 4% System integration 23% Textile 2% Woodworking 2% Other 10% Job function 1 800 358-9068 www.parker.com Control system design/ engineering 55% Company management 20% Tech support 12% Research/development 9% Other 3% Responses from 250+ study participants controldesign.com THE SEARCH FOR A WELL-TUNED ENGINE Table IV Technical search using global search engines You agree or strongly agree that: ‘12 ‘11 ‘10 ‘09 ‘08 The first page (or more) of results contains well-focused hits 79% 78% 76% 82% 82% Too many results are biased, vendor product plugs 40 67% 61% 70% 69% 68% Advancing Automation Too many results are outdated 45% 47% 52% 51% 61% Too many results have nothing to do with what I’m looking for 71% 70% 75% 73% 77% It’s a pain to sift through the results, but at this point there’s no better web-based research tool for me 77% 74% 73% 76% 82% I’ve gotten better at search strategies and techniques, and that has helped get better results 88% 90% N/A N/A N/A dents agree with the statement that they’ve gotten better at search strategies and techniques. years The future today: CPX r5IFZTIPVMECFBCMFUPFBTJMZ access pricing information. Don’t make them register to get it. r'FXBSF0,XJUIQSPWJEJOH What Makes a Site Good? contact information early in the To learn what this audience judges process. Many say it’s a barrier to be a useful supplier website to they won’t cross. do product research, we asked a “Give me immediate access to few open-ended questions and, engineering data without having not surprisingly, we received to fill out a request form or give my many thoughts. We did the same family history,” says our electro- for determining what they think is plating engineer. “The needed a non-helpful site. information should be available on “Make it easy to find and compare the website and should be accurate products,” Wynright’s Cash says. and up-to-date. A bad site usually “Have tech specs available on the means having to complete a ‘re- site, because I probably have a very quest form,’ which almost invari- specific use for this product and ably leads to a time-wasting sales want to know if it will do the job.” phone call that is not needed dur- Picking through the data reveals For more information: Call: 1-800-Go-Festo ing the initial phases of selection. a few other common thoughts I will call if I want to talk to a sales about supplier websites: or, more often, tech support per- r6TFSTXBOUFBTZUPàOEBDDFTT son. I’ve seen bad sites where the needed detailed engineering data is technical explanations, not mar- not available even after filling out a keting points of view. Make them form. If I must call to get questions downloadable as PDFs if desired. answered and another supplier offers complete data easily available understand a supplier’s part online and their product is suitable, numbering system. I put them in the spec.” controldesign.com March 2012 Control Design 1-800-463-3786 www.festo.com/us/cpx-ia Global manufacturer of process control to product manuals, specs and r5IFZEPOUXBOUUPIBWFUP Integrated automation for the 21st century: CPX. For maximum modularity and flexibility with remote I/Os. And for best in class motion controls and pneumatics. 31 and factory automation solutions Protect what’s inside. Crenlo® products are made to keep your technology safe and secure. As an industry leader in the design, manufacture, and integration of high quality enclosures, we offer: standard Emcor® enclosure solutionsZKLFKFDQEHPRGL¿HGWRPHHWWKHQHHGVRIPRVWDSSOLFDWLRQVDQGcustom Crenlo enclosure solutions, which can be built for any application, ranging from inverter enclosures to package drop boxes. The only thing stronger than our enclosures is our commitment to customer satisfaction. At Crenlo, we see enclosures differently. Crenlo leads the market in premium enclosures by providing: +LJKTXDOLW\FUDIWVPDQVKLSIRUGXUDELOLW\DQGVWUHQJWK &XVWRPHQJLQHHUHGGHVLJQVLQDQ\YROXPH 0RELOHSURGXFWVWKDWSURWHFW\RXUHTXLSPHQWRQWKHURDG 3URGXFWVWKDWFDQEHPRGL¿HGIRU\RXUDSSOLFDWLRQ _ZZZFUHQORFRPHQFORVXUHVSURWHFW We see enclosures differently. &UHQOR&DE3URGXFWV,QF$OO5LJKWV5HVHUYHG&UHQORDQGWKH&UHQOR/RJRDUHUHJLVWHUHGWUDGHPDUNVLQWKH 8QLWHG6WDWHVDQGYDULRXVRWKHUFRXQWULHVRI&UHQOR&DE3URGXFWV,QF (PFRU(QFORVXUHV,QF$OO5LJKWV5HVHUYHG(PFRULVDUHJLVWHUHGWUDGHPDUNLQWKH8QLWHG6WDWHVDQGYDULRXV RWKHUFRXQWULHVRI(PFRU(QFORVXUHV,QF INPUT/OUTPUT SYSTEMS Arc Flash: Not My Fault End Users Are Responsible for Keeping Workers Safe From Electrical Hazards, but More of the Onus Is Now on Machine Builders by Aaron Hand, managing editor ALTHOUGH STANDARDS HAVE EVOLVED to help keep workers safe around electrical equipment, tens of thousands of electrical accidents occur each year in industry. According to the National Fire Protection Assn. (NFPA, www.nfpa.org), hundreds of deaths and thousands of disabling injuries occur each year. Arc flashes are responsible for about 80% of the electrical-related injuries, and can cause severe personal injury and equipment damage when an arc fault superheats the air around it, expanding and creating a pressure wave within an electrical enclosure. Explosions can be as hot as 35,000 °F, and can send shrapnel and molten metal flying out from equipment (Figure 1). NFPA 70E dictates the precautions that manufacturers should take with their electrical equipment. It provides HOFFMAN guidelines on hazard/risk classifications, personal protective equipment (PPE), arc flash boundaries, etc. Push Back on OEMs Because it is the factories that are mandated to keep HOTTER THAN THE SUN their own workers safe, the bulk of the responsibil- Figure 1: Arc flash explosions can be as hot as 35,000 °F, and can send shrapnel and molten metal flying out from equipment. ity falls to them to make sure equipment is properly labeled, the appropriate level of PPE is provided, and workers are properly trained. As standards tighten, users are beginning to put some of the burden back on the machine builder. “Some customers are requiring us to isolate the high- open up the panel, no problem. You don’t want to create a situation where somebody’s trying to work on the logic right above a high-voltage area.” Filamatic takes other steps as well, including data taps voltage areas from the low voltage that we would and/or Lexan windows in panel doors so they don’t have use for PLCs and sensors on the machine,” says Chris to be opened as often; interlocks and other hardware Lovendahl, sales manager for Concep Machine (www. that make it harder for users to open panels without concepmachine.com), Northbrook, Ill. “We are physi- thinking; and coordinated fuse protection. A trend cally separating them so that technicians can debug or toward finger-safe devices also plays a part in improving troubleshoot the controls system without the require- safety, Chopper says. “It used to be lugs were wide open,” ments for the protective gear.” he says, describing how easy it would be to create a fault Filamatic (www.filamatic.com) in Baltimore also has been separating high- and low-voltage components. by dropping a wrench across open copper bus bars. It’s a growing debate as to just how much responsibil- “We put logic on one side, power on the other side of ity machine builders should take, says Wayne Tompkins, the panel,” says Jack Chopper, chief electrical engineer. global marketing manager for Rockwell Automation “That way if you need to troubleshoot the logic, you can (www.rockwellautomation.com). “What we’re starting to controldesign.com March 2012 Control Design 33 TIME TO SUIT UP? NFPA 70E standards define the level of personal protective equipment (PPE) needed for a given hazard classification. Figuring out the hazard level, however, can be difficult to do, so manufacturers are sometimes at a loss as to just how much protection each worker needs to wear. “One of the things that our customers have tried to do is to put the workers in as much PPE as possible so they can be safe,” says Wayne Tompkins, global marketing manager for Rockwell Automation. “But when an electrician has been doing the job for 20 years, and for the first 19 years he did it with just gloves and safety glasses and now he’s being told he has to wear a whole arc suit, he has a hard time accepting that.” Just as having to shut down the power to equipment can mean a big productivity hit, having to put on all the clothing and gear necessary to protect against the high heat of arc flashes is also seen as a productivity loss. “If we can allow technicians to get at the controls of the machine, which tends to be low-voltage equipment, without the need for protective gear, we can make their tasks easier to complete,” says Chris Lovendahl, sales manager for Concep Machines. “In this way, we reduce the need for protective gear and that does not reduce their productivity; they do not need the time to suit up.” It’s not just the time it takes to don the PPE gear that hurts productivity, notes Jack Chopper, senior electrical engineer at Filamatic. It’s also that PPE can make it difficult to get the job done. “You can’t feel things, you can’t hold tools, you can’t maneuver like you could otherwise,” he says. “The equipment is so cumbersome, it’s hard to troubleshoot with all that equipment on.” By introducing solutions that let workers perform jobs remotely, with doors closed, machine and MCC builders also remove the need for protective gear, either increasing productivity or reducing the chance of sustained injuries. see is that the end user is pushing back on them saying you need to Positioned for Tough, Compact Applications design me a safe machine,” he says. Novotechnik’s TX2 Series’ pivot-head mounting can handle up to ±12.5° of offset from misalignment without affecting performance. The TX2 is designed for mobile and other tough environments with heavy-duty construction featuring a stainless steel rod and metal housing. It is sealed against ingress of dust and liquids. from users who are becoming more Lacking Proper Training Such solutions are increasingly necessary in part because of demands aware of arc flash hazards, Chopper says, but also because of just the opposite: more people servicing these units with less training than their predecessors. In 2007, the Occupational Safety and Health Administration (OSHA, www.osha.gov) changed how it defines a “qualified person” from one Specifications • Stroke lengths from 25 to 300 mm • Very long life to 50 million movements • Resolution better than 0.01 mm • Repeatability to 0.01 mm • Linearity up to ±0.05% familiar with the construction and operation of the equipment and the hazards involved to one who has actually received the proper training and has demonstrated skills and knowledge. Unfortunately, the “demonstrated skills” often are lacking, For complete TX2 information, visit www.novotechnik.com/tx2 Novotechnik U.S., Inc. 155 Northboro Road • Southborough, MA 01772 Telephone: 508-485-2244 Fax: 508-485-2430 according to Patrick Ostrenga, compliance assistance specialist controldesign.com INPUT/OUTPUT SYSTEMS for OSHA. “Often I hear, ‘Oh, he’s been doing that for 24 years,’” he said during a Plant Services webcast about how to set up an arc flash mitigation program (www. ControlDesign.com/arcwebcast). “But what skills has he had and what training does he have? And oft-times we accept time in place of those real demonstrated skills. And oft-times that leads us to a failure.” Unpredictable So machine and panel builders are taking what steps they can to keep arc faults from occurring in the first place. “It’s a two-tiered approach,” says Garrett Potvin, global product manager for arc flash safety products at Pentair Technical Products’ Hoffman (www.hoffHOFFMAN manonline.com). “You want to lessen the number of times an electrical worker has to open a cabinet, and also make it safer when they do have to open it.” POWER ISOLATION Figure 2: The Sequestr enclosure helps to mitigate arc flash occurrences when working on interior components by isolating incoming power from the main enclosure. For the first tier, Hoffman has enclosures that include Intersafe data interface ports, which allow access to the programming devices inside the enclosure without opening the enclosure door; and external INPUT/OUTPUT SYSTEMS data pockets, an alternative to placing reference happens and there’s an arc flash there. If it’s severe manuals inside the cabinet. enough, the explosion can propagate to other units.” In the event of an explosion, Siemens’ arc-resistant Hoffman’s second-tier solutions include a disconnect switch that cuts the power to most if not all of tiastar MCC directs the arc blast, including the heat, the components inside when a handle is pulled. The plasma and pressure, away from workers. For its latest technology to address arc flash, Rock- company’s Sequestr solution adds a smaller enclosure on the side of the main enclosure (Figure 2), which well focuses on keeping workers outside the arc flash isolates power to the smaller enclosure so that work- boundary. SecureConnect removes the voltage from ers don’t have to shut the whole system down. the MCC without having to open the door or go inside Besides arc mitigation, manufacturers of low-volt- the arc flash boundary. “On every MCC unit, there’s a age motor control centers (MCCs) have introduced arc- connection that’s made on the backside of a vertical resistant equipment, which addresses what happens unit that gives it its power,” Tompkins explains. “With- if an arc flash occurs when the doors are closed and out having to open the door, this allows the customer latched. “An arc flash is more likely if people are work- to disconnect the power from the vertical bus.” A re- ing with an open door and the system is energized, mote operator station attaches to the center of the door adding potential for human error,” says Pablo Medina, and allows a worker to perform tasks from 30 ft away. The range of solutions—whether mitigating or product manager for the tiastar MCC at Siemens Industry (www.industry.siemens.com). “Arc-resistant resisting arc flashes—are geared not only toward gear will not protect you from that because it will only keeping workers and equipment safe, but also improv- work when the door is closed. But what people tend to ing productivity. “If implemented properly, you can forget is that I can have the door open and something achieve both,” Potvin says. LOW- COST TEMPERATURE MEASUREMENT Engineered with Innovation. 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All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies. 132 Fairgrounds Road, West Kingston, RI 02892 USA s 998-4624_US I ller HMntro Co s ine ch Ma r ive lle Dr ntro Co JUST A FEW years ago, every controller vendor factors, providing DIN-rail mounting capability. touted its PLCs, and machine and robot builder “Our ILC 100 class controllers feature an integrated OEMs echoed the theme when discussing automa- web server and function block libraries for IT- tion features with their customers. But past affec- friendly functionality,” notes Dan Fenton, control tion for PLCs is now the love that dares not speak its and software product marketing specialist at Phoe- name—as controllers now are called programmable nix Contact. Technologies borrowed from the PC automation controllers (PACs), industrial PCs, or just world such as SNMP and web-based HMIs further about anything else except PLCs. enhance connectivity and communications. Changing names sometimes is just about market- Dan Hebert Rockwell Automation (www.rockwellautoma- ing hype, but not in this instance. Virtually every tion.com) didn’t invent the PLC, but it certainly modern machine, robot or motion controller em- was a leader in promoting its use in machine ploys multiple technologies directly borrowed from automation. But when it comes to making the the commercial PC world. This makes the modern term PLC verboten, it’s et tu Rockwell. “Our Con- controllers more like PCs, and a lot less like PLCs. trolLogix PAC enables a manufacturer to integrate For a variety of reasons, chief among them in- motion, safety, sequential, drive and process stalled base, major U.S.-based vendors were among control to provide a high-performance control so- the last to relinquish proprietary PLC technology lution,” says Mike Burrows, a director at Rockwell. and move to the PC world. On the other hand, ven- “One common Ethernet layer allows the integra- dors based in Europe, particularly in Germany, were tion of plant information with enterprise systems, among the first to jump on the PC bandwagon. using standard Cisco technology for security. The “Beckhoff follows the technology migration set by t senior technical editor t dhebert@putman.net TECHFLASH Is PLC a Dirty Word Now? Intel and adopts the latest processors for industrial use. We offer industrial PCs that use second-gener- CompactLogix controller gives machine builders integrated motion on EtherNet/IP.” Although larger U.S.-based PLC vendors were relatively slow to jump on the PC train, smaller Controllers now are called PACs, industrial PCs, or just about anything else except PLCs. suppliers were onboard early. “Our SoftPLCs are open-architecture PACs, running ladder logic as their primary language, but also supporting C++,” explains Cindy Hollenbeck, vice president of Soft- ation Intel Core i3, Core i5 and Core i7 processors in PLC (www.softplc.com). “SoftPLCs have advanced a rugged plant floor-worthy housing,” says Graham PAC features such as data logging, database Harris, president of Beckhoff Automation (www. interface, advanced math calculations, email/tex- beckhoffautomation.com). “For machine builders ting and other communications, and more. The and robot builders, this adds functional layers in SoftPLC runtime engine is a Linux-based kernel software rather than via separate hardware boxes.” that runs on an embedded computer such as an When Wago (www.wago.us) describes its current controller offering, it does so using PC and IT x86-, ARM- or PowerPC-based system.” Opto 22 (www.opto22.com) has long cham- terminology. “Our Ethernet 2.0 platform provides pioned Ethernet-based I/O, along with other modularity, scalability and high performance,” technologies from the PC world such as task notes Charlie Norz, product manager of I/O sys- scheduling and distributed processing. “Unlike tems for Wago. “Gen II of our Wago-I/O-System with a PLC, individual tasks can be scheduled Ethernet 2.0 packages those attributes with and executed more logically with our Snap PAC higher-performance processors into three distinct and its flowchart-based control programs,” says and compact programmable fieldbus controllers Selam Shimelash, application engineer with Opto (PFCs). For networking/control flexibility, OEMs 22. “If some of the machine I/O is less critical and can choose features like SD card capability and doesn’t need to be scanned as often, the control network redundancy, and all our PFCs have a dual- program can be designed and written that way. port Ethernet switch to support daisy-chaining.” The PAC won’t communicate with the I/O unless Like Wago, Phoenix Contact (www.phoenixcontact.com) uses PC technology to greatly reduce form 38 Control Design March 2012 it needs to because the scanning of I/O points is a task performed by the remote brains.” controldesign.com A Sense of the Market WE CONDUCTED A STUDY in December 2011 ALL-PURPOSE SENSOR to identify use and application trends for sensors LR-Z Series all-purpose laser photoeye has a and vision products among the industrial ma- CMOS image sensor and laser power control chine builders in our print and digital audience. function for stable detection of targets with col- No huge technological changes have shaken or, angle, material and surface fi nish varia- first conducted this type of survey in 2008, and the tions. The sensor has pecking order of sensor popularity and selection is an SUS316L stainless largely unchanged. About 72% of respondents use steel enclosure with inductive proximity sensors, 64% use photoelectric NEMA 4X, 6P and 13, sensors, and a further 64% use process variable and IP68/69K ratings. sensors. Some 62% use rotary encoders/resolvers, Operation is simplified 45% use capacitive proximity sensors, and a further by a digital, seven-segment display and one- 45% use linear position indicators. About one-third touch teaching technology. of respondents said they also employ ultrasonic Keyence; 888/539-3623; www.keyence.com/PRLRZ cdroundup@putman.net the world of sensors and machine vision since we proximity, vibration and machine vision. The use of point-to-point hardwiring to connect sensors to I/O points seems to have MORE THAN BLACK AND WHITE stabilized around 57%, which is down from DK12-11-IO contrast sensors detect differences the 78% reported in 2009. About one in nine in two colors of media, respondents reported using device-level digital with a three-color light networks in 2011, down from 15% in 2010. source. The sensors Showing no significant change from 2010 were are IO-Link compatible, users of Ethernet (9%), proprietary (8%) and se- include customizable and rial (6%) networking solutions. diagnostic LEDs, and can Some 41% of 2011’s respondents reported invert the output state using machine vision-based sensing, up from and disable the adjust- 36% in 2010. Of those, 46% reported using vision ment potentiometer for tamperproof require- for online inspection (down from 57% in 2010). ments, and log the output. Showing no significant change from 2010, 30% Pepperl+Fuchs; 330/486-0001; www.pepperl-fuchs.us used it as feedback for real-time machine control; 6% used it for offl ine inspection. This time, 39% said they use all-in-one, inte- FLOW MEASUREMENT grated, smart cameras. Last year, 37% said that. Cubemass Coriolis flowmeter measures mass About 27% are using vendor-built systems with flow, volumetric flow, temperature and density, camera, frame grabber and processor (down from and communicates to controllers via pulse, fre- 31%). That’s similar to prior studies. quency, 4-20 mA with HART, and Modbus RS-485. WIDE RANGE SENSING ¼ in. measure flow of a few BOS 50K photoelectric sensors with drops or 2,200 lb/hr with glass lens and IP67 housing have mass flow accuracy ±0.10% 2 m sensing range, background sup- of reading, and repeat- pression, and a red light emitter for ability of 0.05% for liquids. setup and adjustment. Some mod- It measures density in els include polarized retroreflective liquids with accuracy to with 18 m range, and a through- ±0.001 g/cc with repeat- beam version with a 60 m range. ability of 0.0005 g/cc. Balluff; 800/543-8390; www.balluff.com/50k Endress+Hauser; 317/535-1329; www.us.endress.com Four pipe sizes from 1/24 to controldesign.com March 2012 Control Design PRODUCT ROUNDUP Machine Builders Remain Consistent With Sensor Choices 39 PRODUCT ROUNDUP CURRENT SENSING tion with one fixed response AS1 Series compact case time is needed. Protective current-sensing switch heights to nearly 2.5 m are avail- monitors an energized able with M12 connector pigtails circuit in tight spaces. or a pre-wired 3 m cable. The ring design slips Omron STI; 800/479-3658; onto a conductor to reli- www.sti.com ably detect currents as low as 0.5 A with a single conductor pass. Solid-state output provides a nearly unlimited number of operations. It can CLEAR AND PRESENT DETECTION control ac or dc circuits to 120 V, with a maxi- Q26 photoelectric clear object detection sen- mum load capacity of 150 mA. sors have a polarized retro coaxial design that NK Technologies; 800/959-4014; permits operation over a wide range of distances with the reflector www.nktechnologies.com mounted as close as 5 mm for applications READ INFRARED with restricted spaces. Pro 100 and Pro 200 Series multi-wavelength It has an LO/DO switch infrared temperature sensors use ESP algo- to control the output type, a single-turn rithms to provide aim-and-read capabilities for non-graybody materials potentiometer to adjust detection sensitivity, and that are not accurately a Health Mode output for application monitoring. measured by single- or Banner Engineering; 888/373-6767; dual-wavelength sensors. www.bannerengineering.com The sensors can be used as a standalone transmitter with a choice of inputs, outputs and alarms. NO CONTACT For advanced capabilities, remote interface mod- Q-track compact, non-contact inductive sensors ules, PID controllers and PC software programs have printed emitter and receiver coil systems. are available. The emitter coils are activated with a high- Williamson; 978/369-9607; www.williamsonir.com frequency ac field, and produce an inductive RLC circuit with the positioning element. They include current and voltage out- THINK BIG, DETECT SMALL puts, eliminating the need BJ Series photoelectric for two separate sensors. sensors detect transparent Turck; 800/544-7769; objects and include re- www.turck.us verse polarity protection, output short-circuit protection, and auto mutual MAGNETIC SENSING interference prevention R-Series magnetic rotary angle sensors with an function, and are opti- embedded micro- mized for sensing small objects. They include a processor convert setup sensing spot via a red LED. magnetic orienta- Autonics; 847/680-8160; www.autonics.com tion to an analog output repeatable to 0.03% or 0.1° of measurement range. The sen- SAFETY SIMPLY sors have a measurement range up to 360° and F3SJ-E safety light curtains have quick-mount have 12- or 14-bit resolution. brackets, reduced wiring and alignment indicators Novotechnik U.S.; 508/485-2244; for applications where simple on/off hand detec- www.novotechnik.com 40 Control Design March 2012 controldesign.com OBJECT OF MY DETECTION ProSense digital pressure switch/transmitters SA1E-X miniature photo sensors for air, non-corrosive gas and non-flammable gas for transparent or translucent applications have a three-color LCD and provide object detection offer an optimum two digital outputs and response speed of 500 μs, feature one analog output. They a coaxial optic and narrow beam have three operation to ensure stable detection, and are modes and six pressure not affected by angle, inclination or target shaking. unit conversions, and Objects as far as 2 m can be detected. NPN or PNP two vacuum to pressure outputs are available, as well as a choice of Dark ON ranges (-14.5 to 14.5 psi and -14.5 to 145 psi). or Light ON operation modes. AutomationDirect; 770/889-2858; IDEC; 800/262-4332; www.idec.com/usa www.automationdirect.com FLEXIBLE SENSOR CHOOSE THE CLEAR Worm flexible sensors bend Ultrasonic clear label sensor with an OLED on- around and through the en- board display has a home screen and one-button closure and are immune to autoset (gap set), and is tweakable external temperature effects (momentary up/down adjustable). even in a short thermowell. It has M12 and M8 versions, The temperature assembly and 200 μs response. keeps the spring-loaded sensor in place, and it Tri-Tronics; 800/237-0946; trims to lengths to handle thermowell assemblies, www.ttco.com transmitter head, hockey-puck connection head and dual-sided enclosure. The sensors are available with 100 and 1,000 Ω, platinum, copper and nickel INDUCTIVE THINKING RTDs, and J- and K-type thermocouples. E2E two-wire dc inductive proximity sensors Moore Industries; 818/894-7111; www.miinet.com have a sensing range of 2-20 mm in shielded and unshielded models with SENSE THE POWER short barrel or standard OptoEMU Sensor is a web-enabled energy lengths. They have solid monitoring and data acquisition hard- potted internal circuitry ware appliance that lets commercial to withstand shock, vibra- and industrial customers acquire power tion and severe environment locations. consumption data from facility systems, Omega Engineering; 203/359-1660; www.omega.com machines, equipment and metering devices in real time and with minimal configuration. HUMID NAVIGATION Opto 22; 951/695-3010; www.opto22.com LS5 Navigator is designed to withstand -30 to 50 °C, 95% relative humidity, and WELL-CONNECTED SENSOR vibrations and shocks. It Sensor-actuator cable has M12 has an optics system and is connector with black polyamide adaptable to different types of communication. coupling nut, is corrosion-resis- It works with AutoSurveyor, a software tool for tant, and comes in 3-, 4- and 5-pole determination of reflector coordinates, and is configurations. Halogen-free PUR cable is available available in an outdoor/indoor-use and an indoor- in lengths 0.2–40 m and rated for IP67/IP68/IP69K. use-only version. Phoenix Contact; 717/944-1300; Kollmorgen; 540/633-3545; www.kollmorgen.com www.phoenixcontact.com controldesign.com March 2012 Control Design 41 PRODUCT ROUNDUP HANDLES THE PRESSURE PRODUCT ROUNDUP DRY SENSING mum, and will switch Photoswitch 42CS inductive sensor has smooth 0.1 Adc with a carry cur- or threaded 18 mm 316L stainless steel housing rent rating of 0.5 A. with a hard plastic lens for an operating range Standex Electronics; of -25 to 85 °C. Ferromagnetic teach feature 513/871-3777; minimizes the possibility of water ingress as- www.standex.com sociated with pushbuttons or potentiometers. It has polarized retroreflective, diffuse, transmitted beam, clear-object detection and background INSENSITIVE TO COLOR suppression sensing modes. OADM 250 optical laser distance sensor detects Rockwell Automation; target objects, regardless of their surface prop- 440/646-3434; erties or color at distance ranges of 0.2–4 m with response times below 10 ms, www.ab.com/sensors 1.2 mm resolution, and ±5 mm repeat accuracy, even CUSTOM PRESSURE on moving targets. It has an Unik 5000 pressure sensing platform has a modular aluminum housing, wash- design to allow users to customize pressure mea- able glass front optics, and IP67 certification. surement parameters. The sensors are available with pressure ranges 1.5–10,000 psi. Three grades Baumer; 860/620-6369; www.baumer.com of performance—industrial, improved and premium—offer TEACH COLOR accuracies 0.2–0.04%. Series 4055 color A choice of eight elec- sensors have three tronics boards provides teachable color chan- a variety of outputs. nels with indepen- GE Measurement & Control; 203/373-2211; dent 200 mA outputs, www.ge-mcs.com which allow for three color tones to be programmed. The teach process provides five different tolerance levels, and color SHAFT SENSOR detection within the 30–40 mm operating range is PST-360 shaft- virtually independent of target distance. angle, rotary Contrinex; 866/289-2899; www.contrinex.com position sensor through-hole design fits over existing shaft and bearing assem- LEVEL VARIETY blies. The sensor has a ring magnet with a fully OEM series of level sealed Hall ASIC as the sensor element. Standard sensors have thermal rotor has a 14.05 mm inside diameter shaft design dispersion technol- and custom configurations are available. It has ogy with solid-state or electrical angles to 360° with no dead band, and relay contact outputs linearity error as low as ±0.5%. in a range of materials Piher Int’l.; 224/475-0582; www.piher.net independent of conductivity or dielectric constant, and resist a high degree of coating. Standard designs include two-wire, loop-powered; MIGHTY, SMALL insertion type with pigtail; level and tempera- R12575 micro-proximity switch is 0.379 in. long ture; mass level with two-wire, loop-powered; with a 0.098 in. diameter. There is no power draw integral type; high temperature; and wet/dry. in the off state. It has a response time of 0.2 ms, Fluid Components Int’l; 760/744-6950; release time of 0.1 ms, a power rating of 3 VA maxi- www.fluidcomponents.com 42 Control Design March 2012 controldesign.com touch, to control precise dimensional product E3Z photoelectric sensor family includes an ad- parameters. They combine an AC-LVDT with a vanced condition monitoring series, 30 m through- linear ball bearing assembly to reduce radial play beam models, oil-resistant series and stainless- and core skewing for repeatability of 0.15 μm and steel sensors. The E3Z dc sensor has a built-in long life of 2x108 cycles. amplifier with pulse synchronization. Intensive Macro Sensors; 856/662-8000; www.macrosensors.com shielding prevents malfunctions caused by inverter noise or wireless communications equipment. The electronics are fully potted to resist dust and POWERLINK INTERFACE water spray to 1,200 psi. Stainless-steel E3ZM Temposonics magne- series is rated IP69K for 1,450 psi washdowns. tostrictive linear- Omron Electronics; 866/88-omron; www.omron247.com position sensors include the R-Series Ethernet Powerlink sensor. Resolution of 1 μm LIVE LONG AND PROBE is possible for lengths 25–20,000 mm. Position BBPM Series spring- and velocity measurements can be provided for loaded LVDT position up to four locations on the sensor. For higher sensors for use as accuracy requirements, a linearity correction dimensional gauging option is available to improve the sensor’s non- probes come in four linearity specification within ±20 μm. Even bet- models, including full ter sensor accuracy (±10 μm) is available with a bridge, half bridge, proprietary magnet. pneumatic and soft MTS Systems; 919/677-0100; www.mtssensors.com PRODUCT ROUNDUP PHOTOELECTRIC FAMILY In the world of rapidly changing technologies and a shifting marketplace, find answers here. April 25–26, 2012 Boston Convention & Exhibition Center Boston, MA Meet top suppliers face-to-face and see the full spectrum of resources to help accelerate your project to completion: f CAD/CAM/CAE Software f Electronic Components and f Precision Machining Subassemblies f Computer Hardware and Peripherals f QA/QC, Sensing, f Fastening and Joining Systems and Inspection Services f Contract Manufacturing and Engineering f Lasers f Rapid Prototyping and much more! f Custom Automation and Assembly f Packaging Equipment REGISTER ONLINE TODAY! Visit 1SPEVDFEBOENBOBHFECZ6#.$BOPOr6#.$BOPODPN DM-NewEngland.com Promo Code: AB WE HAVE A MIXED customer base with regard to preferences for permanent magnet motors or standard induction motors. Have induction motors reached the end of their efficiency improvement road? But we still periodically hear about the potential for magnet material shortages. We’d like to standardize where we can. Anyone else having thoughts about the direction to take? —From January ’12 Control Design ANSWERS KOLLMORGEN RealAnswers@putman.net REAL ANSWERS How to Push Motor Efficiency AC Motor Efficiency Improvement Today’s ac premium efficient industrial and commercial motors, which are typically manufactured with premium-grade electrical MAGNETIC ATTRACTION steel, additional copper in the windings and The neodymium iron boron (NeFeB) magnets found in most permanent magnet motor designs offer high efficiency, but manufacturers also use alternative rare-earth magnet compounds that do not carry such a high price tag. aluminum cast rotors, have reached a point of diminishing returns. Higher efficiency levels are possible, but incremental cost vs. energy savings makes a reasonable payback period much more difficult to justify. Copper cast rotors vs. conventional alumi- cy and improvement in power factor can result in smaller, more-compact motor designs. The hybrid num cast rotors are an excellent next step to electric vehicle is just one example for which higher-efficiency induction motor designs. ultra-efficient, lightweight and compact PM motor Copper cast rotors are more expensive to technology can be justified. manufacture and currently are produced only One thing seems certain: More efficient motors in relatively low volume compared with their will be in our future because the demand for aluminum rotor counterparts. Higher-efficiency electrical energy is going to continue to increase. copper cast rotor designs are used today mainly What technology will evolve as the next gen- for specialty applications. eration of ultra-efficient motor? Will they use a Permanent magnet (PM) rotor designs also copper rotor, PM rotor, a hybrid combination of offer a significant potential for improved ef- induction and PM suitable for sine-wave power, ficiency. Most PM rotor motors are designed to conventional induction designs upgraded using run exclusively on adjustable-frequency power. higher-grade electrical steels, or some other tech- They also run at true synchronous speed with- nology such as synchronous reluctance? out slip and therefore are a synchronous-speed machine. The high-performance neodymium iron boron (NdFeB) magnets found in most PM motors are relatively expensive. Today China has exclusive control over the NdFeB market, and has driven magnet cost to unprecedented levels in the past year. New global Higher efficiency levels are possible, but incremental cost vs. energy savings makes a reasonable payback period much more difficult to justify. supply markets are emerging to produce these magnets, but this will take time to significantly The answer could lie in how the free market influence the dominance that China has in the responds to the need for more cost-effective market. However, even with these high magnet permanent magnets compared with the cost costs, many specialty applications can benefit of a high-volume copper rotor design. I highly from the PM technology. The increase in efficien- suspect that not one but a combination of these 44 Control Design March 2012 controldesign.com Ferrite Alternative application will ultimately dictate the technol- Induction motors have been around for nearly ogy solution that gets employed. The next gen- 100 years. Over the past two decades, a lot of eration of ultra-efficient motors is likely to follow serious effort has been focused on improving the same progression as today’s energy-efficient their efficiency. Today, these efforts are reach- motors, which started with just a handful of ing the point of rapidly diminishing returns. end users concerned with energy saving and Achieving higher efficiency with induction evolved into federally mandated premium-effi- motors will require either using more costly ciency laws. In the end, it all will come down to materials (e.g., substituting copper for alumi- economics—motor cost for higher efficiency and num in the rotor) or more total material. Either energy savings based on the cost of energy. of these costly options must be weighed against RICHARD SCHAEFER, senior product manager, Baldor Electric, www.baldor.com the small additional improvement in efficiency that would result. Although most new permanent magnet motors Rare-Earth Issues Temporary rely on expensive rare-earth materials, a new Permanent magnet motors still hold a significant design achieves much higher levels with low- efficiency and package-size advantage for motors cost, readily available ferrite magnets. By using under 3 kW. Both technologies have continued to novel, conical air-gap geometry, this motor con- progress, but for these smaller powered devices, centrates the magnetic flux, achieving rare-earth the PM solutions are still superior. The rare-earth magnet motor performance at a cost competitive magnet issues of late will be only a temporary with induction motors. supply issue. In addition, many manufacturers The only significant drawbacks to this design are using alternative materials to counteract the are high rotor inertia, which actually can be rare-earth supply issue. an advantage in many applications, including fans and pumps; and that PM motors require a Samarium used in samarium cobalt (SmCo) alloys does not suffer from as high a price premium or availability issue as neodymium, dysprosium and terbium. SmCo offers performance equal to certain grades of NdFe. There is a wide variety of rare-earth magnet variable-frequency drive to operate, making it most easily justified in applications that already require speed control. JOHN PETRO, chief technology officer, NovaTorque, www.novatorque.com MAY’S PROBLEM compounds, and not all experience severe price SOME AUTOMATION VENDORS offer direct and availability pressures. For example, sa- access to machine HMIs and OITs with iPhone apps. Apps are useful for personal purposes, particularly for quick access to online info. We’re wondering if app access for machine operator interface is better than browser-based access through a smartphone, or just a sexier marketing of the same capability. marium used in samarium cobalt (SmCo) alloys does not suffer from as high a price premium or availability issue as neodymium, dysprosium and terbium. SmCo offers performance equal to certain grades of NdFe. Additionally, ferrite magnet designs have been used to avoid the rare-earth pricing challenge. These motors, however, suffer 25%+ reduction in output from the same size motor. In general, they still would be superior to induction motors, but as the motor’s horsepower grows into the 20 SEND US YOUR COMMENTS, SUGGESTIONS OR SOLUTIONS FOR THIS PROBLEM. We’ll include it in the May ’12 issue, and post it on ControlDesign.com. Send visuals if you’d like—a sketch is fine. Email us at RealAnswers@putman.net. Please include your company, location and title in the response. hp range, the induction motor closes the gap on performance significantly. TOM ENGLAND, director, global product planning, HAVE A PROBLEM YOU’D LIKE TO POSE to the readers? Send it along, too. Kollmorgen, www.kollmorgen.com controldesign.com March 2012 Control Design 45 REAL ANSWERS technologies will evolve and that the customer’s EXCLUSIVE OI Consolidates PLC, I/O, Wiring TRADITIONALLY, IF YOU designed a machine with a PLC from one manufacturer, you’d have to use the software from that manufacturer. If a customer specified a different PLC brand, you’d be stuck making a software switch, too. But Controller Development System (CoDeSys) software, an IEC 61131-3 development system for controller applications, now is used by more than 300 suppliers to program their automation FOR MORE INFORMATION components, making it easier Call 414/449-6555, email richardcharwell@eaton.com, or browse to www.eaton.com. for machine OEMs and users to swap out devices as needed. Eaton has programmed What sets the latest version mation. “You’re not just saving devices with CoDeSys in Europe apart from its European prede- the components and spend- for close to a decade. Now cessors is that the series also ing less, but also reducing the that the software has gained integrates directly with the amount of time you spend in momentum elsewhere, the Eaton SmartWire-DT system, commissioning,” Harwell says. company is releasing its XV which replaces control com- “It saves configuration time Series of operator interface and ponent wiring with a single and administration time, while CoDeSys into the North Ameri- cable, enabling more compact, providing remote access and can market. The XV Series with cleaner panel design. The diagnostic information at the CoDeSys removes the physical SmartWire-DT panel wiring device level.” PLC, incorporates logic into solution eliminates the need The new XV Series has an the OI, and provides a single to cut wires to length and at- optional integrated SmartWire- software package for control tach them as with traditional DT master, which eliminates and visualization. By using the cabinets, instead snapping in the need for a gateway. The CoDeSys programming envi- cleanly and quickly. integrated SmartWire-DT option ronment, the XV Series enables The SmartWire-DT system is available in the compact high- OEMs to lower costs, program also sets the XV Series apart performance series with screen their equipment faster and from competing systems that sizes ranging from 3.5 to 10.4 in. simplify integration. combine HMI and PLC, according Additional communication op- to Rich Harwell, advanced solutions include RS-485, CANopen alization and data management tions and connectivity manager and Profibus-DP/MPI. tasks into a single device. “It’s a for Eaton. “It becomes about series of products that enable the smart points. It makes that programming software is IEC end customer to make smaller, combination all that much more 61131-3 compliant and used to smarter machines and develop powerful,” he says, explain- program both the visualization them faster,” says Amy Beaudry, ing that I/O modules are also and logic control in the XV Series. product manager at Eaton. “The eliminated from Eaton’s OI. “We The SmartWire-DT system can XV Series with CoDeSys enables don’t put I/O into the integrated also be configured with xSoft- remote intelligence, eliminates system; we remove it altogether CoDeSys-2 so that the visualiza- entire device levels and makes if possible. The combination is tion, logic and end devices are all complex wiring unnecessary for really unique.” conveniently programmed with a The OI combines control, visu- smaller, smarter machines.” 46 Control Design March 2012 Eaton touts it as lean auto- Eaton xSoft-CoDeSys-2 single software package. controldesign.com dynamic noise control, and PS-RS25-5 convection- an onboard EMI/RFI filter cooled, ac/dc power compliant with IEC 61800-3 supply for embedded that minimizes interference systems is a 25 W unit of surrounding equipment. capable of 5 Vdc at 5 A. The 50 Yaskawa; 800/yaskawa; W PS-RS50-5 supplies 5 Vdc at 10 A. The outputs www.yaskawa.com have short-circuit and overvoltage protection with automatic recovery. Both devices accept 88–264 Vac input at 47–63 Hz, and operate from SIL 2 SIGNALING -20 to 70 °C without a fan. Audible and visual signaling devices are designed WinSystems; 817/274-7553; www.winsystems.com with statistical-data-supporting conformity to SIL 1 and SIL 2 safety requirements, and have self-monitoring circuitry and fault-indicat- UL DIN-rail surge-protective device (SPD) with ing contact closures to alert of color coding has finger-safe construction, and a failure or initiate shutdown/ rejection feature assures system integrity by pre- lock-out of machinery. venting misapplication of SPD modules. Vibration Pfannenberg; 716/685-6866; and shock resistance according to EN 60068-2 www.pfannenbergusa.com are ideal for harsher conditions. Users can rely on easyID local visual indication and optional remote contact signaling to monitor module sta- DISCRETE CONNECTIONS tus. They are available with short-circuit current EtherNet/IP I/O modules ratings (SCCR) up to 200 kA. for discrete devices have 16 Cooper Bussmann; 636/527-3877; digital I/O channels with www.cooperbussmann.com/surge universal input/output or input functionality. They are available with 16 universal user-selectable digi- SAFE UNDER PRESSURE tal inputs/outputs or 16 dedicated inputs. The loca- PSSR-2 safety controller is for tion of any faults for each I/O port is identified via use with two conductor wire, LED diagnostic indicators or via the network. The pressure-sensitive safety prod- modules support the ODVA Device-Level Ring (DLR) ucts that incorporate an integral standard enabling multi-port EtherNet/IP devices to 6.8 kΩ end-of-line resistor. It meets operate in a ring or linear topology. requirements of EN13849-1:2006 and is Category 3 Belden; 314/854-8000; www.belden.com SIL 2 PLd level. It has a manual or auto reset function and operates from 24 Vdc. With a response time of 13 ms, it is a safety relay with force MORE FORCE guided relays and two normally open (safety) and ERD20 rod-style electric actua- one normally closed (monitor) contacts. tor has a larger-diameter ball Tapeswitch; 800/234-8273; www.tapeswitch.com screw and a stroke length to 24 in. to deliver forces to 500 lb. It is stroke-configurable, and ac- MINIMIZE INTERFERENCE cepts a variety of NEMA and metric stepper and Z1000 Variable Speed Drive for building automa- servo motors. It can accommodate six different tion applications through 500 hp has an LCD sensing or switching choices: reed, solid-state operator with Hand-Off-Auto functions. It has a PNP (sourcing), solid-state NPN (sinking), nor- built-in 5% line impedance to reduce input har- mally open, flying leads or quick-disconnect. monic distortion, a 5 kHz carrier frequency with Tolomatic; 800/328-2174; www.tolomatic.com controldesign.com March 2012 Control Design 47 cdproducts@putman.net SOLVE OVERVOLTAGE PRODUCT SHOWCASE EMBEDDED POWER PRODUCT SHOWCASE ALL FOUR QUADS 24 Vdc power and 10 A DPDT output contacts. Escon 36/2 dc four-quad- Mode and range select switches are located on rant PWM servo controller the side of the unit so that when panel-mount- for dc motors to 72 W pro- ed, they are not operator-accessible. A special vides drift-free, dynamic LED indicator provides a unique and effective speed behavior, has con- flashing method of cycle progress indication. figurable digital and analog inputs and outputs, Marsh Bellofram; 304/387-1200; and can be run in various operating modes, www.marshbellofram.com including speed controller (closed loop), speed controller (open loop) and current controller. Maxon Motor; 508/677-0520; FAULT DETECTOR www.maxonmotorusa.com CMPT Copperhead transmitter unit (CTU) 24/7 digital vibration and temperature measurement and transmission tool, for machinery fault POWER OF THE ATOM detection systems for fans, pumps, gearboxes DIN-rail controller platforms Uno-1170A and Uno- and electric motors, measures temperature and 1170AE have 1G DDR2 RAM, Intel Atom N270 pro- analyzes three types of vibration signals. The cessor, fanless design, compact size, energy-effi- unit has special functions for low-speed ma- cient power consumption, and operating range of chinery, with an ability to monitor unbalance -10 to 60 °C. They are equipped and misalignment to 120 rpm, and bearing and with two Ethernet ports, three gearbox condition to 20 rpm. It transmits data via serial ports (two RS-232 ports 4–20 mA or 0–10 Vdc or CANbus. A touchscreen and one RS-232/422/485 port), HMI for alarm display and logging is available. three external USB 2.0 ports, 2.5 SKF; +44 (0) 7980 712881; www.skf.com in. SATA bay, and one internal secure USB port to support a USB encryption dongle key. STATE IS SOLID Advantech Industrial Automation; 800/205-7940; RG Series of ac and dc solid- www.advantech.com/ea state switching devices are for switching resistive, slightly inductive and motor MOTION+PLC loads, up to 85 AAC (15 hp) A3200 MotionPAC is switching, with nominal ratings at 40 ºC and high a software-based PLC SCCR rating of 100 kA. The devices are 17.5 mm integrated with an A3200 wide, and are cUL listed, UL recognized and/or CSA motion controller. It can approved, VDE approved and CE certified. be used independently for Carlo Gavazzi; 847/465-6100; www.gavazzionline.com full machine control or with AeroBasic programs, and complies with IEC 61131-3 and PLCopen. Users can program in ladder SCAN WITH TRIPLE CORE diagrams (LDs), function block diagrams (FBDs) or XG-8000 vision system structured text (ST). includes line scan camera Aerotech; 412/963-7470; www.aerotech.com models, a triple-core processor and multi-camera connectivity of up to eight DELAY RELAY cameras. It has an integrated development envi- 405AR industrial timer fam- ronment, toolset and user interface. Visual LED ily with on-delay instanta- indicators, built into the line scan cameras, dis- neous relay functionality play received light intensities and image sharp- has 12 timing ranges and ness to simplify setup process. operates on 24–240 Vac or Keyence; 888/539-3623; www.keyence.com/PRXG8 48 Control Design March 2012 controldesign.com is the only magazine exclusively dedicated to the original equipment manufacturing (OEM) market for instrumentation and controls—the largest market for industrial controls. SOFTWARE RESOURCES DATA FOR DECISIONS RIGHT SIZING FactoryTalk VantagePoint 4.0 software Motioneering includes enhanced connectors and precon- Application figured reporting content for Logix pro- Engine 6.2.0 grammable automation controllers (PACs), motion sys- FactoryTalk His- tem sizing torian, Facto- and selection PUBLISHING TEAM ryTalk Metrics software has a mechanism project concept GROUP PUBLISHER & VP, CONTENT and FactoryTalk to collect and save load information for KEITH LARSON klarson@putman.net EnergyMetrix, multiple axes, automatically calculate DIRECTOR OF CIRCULATION to set up report- application results, and compare them JACK JONES jjones@putman.net ing around common equipment types. Web- against a database of company products based dashboards monitor key performance to identify the optimized linear or rotary SALES TEAM indicators (KPIs) in real time. motion system solutions to meet specific NORTHEASTERN AND MID-ATLANTIC REGIONAL MANAGER Rockwell Automation; 440/646-3434; machine builder application requirements. DAVE FISHER dfisher@putman.net www.rockwellautomation.com Kollmorgen; 540/633-3545; 508/543-5172 Fax: 508/543-3061 www.kollmorgen.com 24 Cannon Forge Dr. 555 W. Pierce Rd., Suite 301 Itasca, Illinois 60143 630/467-1300 Fax: 630/467-1124 Foxboro, Massachusetts 02035 THIRD GEN MIDWESTERN AND SOUTHERN REGIONAL MANAGER GREG ZAMIN gzamin@putman.net TwinCat 3 PC-based GET SERVED control software has Brochure includes object-oriented IEC updates to the 61131-3 extensions, C ProServe Design, and C++. The integra- Assembly and LAURA MARTINEZ lmartinez@putman.net tion of Matlab/Simu- Marking suite of 310/607-0125 Fax: 310/607-0168 link facilitates a con- free professional- 218 Virginia, Suite 4, El Segundo, nection to scientific grade software, California 90245 fields. The software modules can run in dif- and plotters/print- DIGITAL SALES SPECIALIST ferent languages within a common runtime, ers that combine design and engineering JEANNE FREEDLAND and all widely used fieldbuses are supported. tasks with company’s products to create jfreedland@putman.net The eXtended Automation Engineering envi- assemblies. New version 6.0 software uses ronment (XAE) in TwinCat 3 is essentially the a SQL server database, and has expanded Microsoft Visual Studio platform. marking/design tools such as AutoSave Beckhoff Automation; 952/890-0000; and SAP export. www.beckhoffautomation.com Wago; 800/din-rail; www/wago.us 630/551-2500 Fax: 630/467-1124 555 W. Pierce Rd., Suite 301 Itasca, Illinois 60143 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 PRESIDENT & CEO JOHN M. CAPPELLETTI AD INDEX Adalet ......................................................................35 Allied Electronics ......................................................17 AutomationDirect ......................................................52 Autonics USA............................................................16 AVG Automation ..........................................................2 B&R Industrial Automation ..........................................8 Baldor Electric ..........................................................12 Beckhoff Automation ...................................................6 Bosch.......................................................................25 c3controls ................................................................10 Crenlo ......................................................................32 CSA International ......................................................19 Eaton .......................................................................18 Festo ........................................................................31 Harting .....................................................................29 VICE PRESIDENT IDEC ........................................................................27 Lapp USA .................................................................28 Maple Systems..........................................................26 Measurement Computing ...........................................36 Molex .......................................................................20 National Instruments ...................................................4 Novotechnik ..............................................................34 Omega Engineering .....................................................3 Parker Hannifin .........................................................30 Patlite ......................................................................24 Schneider Electric .....................................................37 Siemens Industry ......................................................15 UBM Canon Communications .....................................43 Yaskawa Electric .......................................................51 JULIE CAPPELLETTI-LANGE VP, CIRCULATION JERRY CLARK VP, CREATIVE SERVICES STEVE HERNER REPRINTS FOSTER REPRINTS www.fosterprinting.com JILL KALETHA jillk@fosterprinting.com 866-879-9144 ext. 168 controldesign.com March 2012 Control Design 49 METALWORKING OPERATIONS have an obligaCutting Tools ~4% tion to develop sustainable manufacturing. Some 14% Coolant 7% Energy might think this a bold statement. Although the idea of sustainability is becoming better defined 10% Personnel 40% Equipment 22% Disposal and understood, many manufacturers still are not taking the necessary steps to implement newer proven technologies that foster sustainability. One of those technologies is minimum quantity Other Costs lubrication (MQL), which eliminates large quantities of water- and oil-based coolants and replaces them with a small quantity of lubricant mixed with air. This air-oil stream is precisely metered and Coolant ~8-16% 7% delivered to the cutting tool’s edge. The philosophy behind MQL is based on a simple principle—more is not always better. Use only what’s needed for the application, because enough is as good as a feast. Manufacturers that apply MQL reap many sus- COLD CASH Investment and operating expenses of a typical machining system using water-soluble coolant shows the many aspects that go into coolant expenses. tainable benefits. Their workers are safer, with both short- and long-term benefits. Operators, skilled mist-collection equipment. Operating wet equip- tradesmen and engineers no longer are exposed to ment produces increased and ongoing lifecycle the toxicity, bacteria and fungus risks that come costs in the form of energy consumption, chemical with traditional wet machining. The small amount maintenance, water makeup, disposal of used cutting fluids, then starting the cycle of waste/recovery Our environment is cleaner because there are no cutting fluids used that require stringent disposal. all over again by replenishing consumed fluids. The figure illustrates the investment and operating expenses of a typical machining system producing a large volume of aluminum transmission of oil used for MQL generally is based on vegetables or esters, which are less harmful to humans. Metal components for cars, with water soluble coolant. So with all of these benefits, why don’t more chips produced during MQL machining are nearly manufacturers implement MQL technology? As an dry and much cleaner than with conventional ap- industry, why don’t we behave more responsibly to proaches. Near-dry chips are easier to recycle and implement sustainable manufacturing processes more valuable as a recycled material. and systems in our factories? Do we hide behind Our environment is cleaner because there are the myth that sustainability adds cost? In the case no cutting fluids used that require stringent dis- of MQL, we have proven sustainability pays for posal—benefiting everyone and helping to change itself. So again, why aren’t more manufacturers in- the dirty perception of manufacturing. Oil and sisting on MQL solutions? Is it fear of new technol- other wastes present significant disposal impacts ogy or the cultural change associated with it? and implications to our environment. Although These questions and others are a real challenge legislation and regulation specify mitigation to for our industry. Until we answer them and have the environment, enforcement of this legislation the courage to change our behavior, we cannot is challenging, expensive and difficult. embrace a new idea like sustainability. Without Most manufacturers still associate sustainability change, we might miss the next real technology with higher costs. However, when we break down opportunity to restore American manufacturing the investment and operating expenses of wet leadership—and no one can afford that. manufacturing systems, one begins to understand how much these conventional systems cost. Trans- DOUG WATTS is CTO at MAG Americas (www.mag-ias. ferring, recycling and pressurizing coolant results com), Erlanger, Ky., which makes metal cutting and in significant costs for coolant supply, filtration and composites machines for the durable goods industry. 50 Control Design March 2012 controldesign.com Other MAG AMERICAS %PVH8BUUTtEPVHXBUUT!NBHJBTDPN OEM INSIGHT Why Not Lubricate Less? ADAPTABLE Need a drive that works with any application? Have it your way with the flexibility of Yaskawa’s A1000 drive. Network communications, expandable I/O, and feedback are among its many features. Compatibility with interior and surface permanent magnet motors provides highly efficient, precision control with incredible performance, producing up to 200% torque with or without feedback. For new installations or retrofits, the A1000 provides a single robust solution, regardless of your application. Looking for adaptability? Call Yaskawa today. View our Video: Follow us: http://Ez.com/yai291 YA S K A W A A M E R I C A , I N C . - D R I V E S & M O T I O N D I V I S I O N 1 - 8 0 0 - YA S K A W A YA S K A W A . C O M Easiest to configure system you’ll ever meet Use the technology built into the Productivity3000 programmable controller to make your job easier. Build systems with up to 33 total base groups - one local and 32 remote (Ethernet). Each base group can have up to five local (USB) bases for over 115,000 possible I/O points. The convenient USB port on each remote slave module lets you program and monitor from any remote location. One click auto-configures all I/O hardware connected to the system, including up to 64 AutomationDirect AC drives on the Ethernet I/O network, saving hours of setup. And most analog modules are software configurable with easy dialog boxes. The FREE Productivity Suite software makes it all possible! http://bit.ly/p3000

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